BT SWE100 120 120L 120S 140 140L 200D Repair Manual - PDF DOWNLOAD

Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D Valid from serial number: 6061850-

Order number: 258946-040 Issued: 2009-10-05 TP

© BT

en

Document revisions:

Issue date

Order number

Changes

2008-08-25

258946-040

Brand new version.

2008-11-24

258946-040

Updated with SWE120S

2009-04-17

258946-040

Updated

2009-10-05

258946-040

Chapter 4.4 New table and amendments to text in the chapter Chapter 5.3 Measure added in "Maintenance schedule mast" Chapter 6 amendments to text and values Chapter 7 amendments to text and values Chapter 8.1 section "8.1.2 Adjusting the kneeling movement" added Chapter "9.3 Tightening torque drive motor" added Chapter 15 New descriptions related to the repair of the tiller arm Chapter 17 New text related to hygiene when working on hydraulics Chapter "17.8 Tightening torque hydraulic unit" added Chapter 23 updated with a new tool Table "21.4 Overflow pressure mast" added Various minor corrections throughout entire document

This manual contains information on the following trucks:

T-code

Model

841

SWE100

841

SWE120

842

SWE120L

841

SWE140

842

SWE140L

842

SWE200D

843

SWE120S

© BT

Repair manual

Serial number

SWE100, 120, 120L, 120S, 140, 140L, 200D

Contents Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

1 – Contents 2 – General introduction .......................................................................... 2-1 2.1 How to use the manual ................................................................... 2-1 2.2 Warning symbols ............................................................................ 2-2 2.3 Pictogram ....................................................................................... 2-2 2.3.1 Screws/nuts ...................................................................... 2-2 3 – General safety rules ........................................................................... 3-1 3.1 Safety while working....................................................................... 3-1 3.2 Electrical system............................................................................. 3-2 3.3 Safe lifting....................................................................................... 3-3 4 – Installation .......................................................................................... 4-1 4.1 General........................................................................................... 4-1 4.2 Battery installation .......................................................................... 4-1 4.2.1 Battery installation safety ................................................. 4-1 4.2.2 Install battery .................................................................... 4-2 4.3 Programming PIN codes ................................................................ 4-3 4.3.1 Standards for PIN codes .................................................. 4-4 4.4 Setting the parameters ................................................................... 4-5 4.4.1 Adjusting the parameters for collision sensor (option) ..... 4-6 Collision sensor parameters 105, 106 och 111 ................ 4-6 Programming PIN for resetting the truck .......................... 4-7 4.4.2 Adjusting the parameters for the battery and battery charger 4-7 4.4.3 Parameter 107 - battery size ............................................ 4-9 Free ventilated batteries ................................................... 4-9 Verifying the parameter adjustment for free ventilated batteries (Lead/acid batteries) ........................................ 4-10 Verifying the parameter adjustment for valve controlled batteries (Hawker/Exide) ................................................ 4-10 4.5 Function and safety check ............................................................ 4-11 5 – Maintenance .......................................................................................

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

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

5.3 Maintenance schedule....................................................................

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

6 – Functions and parameters ................................................................ 6-1 6.1 General........................................................................................... 6-1 6.2 Function description ....................................................................... 6-1 Symbols on key pads and display .................................... 6-2 6.3 Principle functions .......................................................................... 6-3 6.4 Timer .............................................................................................. 6-8

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

1– 1

Contents T code 841, 842, 843

Valid from serial no.

60618506.5

Date 2009-10-05

Order no.

258946-040

Parameters .................................................................................... 6-9 6.5.1 General ............................................................................ 6-9 6.5.2 Show parameters ............................................................ 6-9 6.5.3 Enter the parameters ..................................................... 6-10 6.5.4 Operator parameters ..................................................... 6-11 Factory installed driver parameters ............................... 6-12 6.5.5 Service parameters ....................................................... 6-13 6.5.6 Factory parameters ....................................................... 6-16

7 – Troubleshooting ................................................................................ 7-1 7.1 General .......................................................................................... 7-1 Software compatibility ...................................................... 7-1 7.1 Emergency travel mode ................................................................. 7-1 7.2 Troubleshooting methods .............................................................. 7-2 7.2.1 Troubleshooting general introduction .............................. 7-2 7.2.2 Completed troubleshooting .............................................. 7-3 7.3 Error code history........................................................................... 7-4 7.4 Error code system .......................................................................... 7-5 7.5 Error codes .................................................................................... 7-6 7.6 Troubleshooting diagram. ............................................................ 7-22 7.6.1 The truck cannot be driven ............................................ 7-23 7.6.2 The truck can only be driven at reduced speed ............. 7-24 7.6.3 The truck can be driven but behaves abnormally .......... 7-25 7.6.4 The truck can be driven but lacks certain functions ....... 7-25 Software compatibility .................................................... 7-25 Matrix for hardware compatibility ................................... 7-26 7.6.5 Faulty hydraulic functions .............................................. 7-27 7.7 Built-in test function...................................................................... 7-30 7.8 Status of digital inputs/outputs ..................................................... 7-31 7.8.1 Test function “9” – Transistor regulator ......................... 7-31 7.8.2 Test function “10” - Logic card ....................................... 7-34 7.8.3 Test function “12” – Expansion unit SEU (optional). ...... 7-35 7.9 Testing display function ............................................................... 7-36

1– 2

8 – Chassis 0000 ......................................................................................

8.1 Support arm 0350 ..........................................................................

8.1.1 Support arm lift, lateral adjustment ..................................

8.1.2 Adjusting the kneeling movement ....................................

8.2 Motor fixing points 0450 .................................................................

8.2.1 Replacing springs (not applicable for SWE120S) ............

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

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

9 – Electrical drive motor 1700 ...............................................................

9.1 Components ..................................................................................

9.2 Disassemble engine and truck .......................................................

9.3 Tightening torque Drive motor........................................................

9.4 Fitting the tempreature sensor .......................................................

9.5 Cleaning.........................................................................................

9-1 9-1 9-2 9-4 9-4 9-5

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Contents Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

10 – Drive gear 2550 ............................................................................... 10-1 10.1 General......................................................................................... 10-1 10.2 Components ................................................................................. 10-1 10.3 Removing the gear from the truck (not applicable for SWE120S). 10-2 10.4 Removing the gear from the truck (not applicable for SWE120S). 10-4 11 – Brake 3180 ...................................................................................... 11-1 11.1 Components ................................................................................. 11-1 11.2 Release of brakes......................................................................... 11-2 12 – Drive wheel 3530 ............................................................................ 12-1 12.1 Changing drive wheel ................................................................... 12-1 13 – Castor wheel 3540 .......................................................................... 13-1 13.1 Components ................................................................................. 13-1 13.2 Changing castor wheel ................................................................. 13-2 14 – Support arm wheel 3550 ................................................................ 14-1 15 – Tiller arm 4000 ................................................................................ 15-1 15.1 Components in tiller arm............................................................... 15-1 15.2 Removing tiller arm....................................................................... 15-2 15.3 Changing gas spring..................................................................... 15-2 15.4 Changing the safety sensor .......................................................... 15-3 15.4.1 Dismantling .................................................................... 15-3 15.4.2 Assembly ........................................................................ 15-3 15.5 Components in tiller arm handle ................................................... 15-4 15.5.1 Removing the tiller arm handle ...................................... 15-5 15.5.2 Replacing the logic card ................................................. 15-5 15.5.3 Changing signal button/switch ....................................... 15-6 15.5.4 Changing raising/lowering button. .................................. 15-7 15.5.5 Changing push button .................................................... 15-7 15.5.6 Changing the position of the controls - support arm lift/fork lift 15-8 15.5.7 Changing a switch for safety reversing .......................... 15-9 16 – Electrical components ................................................................... 16-1 16.1 Changing wiring harness .............................................................. 16-1 16.1.1 Changing the transistor regulator's wiring harness. ....... 16-2 16.2 Replacing the transistor regulator................................................. 16-3 17 – Hydraulic system 6000 .................................................................. 17-1 17.1 General......................................................................................... 17-1 17.2 Hygiene when working on hydraulics ........................................... 17-2 17.2.1 Washing ......................................................................... 17-2 17.2.2 Packaging ...................................................................... 17-2 17.2.3 Handling ......................................................................... 17-2 17.2.4 Storage ........................................................................... 17-3 17.2.5 Carrying out work ........................................................... 17-3

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

1– 3

Contents T code 841, 842, 843

Valid from serial no.

606185017.3

17.4

17.5 17.6 17.7 17.8

Date 2009-10-05

Order no.

258946-040

Hydraulic unit 6100 ...................................................................... 17-4 17.3.1 Emptying the hydraulic tank .......................................... 17-5 17.3.2 Hydraulic system, bleeding ............................................ 17-5 Cylinders with bleeding valve ........................................ 17-5 Cylinders without bleeding valve ................................... 17-5 Hydraulic connections 6230 ......................................................... 17-6 17.4.1 Quick change connector ................................................ 17-6 Assembling the quick change connector ....................... 17-6 Dismantling the quick change connector ....................... 17-7 Hydraulic calibration..................................................................... 17-8 Adjustment of the pressure limit valve.......................................... 17-9 Disassembling the hydraulic unit................................................ 17-11 Hydraulic unit tightening torques................................................ 17-13

18 – Lift mast – 7000 .............................................................................. 18-1 18.1 Main mast 7100 ........................................................................... 18-1 18.1.1 Components .................................................................. 18-1 18.1.2 Maintenance .................................................................. 18-2 Mounting ........................................................................ 18-2 Lubrication ..................................................................... 18-2 18.2 Fork carriage 7420 ....................................................................... 18-3 18.2.1 Maintenance .................................................................. 18-3 ....................................................................................... 18-3 18.3 Main lift chain system 7120 .......................................................... 18-4 18.3.1 Checking the chain setting ............................................ 18-4 18.3.2 Inspecting the chain ....................................................... 18-4 Noise ............................................................................. 18-4 Surface rust ................................................................... 18-4 Rusty links ..................................................................... 18-4 Stiff links ........................................................................ 18-4 Bolt rotation ................................................................... 18-5 Loose bolts .................................................................... 18-5 Plate wear ...................................................................... 18-5 Elongation ...................................................................... 18-6 Damage ......................................................................... 18-7 Damaged plates ............................................................ 18-7 Damaged bolts .............................................................. 18-7 Dirty chain ...................................................................... 18-7 18.3.3 Cleaning ........................................................................ 18-7 18.3.4 Lubrication ..................................................................... 18-8 18.4 Changing the fork-lift trolley ......................................................... 18-9 18.5 Changing the stand .................................................................... 18-11 19 – Accessories ...................................................................................

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

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

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

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

19.5 Built-in battery charger .................................................................

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

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

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

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

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

1– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

19-1 19-1 19-2 19-2 19-2 19-3 19-3 19-4 19-4 19-4 19-4 © BT

Contents Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

20 – Appendices ..................................................................................... 20-1 20.1 General......................................................................................... 20-1 21 – Technical data ................................................................................ 21-1 21.1 SWE100, SWE120, SWE140 ....................................................... 21-1 21.2 SWE120L, SWE140L, SWE200D ................................................ 21-4 21.3 SWE120S..................................................................................... 21-7 21.4 Overflow pressure for the mast................................................... 21-10 22 – General tightening torque ............................................................. 22-1 22.1 General......................................................................................... 22-1 22.2 Galvanised non-oiled bolts ........................................................... 22-1 22.3 Untreated, oiled bolts.................................................................... 22-1 23 – Tools ............................................................................................... 23-1 23.1 MQS contacts ............................................................................... 23-1 23.2 AMP contacts ............................................................................... 23-3 23.2.1 AMP contacts Multilock series 040 ................................ 23-4 23.3 Molex contacts.............................................................................. 23-4 23.4 Grease guns ................................................................................. 23-5 23.5 Other tools .................................................................................... 23-6 24 – Oil and grease specification ......................................................... 24-1 25 – Electrical components and wiring diagram ................................. 25-1 25.1 Electrical components .................................................................. 25-1 25.2 Wiring diagram ............................................................................. 25-5 25.2.1 Index of symbols ............................................................ 25-5 25.2.2 Overview diagram .......................................................... 25-6 25.2.3 Wiring diagram ............................................................... 25-7 26 – Hydraulics chart ............................................................................. 26-1 27 – Instructions for disposal ............................................................... 27-1 27.1 General......................................................................................... 27-1 27.2 Marking of plastics........................................................................ 27-1 27.2.1 General marking of products and packaging ................. 27-1 27.2.2 Marking to BT Standard ................................................. 27-2 Abbreviations ................................................................. 27-2 Example of marking ....................................................... 27-2 27.3 Pressure vessels .......................................................................... 27-3 27.3.1 Gas damper ................................................................... 27-3 27.4 Sorting categories......................................................................... 27-4

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

1– 5

Contents T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

1– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

General introduction How to use the manual Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

2 – General introduction 2.1 How to use the manual The service manual is divided into chapters containing the following information: • Functions and parameters – This chapter contains a basic description of the main functions of the truck and the control system parameters • Installation and initial operation – This chapter describes the work that needs to be done before the truck is used for the first time • Maintenance – This chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out • Troubleshooting – This chapter describes the error codes that appear in the display when the truck completely or partly stops working. The chapter also describes reasons why errors occur and suggested remedies.

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

2– 1

General introduction Warning symbols T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

2.2 Warning symbols The following warning symbols are used in the service manual: DANGER! DANGER! means there is a risk of potentially fatal accidents or serious injury, as well as material loss or damage. Always accompanied by the warning symbol.

WARNING! WARNING! means there is a risk of damage to components that are sensitive to electrostatic discharge.

Follow applicable ESD protection regulations.

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

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

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

×n s mm

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

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

2– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

General safety rules Safety while working Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

3 – General safety rules Only persons trained in servicing and repairing this type of truck are qualified to carry out servicing and repair work.

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

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

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

• use well maintained tools that are intended for the work being carried out.

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

• do not flush solvents or similar that have been used for cleaning down drains that are not intended for this purpose. Follow the local disposal regulations.

• heated paint gives off harmful gases. Therefore remove the paint at least 100 mm around the welding/grinding area using sanding equipment or paint remover when welding or grinding a painted area.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

3– 1

General safety rules Electrical system T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

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

• disconnect the battery when using electric welding equipment. The welding current can enter and damage the battery.

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

• blow electric motors clean using compressed air.

• clean electrical panels, PCBs, contactors, contacts, magnetic valves, etc., with a moist cloth and a cleaning agent.

Note!

Risk of short circuit that may damage electrical components.

Do not break the warranty seal on the PCBs.

3– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

General safety rules Safe lifting Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

3.3 Safe lifting

All lifting must be carried out on a flat, nonslip and stable surface. Avoid freshly laid tarmac or tarmac at high daytime temperatures.

• When lifting the drive wheel, chock the other wheels so that the truck stands still.

• Select the lifting points so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the lower part of the chassis, these should be used for a well-balanced lift.

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

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

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

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

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

• Never work under a lifted truck without appropriate supports.

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

3– 3

General safety rules Safe lifting T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

3– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

4.2 Battery installation 4.2.1 Battery installation safety Remember the following safety regulations before you begin working with the battery: • Gel batteries are only intended for use at room temperature with a temperature interval of +15 to +30, otherwise there is a great risk that the battery will be damaged and its lifetime reduced.

• Always use protective equipment to protect the eyes, face and skin when you are inspecting, handling or filling batteries.

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

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

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

4– 1

Installation Battery installation T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

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

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

3. Connect the battery cables/battery sleeve.

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

4. Close the battery lid.

5. Put the battery connector back.

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

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

7. Function test the truck before using it.

4– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation Programming PIN codes Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

There are two alternative methods for programming PIN codes. The first and simplest is to use TruckCom where it clearly shows what to do.

See the separate manual for using TruckCom. The other alternative is to use the truck's keypad.

