BT SWE100 120 SWE120S SWE120L SWE160D Service Guide Manual - PDF DOWNLOAD

Service Guide

en

SWE100/120, SWE120S, SWE120L, SWE160D Valid from serial number: 715612-

Order number: 225678-040 Issued: 2005-05-20 ITS

© BT Europe AB

Issue date

Resp.

Changes

2005-05-20

ITS

Completely new issue

This manual covers following truck models:

T-code

Model

Serial number

700

SWE100

715612-

700

SWE120

715612-

701

SWE120S

715612-

702

SWE120L

715612-

702

SWE160D

715612-

© BT Europe AB Service Guide SWE100/120, SWE120S, SWE120L, SWE160DApproved by: L-G Andersson

Table of contents Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

1- Table of contents Technical data – M4 SWE100/120, SWE120S

2-1

Technical data – M4 SWE120L, SWE160D

3-1

Preventive maintenance – P2 SWE100/120, SWE120S

4-1

Maintenance schedule ..................................

1

Lubrication schedule .....................................

6

Preventive maintenance – P2 SWE120L, SWE160D

5-1

Maintenance schedule ..................................

1

Lubrication schedule .....................................

6

Oil and grease specification – P3 SWE100/120, SWE120S

6-1

Oil and grease specification – P3 SWE120L, SWE160D

7-1

Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D

8-1

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

1

AMP connectors ............................................

2 8.2.1 AMP Connectors, 040 series .............................. 3

© BT Europe AB

Service Guide

Molex connectors ..........................................

3

Other tools.....................................................

4

SWE100/120, SWE120S, SWE120L, SWE160D

1- 1

Table of contents T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Electrical systems – 5000 SWE100/120, SWE120S

9-1

Electrical parts ..............................................

1

List of symbols and electrical wiring diagram

3 5 6 7 8 9

9.2.1 9.2.2 9.2.3 9.2.4 9.2.5

Electrical diagram 1(5) Electrical diagram 2(5) Electrical diagram 3(5) Electrical diagram 4(5) Electrical diagram 5(5)

........................................ ........................................ ........................................ ........................................ ........................................

Functional description..................................

Starting the truck ...............................................

Driving ...............................................................

Neutral speed reduction ....................................

Neutral speed reduction on slopes ...................

Braking ..............................................................

Lifting the forks .................................................

Lowering the forks ............................................

Horn ..................................................................

10 10 10 10 10 10 11 11 11

Hour meter...................................................

11

Fault codes ..................................................

12

Parameters ..................................................

25 25 26 26 26 26 26 26 27 28 28 28 28 28 29 29 29 29 29 29 29

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8

9.6.1 Operator parameters ........................................

9.6.2 Parameter description .......................................

Parameter 1 ......................................................

Parameter 2 ......................................................

Parameter 3 ......................................................

Parameter 4 ......................................................

Parameter 5 ......................................................

9.6.3 Service parameters ...........................................

9.6.4 Parameter description .......................................

Parameter 10 ....................................................

Parameter 14 ....................................................

Parameter 15 - Non-configurable option ...........

Parameter 16 - Configurable option #1 .............

Parameter 17 - Configurable option #2 .............

Parameter 18 - Configurable option #3 .............

Parameter 19 - Configurable option #4 .............

Option parameters ............................................

General .............................................................

Parameter #15 Non-configurable options .........

Changing non-configurable options ..................

Parameter #16 to 19 configurable optional functions ........................................................... 30 1- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Table of contents Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Changing configurable optional functions ........ 31 Parameter 20 .................................................... 35 Parameter 21 .................................................... 35 Recommendation on parameter setting for freely ventilated batteries ........................................... 36 Instructions for verifying parameter setting ...... 37 Recommendation on parameter setting for valve-controlled batteries (VRLA) ..................... 38 Instructions for verifying parameter setting ...... 39 Parameter 22 .................................................... 39 Parameter 25 .................................................... 39 Parameter 28 .................................................... 39 Parameter 39 .................................................... 40 Login method and driver parameter access ..... 40 Expanded keypad - General ............................. 40 Expanded keypad - Programming .................... 40 Service indication ............................................. 42

Part numbers...............................................