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

2. State code 341671 and press the ON button.

3. Choose the programming code from the table below:

Function

Programming

Remark

Return to factory settings.

Press 1 + ON button

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

PIN codes in the block can be used.

Press 2 + b + ON button

B = Block 0-9

PIN codes in the block cannot be used.

Press 3 + b + ON button

B = Block 0-9

Programming new PIN codes

Press 4 + b + P + NNNN + ON button Note!

The block that applies must be activated first (see function 2 above in the table).

B = Block 0-9 P = Driver profile 110 NNNN = PIN code Note!

You may only state one number per driver profile. Driver profile 10 must therefore be stated as 0 (zero).

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

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

4– 3

Installation Programming PIN codes T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

Note!

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

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

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

Note!

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

Standard assignment for PIN codes Drive r profil e no.

1

Block 0

0001

0002

0003

0000

0000

0000

0000

0000

0000

0000

Block 1

7901

1437

3731

1049

9439

7265

1322

2869

1574

5421

Block 2

4854

2907

9175

5799

1490

3031

7392

5622

5023

1787

Block 3

3174

1026

3815

6703

1179

5152

7514

5668

3215

4659

Block 4

7110

5477

3846

9491

5918

8222

6923

8139

7025

9197

Block 5

6276

9879

9658

1690

4042

5201

9807

4332

9715

2549

Block 6

4142

8620

3754

8432

8788

7430

1948

2595

8527

7474

Block 7

1482

7135

2395

7365

7092

4611

2831

4185

6067

1930

Block 8

4731

1022

5377

3257

7334

9009

7881

8843

7436

2876

Block 9

3162

5878

2828

1910

6907

2136

5730

2957

7691

3242

4– 4

2

3

4

5

6

7

8

9

10 Note!

Stated as 0

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation Setting the parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Check that parameters are adjusted to desire values with regards to • maximum speed, driver parameter - see chapter Functions and parameters • acceleration, driver parameter - see chapter Functions and parameters • internal braking, driver parameter - see chapter Functions and parameters • Collision sensor (option) • battery • battery charger (option) Note!

When you check or adjust parameters, remember to write down, in a truck report for example, the truck's specific parameter values.

Separate information about the truck specific parameters are good to have e.g. in case of truck breakdown, since the information cannot be received in another way.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

4– 5

Installation Setting the parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

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

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

Collision sensor parameters 105, 106 och 111 See the table below for information about the values that can be stated:

Service parameters Parameter

Name/unit

Min/ Max

Incr eme nt

Std

Description

105

Collision sensor X level

0/100

1

0

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

106

Collision sensor Y level

0/100

1

0

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

111

Resetting following a collision

0/1

1

0

0 = Special pincode required for resetting after a collision.

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

Note!

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

4– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation Setting the parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

Note!

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

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

Note!

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

Note!

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

Note!

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

4– 7

Installation Setting the parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Parameter

Name/unit

Min/ Max

Incr eme nt

Std

Description

107 service parameter

Battery adjustment, Ah

1/20

1

9

9 = Large battery 13 = Medium battery 17 = Small battery For more information, see text following the table. See section“4.4.3 Parameter 107 - battery size”.

109 service parameter

Battery charger, battery type

0/3

1

0

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

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

110 service parameter

Built-in battery charger, battery capacity, Ah

0/300 (100/ 300)

1

0 (100)

State battery capacity.

0 (100) = No charge. Standard type.

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

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

1101 factory parameter

Built-in battery charger

0/1

1

0

0 = No battery charger 1= Battery charger present

Note!

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

4– 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation Setting the parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Note that the acid concentration can vary depending on the make of battery.

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

Free ventilated batteries See the table below for the recommended parameter settings.

Parameter 107 Lower discharge

Deeper discharge

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

Battery size Lead/acid battery

286-320 Ah 251-285 Ah 221-250 Ah 206-220 Ah 191-205 Ah 176-190 Ah 161-175 Ah 146-160 Ah 131-145 Ah 115-130 Ah

Battery size Hawker Evolution

Battery size Exide

271-280 Ah 251-270 Ah 231-250 Ah 211-230 Ah 191-210 Ah 171-190 Ah 151-170 Ah 131-150 Ah 120-130 Ah

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

DANGER! The battery's service life will be reduced if the value of parameter 107 is set to a value that is too high. The standard adjustment of parameter 107 is set for normal handling of the truck. Other applications may require a different adjustment of parameter 107.

Check that the parameter adjustment is right using the instructions below.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

4– 9

Installation Setting the parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Verifying the parameter adjustment for free ventilated batteries (Lead/acid batteries) 1. Charge the battery.

2. Use the truck in its normal application until the battery indicator shows a discharged battery (0% on the display).

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

Note!

Do not charge or discharge during this time.

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

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

Note!

Each change must be followed by renewed verification of the parameter setting.

Verifying the parameter adjustment for valve controlled batteries (Hawker/Exide) 1. Charge the battery.

2. Use the truck in its normal application until the battery indicator shows a discharged battery (0% on the display).

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

Note!

Do not charge or discharge during this time.

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

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

Note!

Each change must be followed by renewed verification of the parameter setting.

4 – 10

Repair manual

Battery type

Battery voltage at rest, Uend

Hawker Evolution/Exide

24.24 V

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Installation Function and safety check Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

4.5 Function and safety check

a,e b

q

c

n

d

m

f

k j

g h

p

o

j

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

Pos. Inspection point

Action

Duration scale

a b c d e f g h j k m n o p q

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

Investigate damage, remove dirt etc.

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

Investigate damage, remove dirt etc.

Investigate damage, remove dirt etc.

2:25 minutes

© BT

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

SWE100, 120, 120L, 120S, 140, 140L, 200D

4 – 11

Installation Function and safety check T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page intentionally left blank

4 – 12

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Maintenance General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

5 – Maintenance 5.1 General This chapter contains a general periodic maintenance schedule and a more detailed description of the maintenance to be carried out.

5.2 Service intervals The service intervals are for guidance only and do not need to be followed strictly. The service technician must adapt these to local conditions, but it is important that the intervals meet BT's minimum demands.

The service intervals are based on the operating times and can be adapted to most normal 8 hour shifts. The following operating hours have been used when calculating the interval: Daytime: 08.00-17.00 (20 h/week) 2 shifts: 06.00-14.00, 14.00-22.00 (40 h/week) 3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 h/week) Ensure the truck receives a regular maintenance service after every 750 driving hours. The truck's safety, efficiency and service life is dependent on the service and maintenance it receives.

When service is completed, the truck must be test driven and a function check must be carried out. See the section Function and safety check in the Installation chapter.

Only use BT approved spare parts during servicing and repairs.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

5– 1

Maintenance Maintenance schedule T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

5.3 Maintenance schedule Service maintenance must happen at continuous intervals of 750 h or 12 months, depending on whichever comes first.

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

Work area

Pos.

Action

750h/12m

0000 Chassis

a

Check hood attachments.

X

b

Check signs and decals.

X

c

Check for cracks and damage.

X

d

Check the mast fixing bolts.

X

e

Check for cracks and damage to the motor fixing points.

X

f

Tighten the paper holder tensioner if necessary

X

Time used 5:20 minutes including hood removal.

b

b

b

d Qmax XXXX kg

a

b

a f

b

d b

b e M-PLATE

c

A B C D E

b

A B C

b

D

E F G

5– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Maintenance Maintenance schedule Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Work area

Pos.

Action

750h/12m

0350 Support arm

a

Check for cracks and damage.

X

b

Check the play in bushings and links1.

X

c

Check for cracks and damage to the push rods.1

X

d

Check all axles, links and locking pins1.

X

Time used 01:30:00 minutes.

1.Only applies to trucks with support arm lift (SWE120L, SWE140L and SWE200D)

g

e

c a

f

b b

d

© BT

d

Work area

Pos.

Action

0380 Fork carriage

e

Check for cracks and damage.

X

f

Check play in rollers.

X

g

Check the load support (Option).

X

Check forks' stop screws (SWE 120S)

X

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

X

Repair manual

750h/12m

SWE100, 120, 120L, 120S, 140, 140L, 200D

Time used 01:30:00 minutes.

5– 3

Maintenance Maintenance schedule T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

b a

5– 4

Work area

Pos.

Action

0560 Platform and bracket

a b

Repair manual

750h/12m

Time used

Check crack formation and damage

X

1:30 minutes

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

X

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Maintenance Maintenance schedule Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Work area

Pos. Action

750h/12m

1700 Drive motor

a

Check the drive motor's attachment.

X

b

Clean the drive motor.

X

c

Check for noise from the drive motor's bearings.

X

2550 Drive gear

d

Check for abnormal noise

X

e

Check the mountings and play in the steering bearings.

X

3180 Brake

f

Check for wear on the brake disc.

Minimum brake disc thickness: 7.9mm

X

g

Check play in released position.

Nominal brake play: 0.3mm

X

h

Cleaning brakes.

X

Time used 4:30 minutes.

f,g,h c b a e d

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

5– 5

Maintenance Maintenance schedule T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Work area

Pos.

Action

3500 Wheel

a b c

Check for wear on the drive wheel.

Check the nuts.

d e

Order no.

258946-040

750h/12m

Check for wear on the castor wheel.1 Check for wear on the support arm wheel.

Check that the castor wheel rotates freely1

X X X

Time used 2 minutes

X X

1.Not applicable for SWE120S

e

Wheel

d

c

b

a

Normal size, mm

Drive wheels Castor wheel1 Support arm wheel

Min size, mm

30 10

15 5

11

5,5

1.Not applicable for SWE120S 5– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Maintenance Maintenance schedule Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Work area

Pos.

Action

750h/12m

4110 Tiller arm

a

Check the mountings.

X

b

Check the mounting of the operating console.

X

c

Check the mounting of the handle.

X

d

Check the gas suspension's force and locking.

The tiller arm should return to the top position from both the bottom position and from the lower position where the brake is activated.

X

Time used 01:45:00 minutes

Check that the braking function is activated in both upper and lower tiller arm positions.

c

a d

b

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

5– 7

Maintenance Maintenance schedule T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Work area

Pos.

Action

750h/12m

5000 Electrical system

a

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

X

b

Check the contactors' function.

X

c

Check error code log, operating times and all the segments on the display.

X

d

Clean and check that there is no play between the steering box and the heat dissipation plate.

X

e

Check and tighten the cable connections.

X

f

Check all switches and sensors.

X

Time used 04:30:00 minutes

c

a

a,e b d

f a,e a,e

5– 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Maintenance Maintenance schedule Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

Work area

Pos. Action

6000 Hydraulic system

a b

c d e

f

6600 Lift cylinder

g h j k

T-code 841, 842, 843

750h/12m Time used

Check wear on hoses and pipes.

Check the oil level.

(Recommended range for oil level with lowered forks, see picture) Check the mountings of the hydraulic unit.

Check for any leaks in the hydraulic system.

Change the oil and clean the oil tank.

NOTE: First time after 750 h/12 m, then after 4,500 h/36 m.

Clean the oil strainer.

NOTE: First time after 750 h/12 m, then after 4,500 h/36 m.

Check lift cylinder for leaks.

Check the mounting of the lift cylinder.

Check the lift cylinder for leaks (support arm lift) Check the mounting of the cylinder (support arm lift)

X X

16 minutes

X X X

X

X X X X

g,h

j,k b a,c,d,e,f

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

20 mm

5– 9

Maintenance Maintenance schedule T code 841, 842, 843

Valid from serial no.

6061850-

Work area

Pos. Action

7100 Mast

a b c d e

f g

Date 2009-10-05

Order no.

258946-040

750h/12m

Check for any cracks or damage.

Check that there is no play in the mast's mounting points.

Check for play between the mast beam and the inner runner's rollers.

Check the inner runner's side play.

Check for wear on lifting chains and sprockets. See section “18.3 Main lift chain system 7120”.

Check adjustment of lifting chains. See section “18.3 Main lift chain system 7120”.

Lubricate the inside surfaces of the beam flanges

d

X X

Time used 16 minutes

X X 500h

500h X

g c

e

e

f a

b b

e e b b

5 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

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

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

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

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

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6– 1

Functions and parameters Function description T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Symbols on key pads and display Symbol

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

Error code

Battery charge as a percentage

Parameter

Timer

6– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Principle functions Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

6.3 Principle functions Event:

1. The battery is connected

Action(s)

Connect the truck battery [G1]

Contributing factors

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

Resulting conditions

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

Event:

2. Start truck

Preceding event(s)

The battery is connected.

Action(s)

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

Contributing factors

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

Resulting conditions

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

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

Event:

3. Fold down tiller arm to drive position

Preceding event(s)

Start the truck.

Action(s)

Lower the tiller arm.

Contributing factors

Sensor for tiller arm in drive position [B60].

Resulting conditions

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6– 3

Functions and parameters Principle functions T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Event:

4. Running in fork direction

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Turn the speed control in the fork direction

Contributing factors

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

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

Resulting conditions

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

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

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

Event:

5. Running in the castor wheel's direction

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Turn the speed control in the castor wheel's direction

Contributing factors

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

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

Resulting conditions

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

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

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

Event:

6. Neutral braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

Let the speed control go back to the free position.

Contributing factors

Adjust driver parameter 5.

Resulting conditions

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

6– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Principle functions Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Event:

7. Reverse braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

The speed control is turned to the other driving direction.

Contributing factors

Parameter 201.

Resulting conditions

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

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

Event:

8. Mechanical internal braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

The tiller arm is folded completely up or down.

Contributing factors

Sensor for tiller arm in drive position [B60].

Resulting conditions

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

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

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

Event:

9. Anti-collision safety switch

Preceding event(s)

Running in the castor wheel's direction.

Action(s)

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

Contributing factors

Safety switch [A5:S17].

Resulting conditions

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6– 5

Functions and parameters Principle functions T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Event:

10. Fork lift

Preceding event(s)

Start the truck.

Action(s)

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

Contributing factors

Main contactor [Q10].

Fuse [F1].

Fork lift button [A5:S19].

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

Resulting conditions

[T1:OUT. P-] becomes {low}.

Pump motor [M3] starts.

Event:

10. Fork lift (SWE100)

Preceding event(s)

Start the truck.

Action(s)

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

Contributing factors

Main contactor [Q10].

Fuse [F1].

Fork lift button [A5:S19].

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

Resulting conditions

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

The pump contactor [Q25] closes, the pump engine [M3] starts.

Event:

11. Fork lower

Preceding event(s)

Start the truck or fork lift.

Action(s)

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

Contributing factors

Main contactor [Q10].

Button for fork lowering [A5:S20].

Resulting conditions

[T1:OUT. LOWER VALVE] becomes {low}, the proportional valve [Q4] opens.

Event:

12. Support arm lift (SWE120L, 140L, 200D)

Preceding event(s)

Start the truck.

Action(s)

Press the support arm lift button [A5:S21].

Contributing factors

Main contactor [Q10].

Fuse [F1].

Support arm lift button [A5:S21].

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

Resulting conditions

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

The pump contactor [Q25] closes, the pump engine [M3] starts.

Event:

13. Support arm lower (SWE120L, 140L, 200D)

Preceding event(s)

Start the truck or support arm lift.

Action(s)

Press the button for support arm lower [A5:S22].

6– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Principle functions Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Contributing factors

Main contactor [Q10].

Button for support arm lowering [A5:S22].

Resulting conditions

[T1:OUT. LOWER VALVE] becomes {low}, the proportional valve [Q4] opens.

Event:

14. Click-2-Creep

Preceding event(s)

Start the truck.

Action(s)

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

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

Contributing factors

Main contactor [Q10].

Adjusting factory parameter 1002.

Resulting conditions

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

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

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

Event:

15. Turtle function (option)

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Press [S206] to activate the function.

Turn the speed control in one direction.

Contributing factors

Option button 1 [S206].

Adjusting driver parameter 7 and service parameter 202.

Resulting conditions

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

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

The pulse current feed to the drive motor is proportional to the speed control's torsion. The maximum speed is limited by driver parameter 7.

“SLO” is shown on the display (shines constantly).

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6– 7

Functions and parameters Timer T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

1. Ensure that the battery is connected.

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

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

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

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

Time measurement value

Display

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

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

Standard display.

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

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

Value 5 = Time remaining until service.

Parameter 101 controls the output value.

6– 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

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

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

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

The display shows: - Operating times and remaining time to the next service (H) - Error codes (E) - Parameters (P) - The hardware and software numbers (Pn) - Display test function (d) - Collision sensor log (c) - Emergency (limp home) mode (Ed) - Calibrating (CAL), Shortcut for setting parameter 108 = 1 2. Release the horn button to select what you wish to view.

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6– 9

Functions and parameters Parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

The parameter symbol remains lit.

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

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

The parameter symbol starts blinking.

4. Change the value by turning the speed control.

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

The parameter symbol lights again, and stays on.

6. Complete the programming by pressing the OFF button.

6 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

6.5.4 Operator parameters Note!

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

© BT

Parameter

Name/unit

Min/Max

Incre ment

Std

Description

4

Acceleration, %

10/100

5

70

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

5

Internal braking, %

10/100

5

90

States the engine's internal braking force when the speed control is in neutral. The lower the parameter value, the lower the internal braking time.

6

Maximum speed, %

30/100

5

90

States the trucks maximum speed.

7

Maximum speed turtle function, %

30/100

5

50

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

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6 – 11

Functions and parameters Parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

Driver profile

Parameter

Driver profile 1

Driver profile 2

Driver profile 3

Factory setting

PIN code

4

70

1

5

90

6

90

4

50

5

90

6

80

4

100

5

100

6

100

2

3

Note!

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

6 – 12

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

6.5.5 Service parameters Note!

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

Note!

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

Note!

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

Note!

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

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

Param eter

Name/unit

Min/ Max

Incre ment

Std

Description

101

Service interval, hours

0/ 2000

50

0

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

0 = Service indicator off.

102

Driver access

1/10

1

3

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

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

103

Timer option

1/5

1

2

States a time value for the timer.

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

104

Automatic log out, minutes

0/20

1

20

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6 – 13

Functions and parameters Parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Param eter

Name/unit

Min/ Max

Incre ment

Std

Description

105

Collision sensor X level

0/100

1

0

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

106

Collision sensor Y level

0/100

1

0

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

107

Battery adjustment, Ah

1/20

1

9

9 = Large battery 13 = Medium battery 17 = Small battery For more information, see text following the table.

108

Calibration

1

1

1 = Calibrating the proportional valve.

Returns automatically to zero after calibration has been completed. See chapter on the hydraulic system for complete instructions on how a calibration is carried out

109

Battery charger, battery type

0/3

1

0

State what type of battery is to be charged.

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

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

110

Battery charger, battery capacity, Ah

0/300 (100/ 300)

1

0 (100)

Determines the battery capacity.

0 (100) = No charge. Default setting. An error code is displayed if this parameter has been set to 0 (100) when a battery charger has been installed and factory parameter 1101 has been set to 1.

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

For more information, see the Installation chapter.

6 – 14

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Parameters Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Param eter

Name/unit

Min/ Max

Incre ment

Std

Description

111

Resetting following a collision

0/1

1

0

0 = Special pincode required for resetting after a collision.

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

2 = The horn sounds once every five seconds.

3 = Alternatively, 1 and 2 combined.

201

Reverse braking

70/ 100

5

100

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

202

Creep speed

-200/ 200

5

0

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

-200 = low speed at the first speed sensor.

200 = high speed at the first speed sensor.

301

Ramp for lowering stop

3/20

1

7

Indicates the proportional valve's closing ramp.

302

Fork, lowering speed

70/ 255

5

190

Indicates the fork's maximum lowering speed. This parameter can be adjusted manually or by using the calibration function (parameter 108 = 1).

303

EVP start position

30/ 150

5

90

Indicates the proportional valve's start position. This parameter can be adjusted manually or by using the calibration function (parameter 108 = 1).

304

EVP support arm, lowering speed

50/ 220

5

130

Indicates the support arm's lowering speed.

This parameter can be adjusted manually or by using the calibration function (parameter 108 = 1).

305

EVP slow lowering speed

40/ 220

5

105

Indicates the low speed when using the “Click-2-Creep” lowering speed. This parameter can be adjusted manually or by using the calibration function (parameter 108 = 1).

306

Activate the two raising/lowering speeds

0/1

1

1

Activate “Click-2-Creep” raising/lowering 0 = Off 1 = On

307

Activate automatic lowering of support arm

0/1

1

1

Activate automatic lowering of support arm.

0 = Off 1 = On

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6 – 15

Functions and parameters Parameters T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

6.5.6 Factory parameters Adjusting the truck's factory parameters is done during production in the factory. You can only change the factory parameters via the software TruckCom in a PC or PDA. Note!

Remember that a change of specific truck parameters changes the truck's properties. Do not change any parameter values without the necessary prior knowledge. Only authorised service technicians with personal TruckCom user identities have the rights to change factory settings. This must only be done if specific needs arise.

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

6 – 16

Param Name/unit eter

Min/ Max

Incre Std Description ment

1001

Truck type

0/8

1

0

0 = Unknown truck type 1 = SWE100 2 = SWE120 3 = SWE140 4 = SWE120L 5 = SWE140L 6 = SWE200D 7 = SWE080L 8 = SWE120S

1002

Non-configurable option

0/3

1

1

You have access to 3 functions via parameter 1002. These functions are either activated or deactivated.

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

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

1003

ConfOption Func1

0/13

1

0

Requires SEU

1004

ConfOption Func1Arg1

0/255

1

0

Requires SEU

1005

ConfOption Func1Arg2

0/255

1

0

Requires SEU

1006

ConfOption Func1Arg3

0/255

1

0

Requires SEU

1007

ConfOption Func1Arg4

0/255

1

0

Requires SEU

1008

ConfOption Func2

0/13

1

0

Requires SEU

1009

ConfOption Func2Arg1

0/255

1

0

Requires SEU

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Functions and parameters Parameters Order no.

258946-040

© BT

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Param Name/unit eter

Min/ Max

Incre ment

Std Description

1010

ConfOption Func2Arg2

0/255

1

0

Requires SEU

1011

ConfOption Func2Arg3

0/255

1

0

Requires SEU

1012

ConfOption Func2Arg4

0/255

1

0

Requires SEU

1013

ConfOption Func3

0/13

1

0

Requires SEU

1014

ConfOption Func3Arg1

0/255

1

0

Requires SEU

1015

ConfOption Func3Arg2

0/255

1

0

Requires SEU

1016

ConfOption Func3Arg3

0/255

1

0

Requires SEU

1017

ConfOption Func3Arg4

0/255

1

0

Requires SEU

1018

ConfOption Func4

0/13

1

0

Requires SEU

1019

ConfOption Func4Arg1

0/255

1

0

Requires SEU

1020

ConfOption Func4Arg2

0/255

1

0

Requires SEU

1021

ConfOption Func4Arg3

0/255

1

0

Requires SEU

1022

ConfOption Func4Arg4

0/255

1

0

Requires SEU

1023

Control for hydraulic function

1/4

1

1

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

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

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

4 = Analogue lift and lowering control is connected to the first hydraulic function and forward control is connected to the second hydraulic function.

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

6 – 17

Functions and parameters Parameters T code 841, 842, 843

6 – 18

Valid from serial no.

6061850-

Date 2009-10-05

Param Name/unit eter

Min/ Max

Incre Std Description ment

1101

0/1

1

Battery charger, on board

Repair manual

0

Order no.

258946-040

0= Battery charger missing 1= Battery charger present

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

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

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

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

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

1. Enter your PIN code.

2. Press the horn button and keep it depressed.

“Ed” is displayed.

3. Relase the horn button.

All lamps blink and “SLO” is displayed.

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

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

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

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7– 1

Troubleshooting Troubleshooting methods T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

7.2 Troubleshooting methods 7.2.1 Troubleshooting general introduction Begin troubleshooting

Has an error code been displayed?

Yes

Follow the instructions in the chapter “Troubleshooting”

Yes

Follow the instructions in the troubleshooting diagram

Choose and prioritise the most likely causes

Where in the workplace did the problem occur?

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

Eliminate unlikely causes

No Are the symptoms in the troubleshooting diagram?

No Collect as much information about the problem as possible

When did the problem occur?

What functions are affected?

What circumstances triggered the problem?

Identify all parts which may cause the problem.

Use the wiring diagram when needed.

7– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Troubleshooting methods Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

7.2.2 Completed troubleshooting Conclude troubleshooting

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

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

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

Let the driver drive the truck.

Verify that the problem does not occur again

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

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

Recreate the circumstances that existed when the problem first occurred

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7– 3

Troubleshooting Error code history T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

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

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

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

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

7– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error code system Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Structure

Description

G.ANN G (3) A (5) NN (10)

Example 3.510 Group. States which system is affected by the error.

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

Error code

Group

Description

1 2 3 4 5 6 7 8

Not used Main control system and other The drive system The hydraulic system Not used Not used Not used Option

Error category

Description

0

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

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

Do not use.

Critical error. The main contactor is open. The truck stops.

Critical error. The main contactor is open. The truck stops.

1-2

3 4 5

© BT

Code

Description

00-09 10-19 20-39 40-59 60-79 80-99

Miscellaneous error codes.

CAN related error codes.

Error codes regarding specific units.

Error codes for short-ciruited outputs.

Error codes for open electrical circuits.

Faulty signals from sensors.

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7– 5

Troubleshooting Error codes T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

Code

Event

Possible cause Action

Main control unit E141

Software download interrupted

Transfer cable disconnected.

Restart the download in “Emergency download” mode

2.001

The transistor regulator stops all functions.

Emergency switch pressed.

Check: • that the emergency switch is unaffected.

• cable 24.

• Fuse [F51]

2.002

No event. The truck can be driven.

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

• Check the parameter settings.

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

2.003

No event. The truck can be driven.

Time for service.

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

2.004

No event. The truck can be driven.

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

Check via TruckCom where the correct data is. See section “16.2 Replacing the transistor regulator”.See Table 7.6.4.

7– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

2.101

Safety speed, raising and lowering the forks not working.

The truck type has not been indicated.

Reset data from backup, See section “15.5.2 Replacing the logic card”. If this does not help, indicate the type of truck by entering factory parameter 1001 (Truck type) or see Table 7.6.4

2.102

Safety speed, raising and lowering the forks not working.

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

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

2.501

The main contactor is open.

Low battery voltage <16.8V> for more than 2 seconds Charge the battery. Check cables and connections

2.511

The main contactor is open.

CAN communication error.

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

2.514

The main contactor is open.

CAN communication error.

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

• logic card in the handle.

2.515

The truck will not start

CAN communication error.

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

2.520

The main contactor is open.

Fault in the software for the control handle or microprocessors.

Download new software.

2.521

The main contactor is open.

The safety reversing function is faulty.

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

Check via TruckCom that the hall sensor works.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7– 7

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Event

Date 2009-10-05

Order no.

258946-040

Possible cause Action

2.522

The main contactor is open.

Faulty power supply to the hall sensor.

Check via TruckCom that the hall sensors work.

2.523

The main contactor is open.

The main contactor is not activated.

• Check that the main contactor works.

• Open the main contactor.

Drive system 3.001

Driving is prevented until the speed control is in neutral.

• The speed control is not in neutral when starting.

• Faulty hall sensor.

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

3.002

The transistor regulator reduces the maximum current to 50 %.

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

• Drive the truck less intensively.

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

3.003

The transistor regulator reduces the maximum current to 50 %.

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

• Drive the truck less intensively.

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

3.040

No event. The truck can be driven.

Faulty energy saving function in the holding position.

• Internal fault in the transistor regulator.

• Restart the truck.

• If the error persists, change the transistor regulator.

7– 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

3.080

The transistor regulator reduces the maximum current to 50 %.

The temperature sensor for the transistor regulator shows abnormal values.

• Internal fault in the transistor regulator.

• Restart the truck.

• If the error persists, change the transistor regulator.

3.081

The transistor regulator reduces the maximum current to 50 %.

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

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

3.101

Safety speed, raising and lowering the forks not working.

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

• Restart the truck.

• If the error persists, change the transistor regulator.

3.120

Safety speed, raising and lowering the forks not working.

Faulty control total for parameters in the transistor regulator.

• Internal fault in the transistor regulator.

• Restart the truck.

• Reprogramme the truck.

• If the error persists, change the transistor regulator.

3.121

Safety speed, raising and lowering the forks not working.

The transistor regulator cannot use the internal memory.

• Internal fault in the transistor regulator.

• Restart the truck.

• Reprogramme the truck.

• If the error persists, change the transistor regulator.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7– 9

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Event

Date 2009-10-05

Order no.

258946-040

Possible cause Action

3.140

The horn does not work. The safety speed.

The horn output has short-circuited.

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

3.501

The main contactor is open.

Faulty transistor regulator.

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

If the error persists, change the transistor regulator.

3.502

The main contactor is open.

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

• Restart the truck.

• Change logic card in the handle.

• If the error persists, change the transistor regulator.

3.510

The main contactor is open.

CAN communication problem with the transistor regulator when starting.

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

See section “7.1 General”.

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

If the error persists, change the transistor regulator.

7 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

3.511

The main contactor is open.

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

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

If the error persists, change the transistor regulator.

3.512

The transistor regulator stops all functions.

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

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

If the error persists, change the transistor regulator.

3.514

The main contactor is open.

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

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

If the error persists, change the transistor regulator.

3.515

The transistor regulator stops all functions.

The transistor regulator discovers CAN communication error.

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

If the error persists, change the transistor regulator.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 11

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Date 2009-10-05

Event

Order no.

258946-040

Possible cause Action

3.520

The transistor regulator stops all functions.

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

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

3.521

The transistor regulator stops all functions.

The transistor regulator discovers low motor voltage.

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

3.522

The transistor regulator stops all functions.

The transistor regulator discovers high motor voltage.

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

3.523

The transistor regulator stops all functions.

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

Internal fault in the transistor regulator.

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

3.524

The transistor regulator stops all functions.

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

Internal fault in the transistor regulator.

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

3.525

The transistor regulator stops all functions.

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

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

7 – 12

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

3.526

The transistor regulator stops all functions.

The transistor regulator's voltage feed is wrong.

Internal fault in the transistor regulator.

Change transistor regulator.

3.527

The transistor regulator stops all functions.

Faulty transistor regulator software.

Internal fault in the transistor regulator.

Check that the last software for the transistor regulator exists.

3.528

The transistor regulator stops all functions.

Internal problem for the transistor regulator's microprocessor.

• Internal fault in the transistor regulator. Check that the last software for the transistor regulator exists.

• If the error persists, change the transistor regulator.

3.529

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

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

• If the error persists, change the transistor regulator.

3.530

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

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

• If the error persists, change the transistor regulator.

3.531

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

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

• If the error persists, change the transistor regulator.

3.532

The transistor regulator stops all functions.

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

• Internal fault in the transistor regulator.

• Change transistor regulator.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 13

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Date 2009-10-05

Event

Order no.

258946-040

Possible cause Action

3.533

The transistor regulator stops all functions.

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

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

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

3.534

The transistor regulator stops all functions.

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

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

3.535

The transistor regulator stops all functions.

Faulty control total for parameters in the transistor regulator.

Download new programme in the handle and transistor regulator.

3.536

The transistor regulator stops all functions.

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

Internal fault in the transistor regulator.

Change transistor regulator.

3.537

The transistor regulator stops all functions.

Multiple direction commands from the handle.

Internal fault in the handle.

3.538

The main contactor is open.

Unknown fault in the transistor regulator.

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

• If the error persists, change the transistor regulator.

7 – 14

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

3.539

The transistor regulator stops all functions.

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

• the battery.

3.540

The transistor regulator stops all functions.