45

Transistor panel...........................................

45 9.8.1 General ............................................................. 45

Diagnostic and troubleshooting ...................

46 9.9.1 Error codes and troubleshooting ...................... 46 9.9.2 Resetting errors ................................................ 47 9.9.3 Safety ............................................................... 47

Technical specifications – Curtis 1243 ........

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

48

1- 3

Table of contents T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Electrical systems – 5000 SWE120L, SWE160D

Order number 225678-040

10-1

Component identification ..............................

1

List of symbols and electrical wiring diagram

3 5 6 7 8 9

10.2.1 Electrical diagram 1(5) 10.2.2 Electrical diagram 2(5) 10.2.3 Electrical diagram 3(5) 10.2.4 Electrical diagram 4(5) 10.2.5 Electrical diagram 5(5)

....................................... ....................................... ....................................... ....................................... .......................................

Functional description..................................

10.3.1 Starting the truck ..............................................

10.3.2 Driving ..............................................................

10.3.3 Neutral speed reduction ...................................

10.3.4 Neutral speed reduction on slopes ...................

10.3.5 Braking .............................................................

10.3.6 Lifting the forks .................................................

10.3.7 Lifting the support arms ....................................

10.3.8 Lowering the forks ............................................

10.3.9 Lowering the support arms ...............................

10.3.10 Horn ................................................................

10 10 10 10 10 10 11 11 11 11 11

Hour meter...................................................

11

Error codes ..................................................

12

Parameters ..................................................

25 25 26 26 26 26 26 26 27 28 28 28 28 28 29 29 29 29 29 29 29

10.6.1 Operator parameters ........................................

10.6.2 Parameter description ......................................

Parameter 1 ......................................................

Parameter 2 ......................................................

Parameter 3 ......................................................

Parameter 4 ......................................................

Parameter 5 ......................................................

10.6.3 Service parameters ..........................................

10.6.4 Parameter description ......................................

Parameter 10 ....................................................

Parameter 14 ....................................................

Parameter 15 - Non-configurable option ...........

Parameter 16 - Configurable option #1 .............

Parameter 17 - Configurable option #2 .............

Parameter 18 - Configurable option #3 .............

Parameter 19 - Configurable option #4 .............

Option parameters ............................................

General .............................................................

Parameter #15 Non-configurable options .........

Changing non-configurable options ..................

1- 4

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Table of contents Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Parameter #16 to 19 configurable optional functions ........................................................... 30 Changing configurable optional functions ........ 31 Parameter 20 .................................................... 35 Parameter 21 .................................................... 35 Recommendation on parameter setting for freely ventilated batteries ........................................... 36 Instructions for verifying parameter setting ...... 37 Recommendation on parameter setting for valve-controlled batteries (VRLA) ..................... 38 Instructions for verifying parameter setting ...... 39 Parameter 22 .................................................... 39 Parameter 25 .................................................... 39 Parameter 28 .................................................... 39 Parameter 39 .................................................... 40 Login method and driver parameter access ..... 40 Expanded keypad - General ............................. 40 Expanded keypad - Programming .................... 40 Service indication ............................................. 42

Part numbers...............................................

45

Transistor panel...........................................

45 10.8.1 General ............................................................ 45

Diagnostic and troubleshooting ...................

46 10.9.1 Error codes and troubleshooting ...................... 46 10.9.2 Resetting errors ............................................... 47 10.9.3 Safety ............................................................... 47

Technical specifications – Curtis 1243 ........

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

48

1- 5

Table of contents T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Hydraulic system – 6000 SWE100/120, SWE120S

Order number 225678-040

11-1

General .........................................................

1

Hydraulic diagram and components .............

1 1 2 2 2 2 2 2

11.2.1 Main components ...............................................

11.2.2 Description .........................................................

Lift .......................................................................

Lowering .............................................................

Operating pressure .............................................

Relief valve .........................................................

Pressure switch ..................................................

Hydraulic system – 6000 SWE120L, SWE160D

12-1

General .........................................................

1

Hydraulic diagram and components .............

1 1 2 2 2 2 2 2

12.2.1 Main components ...............................................

12.2.2 Description .........................................................

Lift .......................................................................