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

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

3.541

The transistor regulator stops all functions.

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

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

3.542

The transistor regulator stops all functions.

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

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

3.560

The transistor regulator stops all functions.

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

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

3.561

The transistor regulator stops all functions.

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 15

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Date 2009-10-05

Event

Order no.

258946-040

Possible cause Action

3.562

The transistor regulator stops all functions

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

Check: • connections and wiring harness • parking brake.

3.563

The transistor regulator stops all functions.

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

Check: • connections and wiring harness • parking brake.

3.580

The transistor regulator stops all functions.

Main contactor closed.

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

3.581

The transistor regulator stops all functions.

Main contactor open.

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

• main fuse [F1]

3.582

The transistor regulator stops all functions.

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

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

Internal fault in the transistor regulator.

Change transistor regulator.

3.583

The transistor regulator stops all functions.

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

Internal fault in the transistor regulator.

Change transistor regulator.

7 – 16

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

Hydraulic system 4.001

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

The analogue control for lifting and lowering is not in the neutral setting when starting. (Not applicable for SWE100).

Speed control not affected when starting the truck.

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

4.101

Safety speed, raising and lowering the forks not working.

Analogue control signals for lifting and lowering shows abnormal values.

Speed control not affected when starting the truck.

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

4.102

Safety speed, raising and lowering the forks not working.

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

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

4.125

Safety speed, raising and lowering the forks not working.

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

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

4.126

Safety speed, raising and lowering the forks not working.

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 17

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Date 2009-10-05

Event

Order no.

258946-040

Possible cause Action

4.521

The main contactor is open.

The pump motor's voltage is too low.

Check: • the wiring harness between the transistor regulator and pump motor.

• the pump motor.

4.522

The main contactor is open.

The pump motor's voltage is too low.

Check: • the wiring harness between the transistor regulator and pump motor.

• the pump motor.

4.540

The transistor regulator stops all functions.

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

• Internal short-circuit in the transistor regulator.

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

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

4.541

The transistor regulator stops all functions.

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

Check connections and wiring harness

4.560

The transistor regulator stops all functions.

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

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

Option 8.001

Safety speed, raising and lowering the forks not working.

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

• Drive carefully.

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

7 – 18

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

8.002

Safety speed, raising and lowering the forks not working.

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

8.003

No event. The truck can be driven.

Argument warning from the Spider expansion unit.

Check the settings for selected parameters.

8.010

No event. The truck can be driven.

CAN communication problem with the battery charger when starting.

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

8.011

No event. The truck can be driven.

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

Check connections and wiring harness

8.014

No event. The truck can be driven.

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

Check connections and wiring harness

8.020

No event. The truck can be driven.

The battery charger is not connected to the battery.

Check connections and wiring harness

8.021

No event. The truck can be driven.

The battery charger has discovered low battery voltage.

Check the battery status.

8.022

No event. The truck can be driven.

The battery charger has discovered high battery voltage.

Check the battery status.

8.023

No event. The truck can be driven.

The battery charger has discovered low charging temperature.

Charge the battery at normal temperature.

8.024

No event. The truck can be driven.

The battery charger has discovered high charging temperature.

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

• that the fan works.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 19

Troubleshooting Error codes T code 841, 842, 843

Code

Valid from serial no.

6061850-

Date 2009-10-05

Event

Order no.

258946-040

Possible cause Action

8.027

No event. The truck can be driven.

Serious fault in the battery charger.

Change battery charger.

8.028

No event. The truck can be driven.

The battery cahrger has exceeded the time limit for charging.

Check the battery.

8.029

No event. The truck can be driven.

The battery charger charges more than maximum capacity.

Check: • battery • service parameter 110.

8.030

No event. The truck can be driven.

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

Check factory parameter 1101.

8.031

No event. The truck can be driven.

Faulty parameter adjustment for the battery charger.

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

8.032

No event. The truck can be operated as usual.

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

8.110

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1 when starting.

Check connections and wiring harness

8.111

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1.

Check connections and wiring harness

8.114

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2 when starting.

Check connections and wiring harness

8.115

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2.

Check connections and wiring harness

8.123

Safety speed, raising and lowering the forks not working.

Spider expansion unit 1 programme warning.

Check parameter selections.

7 – 20

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Error codes Order no.

258946-040

Code

Date 2009-10-05

Valid from serial no.

6061850-

Event

T-code 841, 842, 843

Possible cause Action

8.124

Safety speed, raising and lowering the forks not working.

Spider expansion unit 2 programme warning.

Check parameter selections.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 21

Troubleshooting Troubleshooting diagram.

T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

7.6 Troubleshooting diagram.

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

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

7 – 22

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Troubleshooting diagram.

Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

7.6.1 The truck cannot be driven Symptom

Contributing factors

Possible cause

The mechanical brakes cannot be activated.

Sensor [B60]

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

• The sensor is faulty.

The mechanical brakes cannot be released.

The control handle in drive position is always “Plus”

The cable is damaged and gives faulty plus/minus measurement

Transistor regulator, input [T1:95].

Broken transistor regulator

Brake

If the play is greater than 0.6 mm, the brakes may be hard to use.

Sensor [B60]

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

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

© BT

Repair manual

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

Broken transistor regulator

Corrosion

The brakes are locked due to corrosion

Sensor [B60]

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

The control handle in drive position is always “Plus”

The cable is damaged and gives faulty plus/minus measurement

Transistor regulator, input [T1:95].

Broken transistor regulator.

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 23

Troubleshooting Troubleshooting diagram.

T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

7.6.2 The truck can only be driven at reduced speed Symptom

Contributing factors

Possible cause

Always reduced speed

Click-2-Creep function

Click-2-Creep function activated

Turtle function

Turtle function activated

Driver parameter 6 - speed

Driver parameter 6 not set at the maximum value

Pulse sensor [B11]

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

Connection of motor cables

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

Mechanical brakes

• Partly working brakes • Faulty play.

7 – 24

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Troubleshooting diagram.

Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

7.6.3 The truck can be driven but behaves abnormally Symptom

Contributing factors

Possible cause

The truck goes in the wrong direction.

Connection of motor cables

Connections U, V, W are wrongly connected

Always reduced acceleration

Driver parameter 4

Set at a low value.

Always reduced reverse braking.

Service parameter 201

Set at a low value.

Always reduced neutral braking

Driver parameter 5

Set at a low value

The truck cannot be switched off.

Parameter 102. Red ‘Off’ button on the keyboard not working.

Parameter 102 is incorrectly set to the log-in unit on the truck.

Always reduced speed

Pulser [B11]]

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

Connection of motor cables

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

7.6.4 The truck can be driven but lacks certain functions Software compatibility Make sure that the right software for the logic card [A5] and transistor controller [T1], and battery charger [A30] are installed on the truck. See section “7.1 General”.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 25

Troubleshooting Troubleshooting diagram.

T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

Not replaced ACT transistor regulator [T1]

Replaced ACT transistor regulator [T1]

Not replaced ICH logic card [A5]

OK

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

Replaced ICH logic card [A5]

Error code 2.101. Use TruckCom to upload backup values Select “Copy configuration to primary unit: ICH”

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

7 – 26

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Troubleshooting diagram.

Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

7.6.5 Faulty hydraulic functions Symptom

Contributing factors

Possible cause/Action

The forks can be lowered but not raised.

No or low hydraulic pressure

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

Pump motor [M3] does not work

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

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 27

Troubleshooting Troubleshooting diagram.

T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Symptom

Contributing factors

Possible cause/Action

The forks can be raised but not lowered.

The proportional valve [Q4] for lowering the forks does not open

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

For more information See “ Continued. The proportional valve [Q4] for lowering the forks does not open:” on page 29.

• The magnetic valve's voltage/ current is normal • No current or voltage through/ across the magnetic valve's coil • Voltage across the magnetic valve's coil, but no current through it

The forks can neither be raised or lowered

7 – 28

Fuse [F50] 7.5 A is faulty

change the fuse

Logic card [A5] is faulty

Replace logic card

Transistor regulator [T1] is faulty

Change transistor regulator

Factory parameter 1023

Check the setting of the parameter value

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Troubleshooting diagram.

Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Contributing factors

Possible cause/Action

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

Mechanical fault in the pump

Change hydraulic unit

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

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

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

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

Break in the pump motor [M3]

Change hydraulic unit

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

Contributing factors

Possible cause/Action

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

Mechanical fault in the proportional valve [Q4]

Change hydraulic unit

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

Damage to the proportional valve's [Q4] wiring harness or connections

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

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

Replace logic card [A5]

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

Change transistor regulator [T1]

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

See troubleshooting table The truck cannot be driven

Break in the proportional valve's coil [Q4]

Change hydraulic unit

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 29

Troubleshooting Built-in test function T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

2. The battery status symbol is lit.

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

Note!

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

Setti ng

Flashing symbol

Data shown in the display

Normal value

1

Battery voltage (V)

2

Current over battery (A)

-

3

The set speed value that is sent to the transistor regulator

Min: -142 Max: 142

4

Speed value from the speed sensor

Min: approx. -140 Max: approx. 140

5

Fork lowered to/from Fork lift to/from

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

6

Fork under mast sensor #1

To (0V): Down From (>5V): Up

7

N/A

-

8

N/A

-

9

Status of inputs/outputs, transistor regulator [T1]

-

10

Input/output status, logic card [A5]

-

7 – 30

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Troubleshooting Status of digital inputs/outputs Order no.

258946-040

Setti ng

Date 2009-10-05

Flashing symbol

Valid from serial no.

6061850-

T-code 841, 842, 843

Data shown in the display

Normal value

11

Maximum value registered by the collision sensor (optional)

Min: 0 Max: 100

12

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

-

13

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

-

7.8 Status of digital inputs/outputs 7.8.1 Test function “9” – Transistor regulator In this setting, the digital inputs and outputs are tested by checking specific segments on the display according to the following tables.

A F G B C

E

1

2

3

4

D

H

Position: 1 and 2: The transistor regulator's actiual value. What is the actual value in each input/output.

3 and 4: The transistor regulator's set point. Relating to what the software value should be.

A – H: Reference to segment One or more segments can be lit in each position. Indications can also be combined over several positions. [xxx] in the table is a component name {nn} in the table is a cable number in the wiring diagram.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 31

Troubleshooting Status of digital inputs/outputs T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Actual values Function Fork under mast sensor #2 [B64] INP. MAST SWITCH 2 Main contactor [Q10] Parking brake [Q1]

Pos 1

Pos 2

Pos 3

Pos 4

A

*

*

*

On: Forks down Off: Forks up

B

*

*

*

On: Contactor closed Off: Contactor open

C

*

*

*

On: Brake off Off: Brake on

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

D

*

*

*

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

-

E

*

*

*

Not assigned

Support arm in lower position.

[B62] INP. SUPPORT ARM IN LOWEST POS

F

*

*

*

On: Down Off: Up

Fork under mast sensor #1 [B63] INP. MAST SWITCH 1

G

*

*

*

On: Down Off: Up

-

H

*

*

*

Not assigned

-

*

A

*

*

Not assigned

-

*

B

*

*

Not assigned

-

*

C

*

*

Not assigned

-

*

D

*

*

Not assigned

-

*

E

*

*

Not assigned

Fork valve active.

[Q22] OUT. FORK VALVE

*

F

*

*

On: Valve open Off: Valve closed

Support arm valve active.

[Q23] OUT. SUPPORT ARM VALVE

‘

G

*

*

On: Valve open Off: Valve closed

-

*

H

*

*

Not assigned A F G B C

E D

7 – 32

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

H

© BT

Troubleshooting Status of digital inputs/outputs Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Set points Function

Pos 1 Pos 2

Pos 3

Pos 4

-

*

*

A

*

Not assigned

Main contactor [Q10] OUT. MAIN CONTACTOR

*

*

B

*

On: Contactor closed Off: Contactor open

-

*

*

C

*

Not assigned

Parking brake [Q1] OUT. BRAKE RELEASE

*

*

D

*

On: Brake off Off: Brake on

-

*

*

E

*

Not assigned

Pump motor [M3] active

*

*

F

*

On: Active Off: Not active

Proportional valve [Q4]

*

*

G

*

On: Affected Off: Not affected

-

*

*

H

*

Not assigned

Pump contactor [Q25].

OUT. PUMP CONTACTOR1

*

*

*

A

On: Contactor closed Off: Contactor open

Fork valve [Q22] OUT. FORK VALVE2

*

*

*

B

Not assigned

Support arm valve [Q23] OUT. SUPPORT ARM VALVE2

*

*

*

C

Not assigned

Spare (Digital out 4)

*

*

*

D

Not assigned

-

*

*

*

E

Not assigned

-

*

*

*

F

Not assigned

-

*

*

*

G

Not assigned

-

*

*

*

H

Not assigned A F G B C

E D

1.Only applies to SWE100.

2.Applies only to SWE120L, 140L and 200D.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 33

H

Troubleshooting Status of digital inputs/outputs T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

7.8.2 Test function “10” - Logic card

Function

Pos 1

Pos 2

Pos 3

Pos 4

-

A

*

*

*

Not assigned

-

B

*

*

*

Not assigned

-

C

*

*

*

Not assigned

Front fork lift button [A5:S19]

D

*

*

*

On: Button pressed

Front fork lowering button [A5:S20]

E

*

*

*

Rear fork lift button [A5:S21]

F

*

*

*

Rear fork lowering button [A5:S22]

G

*

*

*

Control for horn [S18]

H

*

*

*

Outermost selection button, right side [S116]

*

A

*

*

Central selection button, right side [S115]

*

B

*

*

Innermost selection button, right side [S114]

*

C

*

*

Outermost selection button, left side [S113]

*

D

*

*

Central selection button, left side [S206]

*

E

*

*

Innermost selection button, left side [S111]

*

F

*

*

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned

On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed On: Button pressed

A F G B C

E D

7 – 34

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

H

© BT

Troubleshooting Status of digital inputs/outputs Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

Function

Pos 1

Pos 2

Pos 3

Pos 4

Digital input 1

A

*

*

*

-

Digital input 2

B

*

*

*

-

Digital input 3

C

*

*

*

-

Digital input 4

D

*

*

*

-

Digital input 5

E

*

*

*

-

Digital input 6

F

*

*

*

-

Digital input 7

G

*

*

*

-

Digital input 8

H

*

*

*

-

Digital output 1

*

A

*

*

-

Digital output 2

*

B

*

*

-

Digital output 3

*

C

*

*

-

Digital output 4

*

D

*

*

-

-

*

E

*

*

Not assigned

-

*

F

*

*

Not assigned

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned A F G B C

E D

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

7 – 35

H

Troubleshooting Testing display function T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

7.9 Testing display function The digital display function can be tested in order to verify that segments are lit correctly.

To test the display, work according to following instructions: 1. Ensure that the battery is connected.

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

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

4. Keep the horn button pressed down until "d" appears, and then release the horn button.

All segments and icons should blink in sequence.

7 – 36

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Chassis 0000 Support arm 0350 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

8 – Chassis 0000 8.1 Support arm 0350 8.1.1 Support arm lift, lateral adjustment b

a

1. Loosen the lock nut 2. Adjust the lateral guides using the adjustment screw (b). There are four adjustment screws.

3. Adjust the lateral guides so that there is no play but so that the lowering does not jam.

4. Lock the adjustment screws position with the lock nut.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

8– 1

Chassis 0000 Support arm 0350 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

8.1.2 Adjusting the kneeling movement

a

Between the chassis pressure plate and the roller on the support linkage there is a min./max. value of 0.4-2.0 which must be maintained.

1. Check the clearance. When checking the clearance the wheels must fitted and in their lowered position.

2. If the clearance is incorrect detach the cylinder (a)(Allen 6mm).

3. Place an appropriate number of shims 7501642 under the cylinder (a).

4. Tighten the cylinder.

5. Check that the clearance is correct.

8– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Chassis 0000 Motor fixing points 0450 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

8.2 Motor fixing points 0450 8.2.1 Replacing springs (not applicable for SWE120S) Use the following instructions in order to replace the springs that press the drive unit towards the surface: 1. Remove the inspection covers and the battery door.

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

2. Lift out the battery.

3. Loosen the cables to the drive motor and pump motor.

4. Loosen the cable duct.

5. Loosen the battery contact and the battery cable bracket.

6. Fit the M16 threaded rod. See section “23.5 Other tools”..

7. Change the upper stop screws for M8 x 120, washers are not needed.

8. Loosen the upper bracket from the chassis.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

8– 3

Chassis 0000 Motor fixing points 0450 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

9. Compress the spring packages using the threaded rod so that brackets are free.

10. Unload the springs by releasing the bracket using the threaded rod

Note!

Check that the bushings do not get stuck or become damaged during reassembly.

8– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Chassis 0000 Removing the platform Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

8– 5

Chassis 0000 Removing the platform T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

NOTE! Take care when working with tensioned springs.

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

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

7. Assemble in reverse order.

8– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical drive motor 1700 Components Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

9 – Electrical drive motor 1700 9.1 Components b a c d

© BT

Repair manual

Pos

Name

a b c c d

Speed sensor Connection, motor cables Motor: SWE120L/140/140L/200D 1.5kW Motor: SWE100/120/120S 1.0kW Temperature sensor

SWE100, 120, 120L, 120S, 140, 140L, 200D

9– 1

Electrical drive motor 1700 Disassemble engine and truck T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

9.2 Disassemble engine and truck 1. Remove the inspection covers.

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

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

a 3. Loosen the operating console's mounting screws (a) and remove the operating console and tiller arm.

4. Loosen the brake's cable connection Q1.

9– 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical drive motor 1700 Disassemble engine and truck Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

5. Loosen the speed sensor's cable connection B1.

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

7. Lift the motor out of the truck.

8. If needed, remove the brake and speed sensor.

Note!

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

Install the motor in the reverse order.

See section “9.3 Tightening torque Drive motor”.

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

Screw the drive motor into place using the four (4) mounting screws (a). Always tighten the screws alternately in two stages. In other words, do not tighten the screw to its full torque in the first stage. See section “9.3 Tightening torque Drive motor”.

a

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

9– 3

Electrical drive motor 1700 Tightening torque Drive motor T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

3.5Nm T30

3 + 0,5 Nm 10 mm

8 Nm T30

9.4 Fitting the tempreature sensor 1. Unclip the cable from the broken temperature sensor and fit the new temperature sensor 2. Place the new temperature sensor in the engine.

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

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

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

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

7. Remove the masking tape.

The temperature sensor should now be covered by plastic padding.

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

9– 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical drive motor 1700 Cleaning Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

Note!

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

9– 5

Electrical drive motor 1700 Cleaning T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page intentionally left blank

9– 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Drive gear 2550 General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

10 – Drive gear 2550 10.1 General The drive gear is combined with the motor and the brake into a complete drive unit.

A complete renovation of the drive gear must be carried out by the supplier.

10.2 Components

b

a

© BT

Repair manual

Pos

Name

a b

Drive gear Screw SWE100, 120, 120L, 120S, 140, 140L, 200D

10 – 1

Drive gear 2550 Removing the gear from the truck (not applicable for SWE120S) T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

10.3 Removing the gear from the truck (not applicable for SWE120S) 1. Remove the inspection covers.

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

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

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

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

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

6. Lift the motor out of the truck.

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

8. Loosen the cable duct.

9. Fit the M16 threaded rod.

10 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Drive gear 2550 Removing the gear from the truck (not applicable for SWE120S) Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

10. Lift the motor bracket using the threaded rod until the drive wheel is lifted approx. 4 mm from the floor. See section “23.5 Other tools”. .

11. Loosen the gear's mounting screws.

12. Lift carefully approx. 70 mm lay the gear down on the floor.

13. Lift a further 100 mm, a total of 170 mm and pull it out to the rear edge.

Assemble in reverse order. © BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

10 – 3

Drive gear 2550 Removing the gear from the truck (not applicable for SWE120S) T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

10.4 Removing the gear from the truck (not applicable for SWE120S) 1. Elevate the drive unit approx 190 mm.

2. Loosen the drive wheel.

3. Remove the inspection covers.

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

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

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

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

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

8. Lift the motor out of the truck.

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

10. Loosen the gear's mounting screws.

11. Put down the gear and pull it out to the rear edge.

Assemble in reverse order.

Place a block under the gear in order to simplify fitting.

10 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Brake 3180 Components Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

11.1 Components A

B

C

F

D

G E

© BT

Repair manual

Pos no.

Description

A

Locking ring

B

Complete brake

C

Screw

D

Key

E

Hub

F

Brake disc

G

Flange

SWE100, 120, 120L, 120S, 140, 140L, 200D

11 – 1

Brake 3180 Release of brakes T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

11.2 Release of brakes Note!

The brakes must only be released when the truck has to be moved for service and repair work.

A

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

Note!

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

11 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Drive wheel 3530 Changing drive wheel Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

12 – Drive wheel 3530 A

B

12.1 Changing drive wheel 1. Lift the truck up on blocks (approx. 100 mm).

2. Loosen the drive wheel (A).

The drive wheel is most easily loosened diagonally from one of the sides.

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

12 – 1

Drive wheel 3530 Changing drive wheel T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

12 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Castor wheel 3540 Components Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

13 – Castor wheel 3540 This chapter does not apply to SWE120S

13.1 Components A B C

D

E

F

G

L

M

H

I

K

© BT

Repair manual

J

Pos.

Name

Pos.

Name

A B C D E F G

Locking ring Washer Screw Bracket Nuts Storage Locking ring

H I J K L M

Screw Distance Distance Storage Protection Nuts

SWE100, 120, 120L, 120S, 140, 140L, 200D

13 – 1

Castor wheel 3540 Changing castor wheel T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

13.2 Changing castor wheel 1. Elevate the truck securely.

2. Unscrew the castor wheel.

13 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Support arm wheel 3550 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

14 – Support arm wheel 3550 c

b

a

f

e

d

© BT

Repair manual

Pos

Name

a

Screw

b

Bracket

c

Bogie wheel

d

Single wheel

e

Axle

f

Locking ring

SWE100, 120, 120L, 120S, 140, 140L, 200D

14 – 1

Support arm wheel 3550 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

14 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tiller arm 4000 Components in tiller arm Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

15 – Tiller arm 4000 15.1 Components in tiller arm A

U

T

B C E

S

D

I

F G

R

J

H

K

Q L

w P

M N

V

O

OO

© BT

Repair manual

Pos.

Name

Pos.

Name

A B C D E F G H I J K

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

M N O P Q R S T U V W

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

L

Axle SWE100, 120, 120L, 120S, 140, 140L, 200D

15 – 1

Tiller arm 4000 Removing tiller arm T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

15.2 Removing tiller arm 1. Remove the inspection cover.

2. Remove the housing (A).

3. Loosen the yoke's (D) mounting screws (B).

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

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

5. Loosen the cable connections [X5] and [X60].

Assemble in reverse order.

15.3 Changing gas spring 1. Remove the casing (T).

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

3. Loosen the adjustment screw (E).

4. Remove the catch (O) from the gas suspension's lock axle (S).

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

6. Remove the gas suspension (N) and rubber fender (M).

Assemble in reverse order.

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

15 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tiller arm 4000 Changing the safety sensor Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

15.4 Changing the safety sensor 15.4.1 Dismantling 1. Remove the gas spring. See section “15.3 Changing gas spring”.

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

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

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

5. Loosen the indicator sleeve (G).

Prize the indicator sleeve away from both sides simultaneously to avoid damaging the sleeve. Check the sleeve's guide pin, if it is damaged the sleeve must be replaced.

6. Remove the axle (H).

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

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

8. Remove the sensor mounting screw (S).

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

10. Remove the sensor.

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

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

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

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

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

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

m 19

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

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

m

8. Fit the gas spring. See section “15.3 Changing gas spring”.

9. Check the function of the safety sensor.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

15 – 3

Tiller arm 4000 Components in tiller arm handle T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

15.5 Components in tiller arm handle H G A

I

F

C A

B

D E K

J

L

S

T M

K

X L R N

Q

P O

U

V

15 – 4

Pos

Description

Pos

Description

A

Symbol board

M

B C D

N O P

E F G

Push button Push button Push button for safety reversing Spring Logic card [A5] Seal

Speed regulator/ direction selector Display Cable holder Cable holder

H I J K L

Spring Cover Seal Signal button Signal switch

T U V X

Repair manual

Q R S

Cover Plug Cap, transparent plastic Seal Handle Cap Wiring harness

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tiller arm 4000 Components in tiller arm handle Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

2. Loosen the screws and press down the upper cover (Q).

3. Disconnect the cable connected to logic card [A5] (F).

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

Assemble in reverse order.

WARNING! Static electricity!

Risk of static discharge that can damage the electronics.

Ensure that necessary measures are taken before working with electronics.

15.5.2 Replacing the logic card NOTE! Access to TruckCom is required to be able to perform this action!

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

2. Disconnect logic card[A5] connections.

3. Remove logic card [A5].

Assemble in reverse order.

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

1. Load new software into the logic card [A5].

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

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

4. Select “Copy truck configuration” in TruckCom. 5. Select “Copy configuration to primary unit: ICH” 6. Start the truck.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

15 – 5

Tiller arm 4000 Components in tiller arm handle T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

15.5.3 Changing signal button/switch 1. Remove the button according to the picture.

2. Disconnect the switch connector on the logic card [A5].

3. Push the switch out from its fastening.

Assemble in reverse order.

15 – 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tiller arm 4000 Components in tiller arm handle Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

15.5.4 Changing raising/lowering button.

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

A

A

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

Assemble in reverse order.

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

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

3. Unscrew the button's holder and arm.

Assemble in reverse order.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

15 – 7

Tiller arm 4000 Components in tiller arm handle T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

15.5.6 Changing the position of the controls support arm lift/fork lift 1. Undo the buttons for the lifting control using a narrow chisel and swap with the rear buttons.

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

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

4. Start the truck to verify the change.

15 – 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tiller arm 4000 Components in tiller arm handle Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

×1 2,5 mm

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

×4 4 mm

3. Disconnect the CAN contact.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

15 – 9

Tiller arm 4000 Components in tiller arm handle T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

×3 3 mm

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

6. Assemble in reverse order.

15 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components Changing wiring harness Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

16 – Electrical components 16.1 Changing wiring harness

A B X5 X21

C

X60

D

Pos.

Name

A

Contack locking

B

Contact, flange

C

Bracket

D

Contact, handle

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

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

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

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

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

16 – 1

Electrical components Changing wiring harness T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

16.1.1 Changing the transistor regulator's wiring harness.

A

B

C

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

• Then lift up the contact ring (C).

16 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components Replacing the transistor regulator Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

16.2 Replacing the transistor regulator Note!

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

a

1. Remove the inspection cover.

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

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

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

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

6. Remove the transistor regulator.

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

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

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

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

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

16 – 3

Electrical components Replacing the transistor regulator T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

16 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

17 – Hydraulic system 6000 17.1 General Remember to take the following safety measures before you beging working with the truck's hydraulic system: • Release the system's pressure gradually.

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

• Take care as the oil in the transmission and hydraulic systems may be hot.

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 1

Hydraulic system 6000 Hygiene when working on hydraulics T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

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

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

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

NOTE! Only new and clean oil should be put into the hydraulic system. If the oil is polluted, the hydraulic components will be damaged.

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

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

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

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

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

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

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

Tape must never be used without subsequent cleaning.

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

Plugs and plastic bags are to be discarded after use.

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

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

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

17 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Hygiene when working on hydraulics Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

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

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

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

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

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

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

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 3

Hydraulic system 6000 Hydraulic unit 6100 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

17.3 Hydraulic unit 6100

o

n m

a

k b

i

c

d

h g f

e

Pos.

Name

Pos.

Name

a

Pump motor [M3]

h

Hydraulic fork connection

b

Magnetic valve, support arm selection [Q23]1

i

Pressure limit valve

c

Magnetic valve, fork selection [Q22]1

k

Max. oil level

d

Proportional valve, lowering [Q4]

m

Filling cap

e

Tank (suitable oil volume 5 l)

n

Pump motor cable connection

f

Screw

o

Pump motor cable connection

g

Hydraulic connection, support arm 1.Only applies to SWE120L, SWE140L and SWE200D

17 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Hydraulic unit 6100 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

17.3.1 Emptying the hydraulic tank 1. Loosen all cables and tubes to the hydraulic unit.

2. Loosen the hydraulic unit from the truck by releasing the clamps that surround the pump motor.

3. Loosen the tank from the hydraulic unit by loosening screw (f).

17.3.2 Hydraulic system, bleeding Cylinders with bleeding valve 1. Loosen all bleeding screws 2 revolutions.

2. Lift slowly at a constant rate until the forks begin to rise (30-40 cm).

3. Close the bleeding screws.

4. Lower the forks and continue to press the lowering button for 10-15 s.

5. Top up with oil.

6. Lift the forks to max.

7. Lower and check the oil level.

Cylinders without bleeding valve 1. Lift slowly at a constant rate until the forks begin to rise.

2. Lower the forks and continue to press the lowering button for 10-15 s.

3. Repeat a couple of times.

4. Top up with oil.

5. Lift the forks to max.

6. Lower to min.

7. Allow to stand approx. 30 min (info for customer).

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 5

Hydraulic system 6000 Hydraulic connections 6230 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

17.4 Hydraulic connections 6230 17.4.1 Quick change connector Assembling the quick change connector

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

2. Push the male fitting into the female fitting until the assembly stop makes contact with the female fitting.

3. The coupling is now made and locked.

17 – 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Hydraulic connections 6230 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Dismantling the quick change connector

1. Remove the assembly stop (with the aid of a screwdriver or similar tool).

2. Push the male fitting all the way into the female fitting.

3. Pull the male fitting out of the female fitting.

4. Refit the assembly stop on the male fitting.

5. Place protective plugs on the valve and hose.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 7

Hydraulic system 6000 Hydraulic calibration T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

17.5 Hydraulic calibration In order to handle the proportional valve’s tolerance a calibration function can be used. To activate calibration mode, service mode “cal” must be set at “1” and the truck restarted. When a calibration is carried out the service key must be connected and maximum rated weight loaded on the forks.

In calibration mode “strt” will appear on the display pending one of the two signal buttons being pressed. The calibration starts when one of the signal buttons is pressed. The lowering valve then opens slowly. As soon as the operator feels the lowering movement of the forks the signal button must be released.Wait until the display “end” appears on the display and then restart the truck. Service parameter 108 resets automatically after a calibration has been carried out.

The calibration process affects the following parameters: • The fork’s maximum lowering speed (parameter 302) • The proportional valve’s start position (parameter 303) • The supporting leg’s lowering speed (parameter 304) • Slow lowering speed (parameter 305) All parameters can be adjusted manually after a calibration.

17 – 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Adjustment of the pressure limit valve Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

17.6 Adjustment of the pressure limit valve

Location of the valve The truck must be able to handle the rated load on the forks.

Place a rated load on the forks and verify that the truck is able to lift it.

If the truck cannot lift the rated load:

c b

a

1. Prise off the sealing cap (a) around the pressure limiting valve using a screwdriver.

2. Loosen the protective cover (b) (17 mm) by turning it anticlockwise. Remove the protective cover and washer inside it.

3. Loosen the lock nut (c) (17 mm) by turning it anti-clockwise. © BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 9

Hydraulic system 6000 Adjustment of the pressure limit valve T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

4. Screw in the adjustment screw clockwise until the truck is able to lift the load without problems.

5. Tighten the lock nut (c) clockwise.

6. Refit the washer and protective cover (b).

7. Push a new sealing cap (a) around the pressure limiting valve Once the truck is able to lift the rated load, add a further 100 kg onto the forks. Verify that the truck cannot lift the load.