Lowering .............................................................

Operating pressure .............................................

Relief valve .........................................................

Pressure switch ..................................................

1- 6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Technical data – M4 SWE100/120, SWE120S Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

2- Technical data – M4 SWE100/120, SWE120S Model

SWE100

SWE120

SWE120S

Type

TSL140S-DS20

TSL140S-DS30

TSL140S-DS30

Output, kW

1.0

1.2

1.2

Duty cycle

S2, 60 min

S2, 60 min

S2, 60 min

Minimum carbon brush length, mm

13

13

13

Nominal commutator diameter, mm

50

50

50

Minimum commutator diameter, mm

47

47

47

Resistance, shunt field winding, Ω at 25 C°

0.55

0.55

0.55

Resistance armature winding, Ω at 24 °C

0.0156

0.0156

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

>=1 Mohm

>=1 Mohm

Weight, kg

14

14

14

Type

BFK457-08

BFK457-08

BFK457-08

Braking force, Nm

12

12

12

Output, W

25

25

25

Resistance coil, Ω

23

23

23

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

0.2-0.4

Minimum thickness brake disc, mm

5.5

5.5

5.5

Thickness of a new brake disc, mm

7.0

7.0

7.0

Type

2-stage angle transmission

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

19,14:1

Oil volume, litre

1.0

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Hypoid olja SAE 80W/90 SAE 75W

Drive motor

Broms

Transmission/drive gear

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

2- 1

Technical data – M4 SWE100/120, SWE120S T-code 700, 701, 702

Valid from serial number 715612-

Model

Date 2005-05-20

Order number 225678-040

SWE100

SWE120

SWE120S

Drive wheel, mm

Dia 215x70

Dia 215x70

Dia 215x70

Axle pressure without load, kg

340

345

690

Axle pressure at rated load, kg

340

345

735

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

65 Nm

Support arm wheel, mm

Dia 80x95

Dia 80x95

Dia 100x75

Axle pressure without load, kg

2x 230 (240)

2x 270 (240)

2x 355(240)

Axle pressure at rated load, kg

2x 1100 (240)

2x 1350 (240)

2x 1510(240)

Support castors, mm

Dia 125x40

Dia 125x40

Axle pressure without load

2x 235 (240)

2x 350 (240)

Axle pressure at rated load, kg

2x 365 (240)

2x 470 (240)

Output, kW

2.2

2.2

2.2

Duty cycle,%

5

5

5

Minimum carbon brush length, mm

12

12

12

Minimum commutator thickness/diameter, mm

4.75

4.75

4.75

Pressure at rated load, bar

193

193

193

Overflow pressure, bar

210

210

210

Pump flow, litre/minute

5.0

5.0

5.0

Tank volume, litre

4.5

4.5

4.5

Oil type: at normal temperature at temperature < -15oC

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Drive motor circuits, A

125

125

125

Pump motor circuits, A

125

125

125

Control circuits, A

7,5

7,5

7.5

Dimensions LxWxH, mm, 180 Ah 240 Ah 320 Ah

196x643x452 196x643x572

196x643x452 196x643x572 244x643x572

196x643x452 196x643x572 244x643x572

Capacity, Ah

180-240

180-320

180-320

Weigh, kg

150-200

150-250

150-250

Wheels

Hydraulic system

Fuses

Battery compartment, Batteries

2- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Technical data – M4 SWE100/120, SWE120S Order number 225678-040

Date 2005-05-20

Model

Valid from serial number 715612-

T-code 700, 701, 702

SWE100

SWE120

SWE120S

Without load, 0-750 kg, km/h

6.0

6.0

6.0

With rated load, km/h

5.3

5.3

5.3

Lift without load, m/s

0.19

0.19

0.19

Lift with rated load, m/s

0.10

0.10

0.10

Lowering without load, m/s

0.15

0.15

0.15

Lowering with rated load, m/s

0.19

0,19

0,19

Driving without load, A

23

23

23

Driving with rated load, A

30

34

34

Lift without load, A

54

54

Lift with rated load, A

148

148

8%

10 %

8%

Medium Long

741

728 780

805 857

Turning radius WA

1482

1479

1519

570

727

765

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

2- 3

Technical data – M4 SWE100/120, SWE120S T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