If the truck is able to lift 100 kg more than its rated load: 1. Prise off the sealing cap (a) around the pressure limiting valve using a screwdriver.

2. Loosen the protective cover (b) (17 mm) by turning it anticlockwise. Remove the protective cover and washer inside it.

3. Loosen the lock nut (c) (17 mm) by turning it anti-clockwise.

4. Unscrew the adjusting screw anti-clockwise until the truck cannot lift the load.

5. Tighten the lock nut (c) clockwise.

6. Refit the washer and protective cover (b).

7. Push a new sealing cap (a) around the pressure limiting valve

17 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Disassembling the hydraulic unit Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

17.7 Disassembling the hydraulic unit Before commencing any work on the hydraulic unit, make sure the forks have been fully lowered.

Step 1.

Step 2.

×n s mm

s: 13 mm, n: 2off

Step 3.

1. Disconnect the hydraulic hose. See section “17.4.1 Quick change connector”.

2. Undo the motor cables using a spanner.

3. Disconnect electrical connection to the lowering valve. © BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 11

Hydraulic system 6000 Disassembling the hydraulic unit T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

Step 5.

×n s mm

Step 4.

s: 7mm, n: 1off

×n s mm

s: 6mm, n: 1off

Step 6.

4. Loosen the hydraulic unit bracket and lift the unit out of the truck.

5. Loosen the clamp in order to detach the tank from the motor, and lift the motor and valve block away from the tank.

6. Remove and clean the strainer, then reattach it in the correct position.

7. Change the oil and clean the tank.

8. Reassemble everything in reverse order. See section “17.8 Hydraulic unit tightening torques”.

NOTE: Take care of the hydraulic unit seals when refitting it

17 – 12

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulic system 6000 Hydraulic unit tightening torques Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

17.8 Hydraulic unit tightening torques The hydraulic unit tightening torques are depicted in the picture below:

10 + 2 Nm 10 mm

8,5 +- 0,5 0,5 Nm 13 mm

45 + 5 Nm 24 mm

45 + 5 Nm 24 mm

5 +- 0,8 0,8 Nm

4 +- 0,5 0,5 Nm 7 mm

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

17 – 13

Hydraulic system 6000 Hydraulic unit tightening torques T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is intentionally left blank

17 – 14

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Main mast 7100 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

18 – Lift mast – 7000 18.1 Main mast 7100 18.1.1 Components

a a

b b

© BT

Repair manual

Pos

Name

Tightening torque

a

Upper mast fixing points.

189±8Nm

b

Lower mast fixing points.

77±4Nm

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 1

Lift mast – 7000 Main mast 7100 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

18.1.2 Maintenance Mounting The maintenance schedule states that only a visual inspection of the mast mounting bolts (a) must be carried out and that they must not be tightened when they are checked. If the mast needs to be changed or if the bolts have become loose, new bolts and washers must be used.

The tightening torque should be according to the table.

Lubrication Lubricating the beam 1

18 – 2

Repair manual

The inner sides of the beam flanges must be lubricated with BT part no. 223690 (Q8 Rembrandt EP2).

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Fork carriage 7420 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

18.2 Fork carriage 7420

a b

c

Pos

Name

a

Shims

b

Roller

18.2.1 Maintenance • Check that there is not too much play in the fork carriage.

• Adjust using the shims (a) if needed.

• There are rollers with different diameters (c) to compensate for wear to the runner.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 3

Lift mast – 7000 Main lift chain system 7120 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

18.3 Main lift chain system 7120 18.3.1 Checking the chain setting The lift chains must be adjusted at regular intervals due to elongation, see below. Chain adjustment is checked as part of regular maintenance as specified in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the fork height according to C-code 7100, 7420, 7700 and 7800 where applicable.

18.3.2 Inspecting the chain The chains are subject to two types of wear – plate wear and chain elongation. Elongation is caused by wear to the bolts and plate holes.

The chains are also affected by the environment in which they are used.

Noise If there has been insufficient lubrication, there will be metallic friction on the chain and this will result in noise.

The chain must be replaced.

Surface rust Surface rust is easy to recognize as the chain will be reddish brown.

Deep-seated rust has generally begun and the strength of the chain is impaired.

The chain must be replaced.

Rusty links Fretting corrosion results in a reddish brown powder being visible near the outer plates. The chain can also appear to bleed when lubricated.

The chain must be replaced.

Stiff links If it is not possible to pull the chain out to its normal position this can be due to link rust or jamming.

The chain must be replaced.

18 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Main lift chain system 7120 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Bolt rotation Bolt rotation can be a phenomenon related to stiff links. The fault is easy to see when comparing with a new chain. .

The chain must be replaced.

Loose bolts If a bolt is loose it will protrude from the side of the chain, and this is due to a stiff link or bolt rotation.

The chain must be replaced.

Plate wear P

H2

H3

P = Pitch.

H2 = Nominal plate height.

H3 = Minimum plate height.

A new lift chain has a specific nominal plate height, indicated by H2 in the figure. As the truck is used, the lift chain is subject to radial wear on the side that passes over the chain wheel. The minimum plate height, © BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 5

Lift mast – 7000 Main lift chain system 7120 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

H3 in the figure, indicates the minimum permitted value of the plate height.

Maximum permitted plate wear is 5% of the H2 height. If a lift chain has reached the maximum degree of wear, the chain must be replaced.

The nominal and minimum disc heights for respective lift chains are stated in the table in the chapter “Stretching”.

Elongation The elongation of a lift chain is measured on the part of the chain that passes over the chain wheel. Elongation in the section of chain where wear is greatest may not exceed 2%.

The measurement is best made over 300-1000 mm of chain.

The nominal and maximum permitted chain lengths for the relevant lift chain are specified in the table below.

Type of chain

Nominal plate height H2 (mm)

Minimum plate height H3 (mm)

Pitch P (mm)

Nominal chain Maximum length for 20/30/ permitted chain 50 plates (mm) length for 20/30/50 plates (mm)

3/4”, 2x3

17,8

16,9

19,05

381/572/953

389/583/972

3/4”, 3x4

17,8

16,9

19,05

381/572/953

389/583/972

3/4”, 4x6

17,8

16,9

19,05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

One cause of chain elongation is wear on the bolts and around the holes in the plates. The chain must be replaced if elongation exceeds 2%.

18 – 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Main lift chain system 7120 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Damage

If there is any other damage, the chain should be replaced

Damaged plates If a plate has broken on the chain, this may be due to overloading or corrosion.

The chain must be replaced.

Damaged bolts It can be difficult to determine whether a bolt has broken. A broken bolt can manifest itself as bolt rotation and/or a loose outer plate.

The chain must be replaced.

Dirty chain If a chain is very dirty the recommendation in the first instance is that it should be replaced. It can also be dismantled and cleaned as set out in the chapter “Cleaning”.

18.3.3 Cleaning If a chain is very dirty you are recommended to replace it.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 7

Lift mast – 7000 Main lift chain system 7120 T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

The chain should be blown dry using compressed air and lubricated directly after cleaning Note!

Take care with degreasing agents as these may contain abrasives.

18.3.4 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains.

Note!

Lubricant must not contain substances such as molybdenum disulphide, PTFE, or similar.

A lift chain must be released from the weight of the fork carriage (suspended) when lubricated.

• Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments.

The chains are sprayed with lubricant. Note the entire chain must be lubricated, including the fixing bolts. It is particularly important that the part of the chain that runs over the chain wheel is well lubricated.

The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C <+ 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

>+ 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

* Similar products from another manufacturer may be used.

Note!

Do not use a special rust protective agent to prevent rust attack on the lift chains.

These agents impair lubrication of the chains. Regular lubrication is the best way of preventing rust attack.

18 – 8

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Changing the fork-lift trolley Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

18.4 Changing the fork-lift trolley 1. Raise the fork-lift trolley using an overhead crane or another truck to relieve the pressure on the chain.

2. Undo the chain bolt.

3. Lower the fork-lift trolley.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 9

Lift mast – 7000 Changing the fork-lift trolley T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

4. Raise the mast.

5. Remove the fork-lift trolley.

6. Assemble in reverse order.

18 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Changing the stand Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

18.5 Changing the stand In the example a Duplex Hilo stand is used.

1. Begin by disconnecting the fork-lift trolley according to the above example.

2. Undo all connections to the lifting height contact breakers.

3. Remove the spiral hose.

4. Undo the main hydraulic hose from the T-connection.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 11

Lift mast – 7000 Changing the stand T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

5. Connect a hose plug to the hydraulic hose to stop the oil flow.

6. Lift out the battery.

7. Lower the stand and secure it at both lifting points using an overhead crane or another truck. See section “23.5 Other tools”.

18 – 12

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Lift mast – 7000 Changing the stand Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

8. Undo the four bolts holding the stand.

9. Lift the stand up past the guide lugs.

10. Assemble the new stand in reverse order.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

18 – 13

Lift mast – 7000 Changing the stand T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

18 – 14

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Accessories Spider expansion unit Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

19 – Accessories 19.1 Spider expansion unit The spider expansion unit, called SEU, allows the main logic card to manage a large number of inputs and outputs. There is no truck control logic in SEU, which means that a faulty SEU can be changed without it affecting the truck's function.

SEU is used for modifying the truck in accordance with special requirements from the customer. .

Electronic card

Truck Log System

Pump controller

Extra/Customised function(s)

CAN bus

Spider Expansion Unit

CAN service connector Motor Controller

The image above shows how SEU is used to allow a large number of functions to be controlled via the CAN bus. SEU has a 42 pin, multipin contact that manages all inputs, outputs, CAN and power supply signals.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

19 – 1

Accessories TLS - Truck log system T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

19.2 TLS - Truck log system See the separate manual that comes with the truck log system.

19.3 ID unit See the separate manual that comes with the software.

19.4 Toyota Wireless Information System T.W.I.S. See the separate manual that comes with the software.

19 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Accessories Built-in battery charger Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

19.5 Built-in battery charger Note!

When retrofitting a built-in battery charger, TruckCom is required to be able to set all necessary parameters. When replacing the existing charger, TruckCom is not required.

If the truck is supplied with a battery from the factory, the battery charger is adapted to suit the battery.

If the truck is delivered without the battery from the factory, the customer/technician must enter the correct parameters according to the type and size of the battery.

B

19.5.1 Technical data Name

SMCO 24/30

Size, mm

240x111x77

Weight, kg

1,7

Ambient temberature, ºC

-25 - +40 (free ventilated batteries) +15 - +30 (valve regulated batteries)

© BT

Mains voltage, V AC

195-264

Rated voltage, V DC

24

Rated current, A

30

Maximum output, W

800

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

19 – 3

Accessories Built-in battery charger T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

19.5.2 Battery charging Open the battery door and connect the charger's contact to wall socket to begin charging.

Note!

Always switch off the truck before charging and disconnect other electrical connections to the truck.

When the truck is being charged, the following is shown on the display:

Main charge On the left of the sign window, lines are shown in sequence as the battery is charged. The battery symbol and OFF button blinks.

Uneven charging Four lines on the left of the sign window shine constantly while four lines on the right are shown in sequence. The battery symbol and OFF button blinks.

Charging complete The sign window shows the capacity value and the unit (Ah) alternately.

The battery symbol shines at a fixed brightness and the OFF button blinks.

Remove the contact from the wall socket when the battery charge is complete. The OFF button now shines permanently. The truck is ready for use.

19 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Appendices General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

20 – Appendices 20.1 General In the chapter Appendices, you can quickly find the following information: • technical data • general tightening torques • tools • oil and grease specifications • electrical components and wiring diagrams • hydraulics chart • instructions for disposal.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

20 – 1

Appendices General T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

20 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Technical data SWE100, SWE120, SWE140 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

21 – Technical data 21.1 SWE100, SWE120, SWE140 Model

SWE100

SWE120

SWE140

Drive motor Type Output, kW Duty cycle Weight, kg

Iskra AML7108 1,0, S2-60 min 9

Iskra AML7109 1,5 10,5

Brake Type Braking force, Nm Output, W Resistance, coil, Ω Nominal play in actuated position, mm Minimum thickness of brake disc, mm Thickness of a new brake disc, mm

Warner PK10 15 51/13 10,5-12,0 0,3 7,9 8,2

Transmission/gear Type Gear ratio Oil volume, litres Oil type

© BT

Repair manual

Kordel Genius 5.72.02.1 30,204 0,8 100 % synthetic API GL-5,SAE 75W-90

SWE100, 120, 120L, 120S, 140, 140L, 200D

21 – 1

Technical data SWE100, SWE120, SWE140 T code 841, 842, 843

Valid from serial no.

6061850-

Model

Date 2009-10-05

SWE100

Order no.

258946-040

SWE120

SWE140

Wheel Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque wheel bolts, Nm Support arm wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

0,2 350 350

235 1185 230 280

230 0,22 400 400 81±19 125 285 1445 85 250 290

0,24 450 450

285 1640 200 245

Hydraulic system Output, kW Duty cycle, % Minimum carbon brush length, mm Minimum commutator thickness/ diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0oC

2,2

ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuits, A

21 – 2

Repair manual

125 125 7,5

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Technical data SWE100, SWE120, SWE140 Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

Model

SWE100

T-code 841, 842, 843

SWE120

SWE140

Battery compartment, Batteries Capacity, Ah Weight, kg

150 158

225 214

Driving speeds Without load, km/h Without load, m/s With rated load, km/h With rated load, m/s

6,0 1,7 6,0 1,7

Lift/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0,28 0,14 0,38 0,38

0,28 0,12 0,38 0,38

0,25 0,11 0,38 0,37

8

8

8

1831 1888 1938 3300

1906 1956 4500

1901 1951 4755

650

715

715

Gradient capabillity With rated load, %

Measurement Short Medium Long Lift height

Weight Truck without battery, Medium

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

21 – 3

Technical data SWE120L, SWE140L, SWE200D T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

21.2 SWE120L, SWE140L, SWE200D Model

SWE120L

SWE140L

SWE200D

Drive motor Type Output, kW Duty cycle Weight, kg

Iskra AML7109 1,5 S2-60 min 10,5

Brake Type Braking force, Nm Output, W Resistance, coil, Ω Nominal play in actuated position, mm Minimum thickness of brake disc, mm Thickness of a new brake disc, mm

Warner PK10 15 51/13 10,5-12,0 0,3 7,9 8,2

Transmission/gear Type Gear ratio Oil volume, litres Oil type

21 – 4

Repair manual

Kordel Genius 5.72.02.1 30,204 0,8 100 % synthetic API GL-5,SAE 75W-90

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Technical data SWE120L, SWE140L, SWE200D Order no.

258946-040

Date 2009-10-05

Model

Valid from serial no.

6061850-

SWE120L

T-code 841, 842, 843

SWE140L

SWE200D

Wheel Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque wheel bolts, Nm Support arm wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

0,24 450 450

265 1345 220 340

230 0,24 450 450 81±19 125 265 1525 85 220 360

0,27 570 570

215 1155 100 360

Hydraulic system Output, kW Duty cycle, % Minimum carbon brush length, mm Minimum commutator thickness/ diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0oC

2,2

ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuits, A

© BT

Repair manual

125 125 7,5

SWE100, 120, 120L, 120S, 140, 140L, 200D

21 – 5

Technical data SWE120L, SWE140L, SWE200D T code 841, 842, 843

Valid from serial no.

6061850-

Model

Date 2009-10-05

SWE120L

Order no.

258946-040

SWE140L

SWE200D

Battery compartment, Batteries Capacity, Ah Weight, kg

225 214

Driving speeds Without load, km/h Without load, m/s With rated load, km/h With rated load, m/s

6,0 1,7 6,0 1,7

Lift/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0,39

0,25 0,11 0,28 0,38

9

8

9

3300

1910 1960 3255

2100

715

715

665

0,12

0,12 0,39

Gradient capabillity With rated load, %

Measurement Short Medium Long Lift height

Weight Truck without battery, Medium

21 – 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Technical data SWE120S Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

21.3 SWE120S Model

SWE120S

Drive motor Type Output, kW Duty cycle Weight, kg

Iskra AML7108 1,0 S2-60 min 9

Brake Type Braking force, Nm Output, W Resistance, coil, Ω Nominal play in actuated position, mm Minimum thickness of brake disc, mm Thickness of a new brake disc, mm

Warner PK10 15 51/13 10,5-12,0 0,3 7,9 8,2

Transmission/gear Type Gear ratio Oil volume, litres Oil type

© BT

Repair manual

Kordel Genius 5.72.02.1 30,204 0,8 100 % synthetic API GL-5,SAE 75W-90

SWE100, 120, 120L, 120S, 140, 140L, 200D

21 – 7

Technical data SWE120S T code 841, 842, 843

Valid from serial no.

6061850-

Model

Date 2009-10-05

Order no.

258946-040

SWE120S

Wheel Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque wheel bolts, Nm Support arm wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

230 0,32 675 635 81±19 100 340 1580 -

Hydraulic system Output, kW Duty cycle, % Minimum carbon brush length, mm Minimum commutator thickness/ diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0oC

2,2

ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuits, A

21 – 8

Repair manual

125 125 7,5

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Technical data SWE120S Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

Model

T-code 841, 842, 843

SWE120S

Battery compartment, Batteries Capacity, Ah Weight, kg

225 214

Driving speeds Without load, km/h Without load, m/s With rated load, km/h With rated load, m/s

6,0 1,7 6,0 1,7

Lift/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0,21 0,11 0,24 0,33

Gradient capabillity With rated load, %

8

Measurement Short Medium Long Lift height

1946 1996 4755

Weight Truck without battery, Medium

© BT

Repair manual

795

SWE100, 120, 120L, 120S, 140, 140L, 200D

21 – 9

Technical data Overflow pressure for the mast T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

21.4 Overflow pressure for the mast Mast (rated load)

Pressure for rated load (on the main lift for the HiLo mast)

Pump flow rate at rated load (from the graph for the hydraulic unit)

Recommended overflow pressure

Simplex (1000 kg)

140 Bar

7.1

165 Bar

Simplex (1,200kg)

165 Bar

6.5

190 Bar

Tele (1000 kg)

145 Bar

7.0

170 Bar

Tele (1,200kg)

170 Bar

6.4

195 Bar

Tele ClearView (1000 kg)

150 Bar

6.8

175 Bar

Tele ClearView (1,200 kg)

175 Bar

6.3

200 Bar

Tele ClearView (1,400 kg)

200 Bar

5.9

225 Bar

Duplex HiLo (1200 kg)

150 Bar

6.8

170 Bar

Duplex HiLo (1,400 kg)

170 Bar

6.4

190 Bar

Triplex HiLo (1200 kg)

185 Bar

6.2

210 Bar

Triplex HiLo (1,400 kg)

210 Bar

5.8

235 Bar

21 – 10

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

General tightening torque General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

22 – General tightening torque 22.1 General Millimetre threads M3 to M24. The following applies under ideal conditions, e.g. steel against steel.

Note!

Experience has shown that if you adjust the torque wrench to the values 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 tables otherwise the bolts may be destroyed.

22.2 Galvanised non-oiled bolts Tightening torque (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24

8,8

10,9

12,9

1,1 2,8 5,5 9,5 23 45 78 123 189 370 638

1,6 3,8 7,7 13 32 62 109 174 266 519 898

2,0 4,7 9,3 16 38 76 130 208 320 623 1075

22.3 Untreated, oiled bolts Tightening torque (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 © BT

Repair manual

8,8

10,9

12,9

1,2 2,9 5,7 9,8 24 47 81 128 197 385 665

1,7 4,0 8,1 14 33 65 114 181 277 541 935

2,1 4,9 9,7 17 40 79 136 217 333 649 1120

SWE100, 120, 120L, 120S, 140, 140L, 200D

22 – 1

General tightening torque Untreated, oiled bolts T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

22 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tools MQS contacts Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

23 – Tools 23.1 MQS contacts

Tools

Number

Use

257841

MQS Basic toolbox.

The box contains: 1 set pliers with tools 25 x splice 0.5-1.5 mm2 2 x 2, 3, 4, 6, 8 and 12 pin complete contacts (male and female) with cables and splice attached.

Used for replacing damaged contacts in the truck.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

23 – 1

Tools MQS contacts T code 841, 842, 843

Valid from serial no.

6061850-

Tools

Date 2009-10-05

Order no.

258946-040

Number

Use

257842

MQS assortment box.

Used for the complete MQS 257843 toolbox.

The assortment box contains: 200 x sleeves 0.2-0.5 mm2 200 x SWS sleeves 0.2-0.5 mm2 400 x SWS sleeves 0.5-0.75 mm2 100 x Clean body sleeves 0.5-0.75 mm2 200 x SWS pins 0.2-0.5 mm2 400 x SWS pins 0.5-0.75 mm2 1200 x seals 200 x blindplugs

257843

Complete MQS toolbox.

Contains 4 pliers with tools: MQS SWS 0.25-0.5 mm2 MQS SWS 0.5-0.75 mm2 MQS Std&Clean body 0.25–0.5 mm2, MQS Std&Clean body 0.5-0.75 mm2 Extraction tool for 2, 3, 4, 6, 8 and 12 pin male and female contacts.

23 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tools AMP contacts Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

23.2 AMP contacts PT = Power Timer (4.8, 5.8, 6.3 mm) JPT = Junior Power Timer (2.8 mm) MPT = Micro Power Timer (1.5 mm)

Figure

2

1

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) 2=163788 (JPT)

Tool for applying sleeves

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2

© BT

Repair manual

Tool for fitting pins For 0.5–2.5 mm2

1

SWE100, 120, 120L, 120S, 140, 140L, 200D

23 – 3

Tools Molex contacts T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

23.2.1 AMP contacts Multilock series 040

Figure

Number

Use

213130

Tool for removing pins

213129

Tool for fitting pins

23.3 Molex contacts 16 9 8 1 Figure

23 – 4

Repair manual

Number

Use

156937

Tool for fitting pins/sleeves

156936

Tool for fitting pins/sleeves

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Tools Grease guns Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

23.4 Grease guns Figure

© BT

Repair manual

Number

Use

24981

Tool with pointed nozzle to apply grease. Length 170 mm.

755132

One-handed grease gun with straight pressure tube and nozzle.

755142

One-handed grease gun with straight pressure tube and nozzle.

755152

Two-handed grease gun with hose and nozzle.

755145 755146 755147

Lubricating hose 450 mm.

Lubricating hose 750 mm.

Lubricating hose 1,500 mm.

202154PM

Pointed nozzle for grease guns, to apply grease in recessed nipples.

Fits grease guns with hose and pressure tube. Length 125 mm.

755140

Nozzle for tall grease nipples. Fits grease guns with hose and pressure tube.

SWE100, 120, 120L, 120S, 140, 140L, 200D

23 – 5

Tools Other tools T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

23.5 Other tools Figure

Number

Use

156263

Service key CAN)

08-13022

Puller, drive gear

Threaded rod M16x500mm 3 x M16 nuts and one washer V11-1666

K

23 – 6

Repair manual

Lifting tool Mast

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Oil and grease specification Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

24 – Oil and grease specification Table 1: Oil and grease specification Lubricant type

Specification

Use

Grease

S213366 Q8 Rubens WB

Storage and bushings

Hydraulic oil

See table below

Hydraulic system

Transmission oil

Synthetic API GL-5 SAE 75W-90

Gear

Grease

See table below

Chains

Grease

Grafloscon A-G1 (Klüber)

Gear rim

Grease

755701-040

Castor wheel

Grease

S213366 Q8 Rubens WB

Mast

Hydraulic oil Ambient temperature

Viscosity class

Specification

< 0°C

VG 27.5

ISO 6743-4 category HV DIN 51524 part 3= HVLP

> 0°C

VG 32

ISO 6743-4 category HM DIN 51524 part 2 = HLP

Ambient temperature

Viscosity class

Recommended products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C <+ 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

>+ 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

Chain grease

* Similar products from another manufacturer may be used.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

24 – 1

Oil and grease specification T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

24 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components and wiring diagram Electrical components Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

25 – Electrical components and wiring diagram 25.1 Electrical components The table below shows a compilation of the most important electrical components on the truck.

© BT

Symbol

Description

Function

A5

Logic card

Logic card tiller arm

A5:S1-18

Hall sensor

Speed control forwards/ backwards

A5:S17

Hall sensor

Safety reversing

A5:S19

Hall sensor

Fork lifting control

A5:S20

Hall sensor

Fork lowering control

A5:S21

Hall sensor

Control of support arm lift

A5:S22

Hall sensor

Control of support arm lowering

A30

Battery charger

Onboard battery charger

B1

Temperature sensor

Temperature sensor for drive motor

B11

Pulse converter

Speed sensor

B60

Inductive switch

Mechanical brake activation

B62

Inductive switch

Support arm, lowered position.

B63

Inductive switch

Mast switch 1

B64

Inductive switch

Mast switch 2

B90

Collision sensor

F1

Fuse

Main fuse

125 A

F50

Fuse

Working circuit A5

7.5 A

F51

Fuse

Working circuit T1

7.5 A

F52

Fuse

Optional equipment

Option

G1

Battery

K110

Data handling unit (DHU)

Repair manual

Remarks

Option

Option

24 V Unit for handling data

SWE100, 120, 120L, 120S, 140, 140L, 200D

Option

25 – 1

Electrical components and wiring diagram Electrical components T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

M1

Motor

Drive motor

M3

Motor

Pump motor

Symbol

Description

Function

P4

Horn

P5

Warning lamp

P6

Display

Truck function display

Q1

Electromechanical brakes

Mechanical brakes

Q4

Proportional valve

Lowering

Q10

Contactor

Main contactor

Q221

Magnetic valve

Fork selection

Q231

Magnetic valve

Support arm selection

Q252

Contactor

Contactor, pump motor

S18

Switch

Horn button

S21

Switch

Emergency switch

S97

Switch

Warning lamp P5

Option

S206

Switch

Turtle function (Turtle)

Option

S111

Switch

Option button

Option

S113

Switch

Option button

Option

S114

Switch

Option button

Option

S115

Switch

Option button

Option

S116

Switch

Option button

Option

S223

Keypad/Smart card

Login with PIN code

S224

Controls

Sensilift

Option

T1

Transistor regulator

T7/T8

DC/DC transformer

T7=24V/12V T8=24V/24V

Option

T20

Antenna

T.W.I.S.

Option

X1

Connection

Battery

X21

Connection point

DC/DC transformer

X40

Connection point

CAN communication (Extra I/O)

X41

Connection point

CAN communication (External)

Remarks Option

Option

1.Applies only to SWE120L, 140L and 200D. 25 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components and wiring diagram Electrical components Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

2.Only applies to SWE100.

A5:S22 A5:S21 A5:S1-9

A5:S10-18

A5

9

1 10 18

A5:S17 A5:S20 A5:S19 P6 S113 S206 S111

S116 S115 S114

S18:1

S18:2

A5:S20 A5:S22 A5:S19

A5:S21

A5:S17

S223 B60 X41

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

25 – 3

Electrical components and wiring diagram Electrical components T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

S21 X1 G1

T7/T8

F50, F51, F52 F1

Q25

Q10

X21 X40 B90

T1 A30

25 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components and wiring diagram Wiring diagram Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

25.2 Wiring diagram 25.2.1 Index of symbols Table 2: Index of symbols Symbol

Description

Symbol

Description

Truck battery

Emergency switch NC

Fuse

Switch, pressure (weight) operated

Horn

Sensor, inductive NO

Motor, a.c.1

Sensor, inductive NC

Contactor

Variable resistance (potentiometer)

Brake (normally joined)

Push switch NO

Coil for hydraulic magnetic valve

Contact, multipolar

M

Pressure sensor, analogue P

NO = Normally open NC = Normally closed

1.AC = Alternating Current

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

25 – 5

Electrical components and wiring diagram Wiring diagram T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

25.2.2 Overview diagram F51

T1

U V W

M1 Q10

MAIN CONTACTOR (106) 31 BRAKE RELEASE (90) 32

-

72 (95) TILLER ARM IN DRIVE POS.

DRIVE MOTOR

Q1

74 (94) SUPPORT ARM IN LOW POS

70 (86) MAST SWITCH 1

F

M3

EXT. EQUIP.

Q25

OUT PUMP CONTACTOR (107) 34 PUMP MOTOR 5

B64

1

+24V (82) 30

SWE100 B63

G1

40

Q4

PROP. LOWER VALVE (108) 33

B62

+

B60

S21

F1

6 (+) B+ 24 (83) +24V 40 (-) B-

M3 Q22

71 (101) MAST SWITCH 2

FORK VALVE (98) 80 Q23 SUPPORT ARM VALVE (110)

OPTION

81

20 (84) ENABLE/PRE-CHARGE

B11

P4

61 (104) CH A, SPEED SENSOR 62 (103) CH B, SPEED SENSOR

SIGNAL HORN (112) 50

B1 63 (92) THERMAL SENSOR (DRIVE MOTOR)

F52

+5V SPEED SENSOR (85) 60 NEGATIVE SPEED/ (105) THERMAL SENSOR

CAN HIGH/LOW (99/100) 119/120

25 +24VDC 40 0VDC T7/T8 X23 12VDC/24VDC 26 41 0VDC OPTION

64

20 F50 1

20

1

24

24 119/120 (3/4) CAN HIGH/LOW

119/120 (X3/X3) CAN HIGH/LOW

B90

20 (1) +24V DC 40 (2) 0V DC

20 (X3) +24V DC 40 (X3) 0V DC

Hall SUPPORT ARM

LIFT

(X4 2) (X1 2) (X2:1/2) TURTLE

S206

S224 A

(X2:1/3) TURTLE

Repair manual

A30

OPTION

MAINS, VAC MAINS, VAC MAINS, EARTH OPTION

LOWER

Hall

A5

SPEED REF. VALUE (X11)

+24V DC (X3) 20 0V DC (X3) 40 CAN HIGH (X3) 119 CAN LOW (X3) 120

(X8:1) +5V DC (X8:2) FORK LIFT/LOWER (X8:3) OUT 0V DC

-

S97

Hall SUPPORT ARM

Hall

S18:1

40

A2:S22

A2:S1-S9 A2:S10-S18

S18:2

20

119/120 (3/4) CAN HIGH/LOW RED (+) POS. VOLT. BLACK (-) NEG. VOLT.

P5

A2:S21

(X1 1) HORN 2 (X4 1) HORN 1

25 – 6

Hall SAFETY

REVERSE

OPTION

+

A2:S17

(X12)

KEYBOARD / SMART CARD S223

X41 T20

119/120 (2/3) CAN HIGH/LOW 20 (1) +24V DC 40 (8) 0V DC

K110

ANTENNA

OPTION

DISPLAY P6

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

© BT

Repair manual

Sh. 2

Sh. 4

Sh. 2

Sh. 3

30

20

24

1

40

X21

24/BN

1

S21

2

SWE100, 120, 120L, 120S, 140, 140L, 200D

B11 4

WH

|R

7,5A F51

BK

21

BU

B11

X21

TEMP. DRIVE MOTOR

B11 3

B11 2

6

B1 GN RD

2

Q10 1

2

1

B1

M1

B1 1

DRIVE MOTOR

1

-

G1

2D2

M3

1D1

PUMP MOTOR

7,5A F50

+

64

63

62

61

60

4

3

2

31

5

6

20

40

105

92

103

104

85

106

84

25 – 7

03182.wmf

Valid from serial no.