This page is intentionally left blank

2- 4

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Technical data – M4 SWE120L, SWE160D Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

3- Technical data – M4 SWE120L, SWE160D Model

SWE120L

SWE160D

Type

TSL140S-DS30

TSL140S-DS30

Output, kW

1.2

1.2

Duty cycle

S2, 60 min

S2, 60 min

Minimum carbon brush length, mm

13

13

Nominal commutator diameter, mm

50

50

Minimum commutator diameter, mm

47

47

Resistance, shunt field winding, Ω at 25 C°

0.49

0.49

Resistance armature winding, Ω at 24 °C

0.0156

0.0156

Insulation resistance between the windings and motor casing

>=1 Mohm

>=1 Mohm

Weight, kg

14

14

Type

BFK457-08

BFK457-08

Braking force, Nm

12

12

Output, W

25

25

Resistance coil, Ω

23

23

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

Minimum thickness brake disc, mm

5.5

5.5

Thickness of a new brake disc, mm

7.0

7.0

Type

2-stage angle transmission

2-stage angle transmission

Gear ratio

19,14:1

19,14:1

Oil volume, litre

1.0

1.0

Oil type at normal temperature at temperature < -15oC

Hypoid oil SAE 80W/90 SAE 75W

Hypoid oil SAE 80W/90 SAE 75W

Drive motor

Broms

Transmission/drive gear

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

3- 1

Technical data – M4 SWE120L, SWE160D T-code 700, 701, 702

Valid from serial number 715612-

Model

Date 2005-05-20

Order number 225678-040

SWE120L

SWE160D

Drive wheel, mm

Dia 215x70

Dia 215x70

Axle pressure without load, kg

345

345

Axle pressure at rated load, kg

345

345

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

Support arm wheel, mm

Dia 80x75

Dia 80x75

Axle pressure without load, kg (Ah)

2 x 270 (240)

2 x 220 (240)

Axle pressure at rated load, kg (Ah)

2 x 1310/1640 (240)

2 x 1195/1515 (240)

Support castor wheels, mm

Dia 125 x 50

Dia 125 x 50

Axle pressure without load (Ah)

2 x 355 (240)

2 x 328 (240)

Axle pressure at rated load, kg

2 x 520/590 (240)

2 x 553/633 (240)

Output, kW

2.2

2.2

Duty cycle,%

5

5

Minimum carbon brush length, mm

12

12

Minimum commutator thickness/diameter, mm

4.75

4.75

Pressure at rated load, bar

191

191

Overflow pressure, bar

220

220

Pump flow, litre/minute

5.0

5.0

Tank volume, litre

4.5

4.5

Oil type: at normal temperature at temperature < -15oC

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Hydraulic oil ISO-L-HM32 ISO-L-HV32

Drive motor circuits, A

125

125

Pump motor circuits, A

125

125

Control circuits, A

7,5

7,5

Wheels

Hydraulic system

Fuses

3- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Technical data – M4 SWE120L, SWE160D Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

Model

T-code 700, 701, 702

SWE120L

SWE160D

Dimensions LxWxH, mm 180 Ah 240 Ah 320 Ah

196 x 643 x 452 196 x 643 x 572 244 x 643 x 572

196 x 643 x 452 196 x 643 x 572 244 x 643 x 572

Capacity, Ah

180 -320

180 -320

Weigh, kg

150 -250

150 -250

Without load, 0 - 750 kg, km/h

6,0

6,0

With rated load, 750 - 1200 kg, km/h With rated load, 1200 - 1600 kg, km/h support arms

5.3 4.4

5.3 4.4

Lift without load, m/s

0.19

0.19

Lift with rated load, m/s

0.10

0.11

Lowering without load, m/s

0.15

0.15

Lowering with rated load, m/s

0.19

0.19

Driving without load, A

23

23

Driving with rated load, A

36

36

Lift without load, A

54

54

Lift with rated load, A

148

148

10 %

10 %

Medium Long

796 848

813 865

Turning radius WA

1685

1786

735

655

Battery compartment, Batteries

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

3- 3

Technical data – M4 SWE120L, SWE160D T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

This page is intentionally left blank

3- 4

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 SWE100/120, SWE120S Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

4- Preventive maintenance – P2 SWE100/120, SWE120S 4.1 Maintenance schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

0000.

Chassis

0000.1

Check all links and locking pins

I

0000.2

Check wear on cover/battery locking

I

0000.3

Check of cracking and damage

I

0000.4

Check the drive housing’s mounting on the chassis

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0350

Support arm

0350.1

Tightening torque inspection of the cap bolts (Tightening torque 120 Nm)

0380.

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check clearance in bushes and links

I

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

© BT Europe AB

Service Guide

T

T

I/T1

I/T

T2

SWE100/120, SWE120S, SWE120L, SWE160D

I

4- 1

Preventive maintenance – P2 SWE100/120, SWE120S Maintenance schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level. Measured using the screwed in dipstick

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean and check functionality

3100.2

Check the brake disc

M

3100.3

Check the clearance in disengaged position 0,2-0,5 mm

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts (New wheel: Drive tread thickness = 30mm) (Tightening torque = 65Nm)

I/T

3500.3

Check that the castor wheel turns and rotates freely

I

3500.4

Check for wear on the castor wheel (New wheel:Drive tread thickness = 10mm)

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

4- 2

Service Guide

I

I3

L

L4

C

I

I I

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 SWE100/120, SWE120S Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5000

Electrical functions

5000.1

Check the function of the brake microswitch

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the horn

I

5000.4

Check for wear to cables in the tiller arm

5000.5

Check the function of the driver’s control

I

I

5000.6

Check the error code log and operating times

I

I

5110

Battery

5110.1

Check the electrolyte level, 10-15 mm over the cell plates

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on display

© BT Europe AB

Service Guide

I

I I

I

C/T

TI

SWE100/120, SWE120S, SWE120L, SWE160D

I 4- 3

Preventive maintenance – P2 SWE100/120, SWE120S Maintenance schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

6000

Hydraulic system

6000.1

Check hoses and connections for leakage

I

6000.2

Check hoses for wear and damage

I

6000.3

Check the oil tank for cracks, leakage and damaged mountings

I

6000.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

7100

Lifting Mast

7100.1

Check for damage and crack formation

I

7100.2

Retighten tha mast mounting bolts (Tightening torque = 197Nm)

T

7100.3

Check the play of the inner section rollers

I

X

7100.4

Check the lateral play of the inner section

I

X

7100.5

Check for wear on the lifting chains and chain rollers

I

X

7100.6

Check the adjustment of the lifting chains

I

X

I

I L

L5

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

4- 4

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 SWE100/120, SWE120S Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

7100

4110

6600

0380

5000 5700 0000

3100

5110

6000

5400 2550 3500 1700

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

4- 5

Preventive maintenance – P2 SWE100/120, SWE120S Lubrication schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

4.2 Lubrication schedule Pos no

Service point

Interval/Running hours 500h

1000h

Lubricant

3000h

1

Wheel bearings

L

2

Mast beam

L

F

3

Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear

O

B

L

G

C

L = Lubrication

A

O C = Check

C

O = Oil change

3

2

1

4

6

4- 6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

5

© BT Europe AB

Preventive maintenance – P2 SWE120L, SWE160D Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

5- Preventive maintenance – P2 SWE120L, SWE160D 5.1 Maintenance schedule I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

0000.

Chassis

0000.1

Check all links and locking pins

I

0000.2

Check wear on cover/battery locking

I

0000.3

Check of cracking and damage

I

0000.4

Check the drive housing’s mounting on the chassis

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0000.7

Press grease into grease nipples SWE160D=standard, SWE120L=option

0380.