6061850-

1/11 PROD D 236986

OUT. NEGATIVE SPEED / THERMAL SENSOR

INP. THERMAL SENSOR

INP. CH B, SPEED SENSOR

INP. CH A, SPEED SENSOR

OUT. +5V SPEED SENSOR

OUT. W

OUT. V

OUT. U

OUT. MAIN CONTACTOR

OUT. P-

INP. B+

INP. ENABLE / PRE-CHARGE

INP. B-

Date 2009-10-05

RD

B11 1

21/WH

MOTOR CONTROLLER T1

Order no.

258946-040

2

Sh. 2

Electrical components and wiring diagram Wiring diagram T-code 841, 842, 843

25.2.3 Wiring diagram

25 – 8

30

20

24

1

40

24/BN

1

S21

A1/1D1

M3

A2/2D2

PUMP MOTOR

X21

Repair manual

|R

B11 4

B1 1

60

4

3

2

34

31

6

20

40

64

63

62

M1

-

G1 7,5A F50

+

B11 3

GN RD

1

DRIVE MOTOR

2

Q10 1

2

61

B1

F1 125A

1

B11 2

6

7,5A F51

TEMP. DRIVE MOTOR

WH

2

2

Q25 1

1

21

BK

B11

X21

BU

10

21/WH

105

92

103

104

85

107

106

84

SWE100, 120, 120L, 120S, 140, 140L, 200D

03269.wmf

Date 2009-10-05

1/11 PROD D 243986 (SWE100)

OUT. NEGATIVE SPEED / THERMAL SENSOR

INP. THERMAL SENSOR

INP. CH B, SPEED SENSOR

INP. CH A, SPEED SENSOR

OUT. +5V SPEED SENSOR

OUT. W

OUT. V

OUT. U

OUT. PUMP CONTACTOR

OUT. MAIN CONTACTOR

INP. B+

INP. ENABLE / PRE-CHARGE

INP. B-

Valid from serial no.

6061850-

RD

B11 1

2

MOTOR CONTROLLER T1

T code 841, 842, 843

Sh. 2

Sh. 4

Sh. 2

Sh. 3

Sh. 2

Electrical components and wiring diagram

Wiring diagram Order no.

258946-040

© BT

© BT

Repair manual

Sh. 4

Sh. 4

2

2

33

32

120/WH

Q4

Q1

30

50

81

80

120/WH

1

1

X20

X20

119/RD

IN

2

Q23 1

2

Q22 1

119/RD

30

P4

X20

X20

24

100

99

108

90

82

112

110

98

83

SWE100, 120, 120L, 120S, 140, 140L, 200D

03184.wmf

2/11 PROD D 236986

INP. CAN LOW

INP. CAN HIGH

OUT. PROP. VALVE

OUT. BRAKE RELEASE

OUT. +24V, "HIGH SIDE DRIVER"

OUT. SIGNAL HORN

OUT. SUPPORT ARM VALVE

OUT. FORK VALVE

INP. +24V, "HIGH SIDE DRIVER"

Date 2009-10-05

Sh. 1

40

24

MOTOR CONTROLLER T1

Order no.

258946-040

Sh. 1 3

Sh. 1 3

ONLY STACKER WITH "SUPPORT ARM LIFT"

Electrical components and wiring diagram Wiring diagram

Valid from serial no.

6061850T-code 841, 842, 843

25 – 9

Repair manual

Sh. 2 4

Sh. 2

EXTERNAL EQUIPMENT

NOTE! EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL CONNECTED TO THE TRUCK FRAME.

40

24

X63

X20

X20

X20

X20

X65

X65

X63

X63

1

X20

X20

1

1

B62

B65 2

2

IF B62 NOT FITTED

IF B64 NOT FITTED

X20

X63

X63

X63

X20

X20

X20

3

25 – 10 B60 2

X20

X20

X65

73

74

72

71

70

87

94

95

101

86

Date 2009-10-05

SWE100, 120, 120L, 120S, 140, 140L, 200D

03185.wmf

3/11 PROD D 236986

INP. SUPPORT ARM, AT TOP POS.

INP. SUPPORT ARM, IN LOWEST POS.

INP. TILLER ARM IN DRIVE POS.

INP. MAST SWITCH, 2

INP. MAST SWITCH, 1

MOTRO CONTROLLER T1

Valid from serial no.

6061850-

3

T code 841, 842, 843

3

IF B63 NOT FITTED

Electrical components and wiring diagram

Wiring diagram Order no.

258946-040

© BT

© BT

Repair manual

Sh. 1 9

20

40

119/RD

120/WH

X41 1

20

119

120

3

4

40

119

120

A5 4

40

A5 8

A5 1

20

20

40

119

120

INP. A_IN

OUT. 0V DC X8:4

Valid from serial no.

6061850-

SWE100, 120, 120L, 120S, 140, 140L, 200D

03186.wmf

4/11 PROD D 236986

OUT. +5V DC X8:1

X8:2

CAN LOW

CAN HIGH

OUT. 0V DC

OUT.+24V DC

INP. +24V DC

INP. 0V DC

CAN HIGH

CAN LOW

X3

X3

X3

X3

X3

X3

X3

X3

Date 2009-10-05

FORK LIFT/LOWER

CAN, SERVICE CONNECTOR

2

A5 5

A5 6

X5

A5 7

A5 3

A5 2

119

120

X5

X5

X5

Order no.

258946-040

Sh. 3 7

Sh. 2 7

Sh. 2 7

ELECTRONIC CARD TILLER ARM A5

Electrical components and wiring diagram Wiring diagram T-code 841, 842, 843

25 – 11

25 – 12

8 8 8 8

DISPLAY P6

DISPLAY P6

1

2

S18:1

1

Repair manual

OPTION

1

S113 2

2

X2:1/3

TURTLE

TURTLE

Date 2009-10-05

SWE100, 120, 120L, 120S, 140, 140L, 200D

03187.wmf

5/11 PROD D 236986

OUT. 0V DC HORN 2 X1 2

X2:1/2

INP. HORN 2 X1 1

Valid from serial no.

6061850-

S18:2

0V DC

OUT. OV DC HORN 1

X12 6

X1 6

LCLK

X4 2

X12 5

X1 5

ENABLE

INP. HORN 1

X12 4

X1 4

SCK

SI

+5V DC

T code 841, 842, 843

X4 1

X12 3

X12 2

X1 2

X1 3

X12 1

X1 1

ELECTRONIC CARD TILLER ARM A5

Electrical components and wiring diagram

Wiring diagram Order no.

258946-040

© BT

Electrical components and wiring diagram Wiring diagram

© BT

T-code 841, 842, 843

9

I

8

0

7

6 5 4

3 2

-0#

LED_GREEN

LED_RED

0V DC

X11 7

X11 8

X11 9

X11 10

789 X11 6

SMART CARD

456

X11 4

X11 5

123

369# X11 3

2580

147X11 1

X11 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

25 – 13

03188.wmf

Valid from serial no.

6061850-

6/11 PROD D 236986

Date 2009-10-05

1

KEY BOARD / SMART CARD S223

ELECTRONIC CARD TILLER ARM A5

Order no.

258946-040

25 – 14

Repair manual

Sh. 4 9

(RED)

X40

X40

119/RD

120/WH

BLACK

RED

3

4

-

+

SWE100, 120, 120L, 120S, 140, 140L, 200D

03189.wmf

Date 2009-10-05

7/11 PROD D 236986

MAINS, EARTH

MAINS, VAC

MAINS, VAC

INP. CAN HIGH

INP. CAN LOW

OUT. NEGATIVE CHARGER VOLTAGE

OUT. POSITIVE CHARGER VOLTAGE

Valid from serial no.

6061850-

MAINS CONNECTOR

119/RD

120/WH

40 (BLACK)

1

BCU A30

T code 841, 842, 843

Sh. 4 9

Sh. 4 8

Sh. 3 8

ONBOARD CHARGER

OPTION

Electrical components and wiring diagram

Wiring diagram Order no.

258946-040

© BT

Electrical components and wiring diagram Wiring diagram

03190.wmf

8/11 PROD D 236986 41 41

OUT. 0VDC

26 26 X23

X21

X21

Repair manual

INP. 0VDC

INP. +24VDC 25

DC/DC CONVERTER (T7=24V/12V, T8=24V/24V)

OPTION © BT

T-code 841, 842, 843

OUT. 12VDC / 24VDC

Valid from serial no.

6061850-

40

Date 2009-10-05

DC/DC CONVERTER T7 / T8

Order no.

258946-040

SWE100, 120, 120L, 120S, 140, 140L, 200D

25 – 15

Electrical components and wiring diagram Wiring diagram

03191.wmf

4

120/WH

119/RD

3

CAN LOW

CAN HIGH

INP. 0V DC 2

40

1

20

Repair manual

X40

X40

X40

X40

SHOCK SENSOR

OPTION 25 – 16

Order no.

258946-040

9/11 PROD D 236986

Date 2009-10-05

INP. +24V DC

Valid from serial no.

6061850-

SHOCK SENSOR B90

T code 841, 842, 843

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Electrical components and wiring diagram Wiring diagram

INP. 0V DC

03183.wmf

10/11 PROD D 236986

8

40

3

CAN LOW

CAN HIGH 2

119/RD

20

1

DHU K110

Repair manual

X40

X40

X40

X40

T20

DATA HANDLING UNIT (DHU)

OPTION © BT

T-code 841, 842, 843

INP. ANTENNA

Valid from serial no.

6061850-

120/WH

Date 2009-10-05

INP. +24V DC

Order no.

258946-040

SWE100, 120, 120L, 120S, 140, 140L, 200D

25 – 17

Electrical components and wiring diagram Wiring diagram Date 2009-10-05

Order no.

258946-040

220 2 S97

25 – 18

Repair manual

X40

X40

1

WARNING LIGHT

OPTION

3

P5

1

03257.wmf

Valid from serial no.

6061850-

11/11 PROD D 236986

T code 841, 842, 843

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Hydraulics chart Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

26 – Hydraulics chart p a

o

b c

n

d e f

m

g

k

i

h

Pos.

Description

Pos. Description

a

Lift cylinder, support arm1

h

Tank

b

Magnetic valve, fork selection [Q22]1 Magnetic valve, support arm selection [Q23]1 Proportional valve, lowering [Q4] Non-return valve Pressure limit valve, max 230 Bar Pump

i

Filter

k

Filter

m n o p

Air filter Flow regulator valve Lift cylinder, forks Hose fracture valve

c d e f g

1.Only applies to SWE120L, SWE140L and SWE200D

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

26 – 1

Hydraulics chart T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

26 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Instructions for disposal General Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

27 – Instructions for disposal 27.1 General The instructions for disposal have been developed in order to support our company's objective to protect the environment. By recycling materials, resources are utilised more efficiently whilst reducing the emission of unwanted substances.

The following instructions specify in which category to sort the materials present in different components. For optimum sorting the components should be dismantled at a level that corresponds to the sorting categories.

27.2 Marking of plastics 27.2.1 General marking of products and packaging The plastic marking consists of three arrows, a numeral, and usually the name of the plastic material. The image shows the markings for polypropylene.

• 01: PET – Polyethylene terephthalate • 02: PE-HD – High-density polyethylene • 03: PVC – Polyvinyl chloride • 04: PE-LD – Low-density polyethylene • 05: PP – Polypropylene (see image) • 06: PS – Polystyrene • 07: O – Other

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

27 – 1

Instructions for disposal Marking of plastics T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

27.2.2 Marking to BT Standard Standards: BT 58-02-001, BT58-02-003 and BT58-02-004.

Some examples of markings are given below. For more information, refer to the standards above.

The item's material/trade name is shown between inward facing arrows, e.g. >PP<.

Abbreviations -

ABS: Acrylonitrile butadiene styrene HDPE:High-density polyethylene LDPE: Low-density polyethylene PA: Polyamide PA6: Polyamide 6 PA66: Polyamide 66 PBT: Polybutylene terephthalate PC: Polycarbonate PET: Polyethylene terephthalate PMMA: Plexiglas POM: Polyoxymethylene, Polyformaldehyde PP: Polypropylene PUR: Polyurethane

Example of marking Items produced from an element ABS (Acrylonitrile-butadiene-styrene): >ABS< Polyurethane: >PUR< Plastic mixtures A blend of Acrylonitrile-butadiene-styrene and Polycarbonate: >ABS+PC< Filled or reinforced material Polypropylene with 30 % mineral powder: >PP-MD30<

27 – 2

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Instructions for disposal Pressure vessels Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

27.3 Pressure vessels Pressure vessels that are sent for recycling/destruction must be depressurised and open if possible.

Examples of pressure vessels are gas dampers and accumulators in the hydraulic system.

27.3.1 Gas damper DANGER! Gas dampers may have very high internal pressure. The manufacturer's recommendations must always be followed to avoid personal injury.

Protective goggles must be worn when the springs are opened.

Gas dampers must be opened according to the manufacturer's recommendations in order to release the gas. On example of this is for the “Stabilus Lift-O-Mat/Inter-stop”:

2

1

ca 20 mm

1: Drill or saw a hole in the cylinder approx. 20 mm from its bottom.

2: Drill or saw a hole in the recess in the sideshift cylinder.

© BT

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

27 – 3

Instructions for disposal Sorting categories T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

27.4 Sorting categories • Plastic and rubber • Iron/steel, including bolts, washers and nuts • Oils • Oil filters • Oil contaminated • Electronic parts including switches and sensors • Cables • Hazardous waste • Complex material – Large amounts of several categories and noncombustible or hazardous waste • Combustible material, including small parts of plastic or rubber • Batteries are returned to the manufacturer.

Component

Category

Chassis

• Iron/steel

Hoods and covers, sheet metal

• Iron/steel

Hoods and covers, plastic

• Plastic

Forks and frames

• Iron/steel

Platforms

• Iron/steel, also any gas dampers

Comment

• Handle: >ABS<

• Flooring, cushions: combustible Roof and protective frame

• Iron/steel

Gates and driver protection

• Iron/steel

Sort according to material markings Gas dampers must be depressurised

• Plastic handle: >PA< • Pinch guard: >PMMA<

Hydraulic unit

• Oil • Hydraulic hoses: Oil contaminated • Oil tank: >PP< • Motor, valves: Electronic parts • Pump: Iron/steel

Ensure that the system is depressurised.

Drain oil carefully.

Any accumulators are emptied of gas and left open if possible.

• Accumulator: Iron/steel Drive motors

• Motor: Electronic parts • Cables • Parking brake: Hazardous waste

27 – 4

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

Instructions for disposal Sorting categories Order no.

258946-040

Date 2009-10-05

Valid from serial no.

6061850-

T-code 841, 842, 843

Component

Category

Comment

Drive gear

• Iron/steel

Drain oil carefully

• Oil

Hazardous waste

• Tread: Plastic according to markings

If it is not possible to separate the tread and the hub, sort the wheel as complex material

Wheel

• Hub: Iron/steel Tiller arms

• Electronic parts • Cables

Gas dampers must be depressurised

• Iron/steel, also gas dampers Electrical system

• Logic board, transistor regulator, Expansion unit SEU, contactors: Electronic parts

Hazardous waste

• Cables

Mast

• Small batteries

Hazardous waste

• Fluorescent tubes

Hazardous waste.

Due to the chemical contents of fluorescent tubes these must not broken up.

Used fluorescent lamps must be packaged and transported according to local regulations.

• Beams, rollers, cylinders and hydraulic pipes: Iron/steel

Oil contaminated items are treated as hazardous waste

• Hydraulic hoses: Oil contaminated () • Cables • Sensors/switches: Electronic parts • Plastic items: According to markings or as combustible Chargers and connections

© BT

Repair manual

• Electronic parts • Cables

SWE100, 120, 120L, 120S, 140, 140L, 200D

27 – 5

Instructions for disposal Sorting categories T code 841, 842, 843

Valid from serial no.

6061850-

Date 2009-10-05

Order no.

258946-040

This page is deliberately left empty

27 – 6

Repair manual

SWE100, 120, 120L, 120S, 140, 140L, 200D

© BT

© BT SE-595 81 Mjölby Sweden www.toyota-forklifts.eu