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check clearance in bushes and links

I

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

© BT Europe AB

Service Guide

T

I/L6

I/T1

I/T

T2

SWE100/120, SWE120S, SWE120L, SWE160D

I

5- 1

Preventive maintenance – P2 SWE120L, SWE160D Maintenance schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level. Measured using the screwed in dipstick

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean and check functionality

3100.2

Check the brake disc

M

3100.3

Check the clearance in disengaged position 0,2-0,5 mm

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts (New wheel: Drive tread thickness = 30mm) (Tightening torque = 65Nm)

I/T

3500.3

Check that the castor wheel turns and rotates freely

I

3500.4

Check for wear on the castor wheel (New wheel: Drive tread thickness = 10mm)

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5- 2

Service Guide

I

I3

L

L4

C

I

I I

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 SWE120L, SWE160D Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5000

Electrical functions

5000.1

Check the function of the brake microswitch

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the horn

I

5000.4

Check for wear to cables in the tiller arm

5000.5

Check the function of the driver’s control

I

I

5000.6

Check the error code log and operating times

I

I

5110

Battery

5110.1

Check the electrolyte level, 10-15 mm over the cell plates

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/ T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on display

© BT Europe AB

Service Guide

I

I I

I

C/T

TI

SWE100/120, SWE120S, SWE120L, SWE160D

I

5- 3

Preventive maintenance – P2 SWE120L, SWE160D Maintenance schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

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

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

6000

Hydraulic system

6000.1

Check hoses and connections for leakage

I

6000.2

Check hoses for wear and damage

I

6000.3

Check the oil tank for cracks, leakage and damaged mountings

I

6000.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

7100

Lifting Mast

7100.1

Check for damage and crack formation

I

7100.2

Re-tighten tha mast mounting bolts (Tightening torque =197N m)

T

7100.3

Check the play of the inner section rollers

I

7100.4

Check the lateral play of the inner section

I

7100.5

Check for wear on the lifting chains and chain rollers

I

7100.6

Check the adjustment of the lifting chains

I

I

I L

L5

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/1 month, and then every 1000 h/12 months 6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.

When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

5- 4

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 SWE120L, SWE160D Maintenance schedule Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

7100

4110

6600

0380

5000 5700 0000

3100

5110

6000

5400 2550 3500 1700

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

5- 5

Preventive maintenance – P2 SWE120L, SWE160D Lubrication schedule T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

5.2 Lubrication schedule Pos no

Service point

Interval/Running hours 500h

1000h

Lubricant

3000h

1

Wheel bearings

L

2

Mast beam

L

F

3

Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear

O

B

L

G

C

L = Lubrication

A

O

C = Check

C

O = Oil change 3

2

1

4

6

5- 6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

5

© BT Europe AB

Oil and grease specification – P3 SWE100/120, SWE120S Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

6- Oil and grease specification – P3 SWE100/120, SWE120S Table 1: Oil and grease specification Lubricant A

Grease

B C

Hydraulic oil Transmission oil

D F G

Grease Grease Grease

Specification > - 15°C

Application area < - 15°C

S213366 Q8 Rubens WB ISO-L-HM32 Hypoid oil SAE 80W/90 See table below BT 055-70111 Staburags NBU 8EP

S213366 Q8 Rubens WB ISO-VG32 Hypoid oil SAE 75W See table below BT 055-74320 Staburags NBU 8EP

Bearings and bushings Hydraulic system Gears Chains Mast Steering bearings

Viscosity class

Recommended products ( Similar 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

Ambient temperature

© BT Europe AB

Service Guide

from other manufacturers may be used)

SWE100/120, SWE120S, SWE120L, SWE160D

6- 1

Oil and grease specification – P3 SWE100/120, SWE120S T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

3

2

1

4

6

6- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

5

© BT Europe AB

Oil and grease specification – P3 SWE120L, SWE160D Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

7- Oil and grease specification – P3 SWE120L, SWE160D Table 2: Oil and grease specification Lubricant A

Grease

B C

Hydraulic oil Transmission oil

D F G

Grease Grease Grease

Specification > - 15°C

Application area < - 15°C

S213366 Q8 Rubens WB ISO-L-HM32 Hypoid oil SAE 80W/90 See table below BT 055-70111 Staburags NBU 8EP

S213366 Q8 Rubens WB ISO-VG32 Hypoid oil SAE 75W See table below BT 055-74320 Staburags NBU 8EP

Bearings and bushings Hydraulic system Gears Chains Mast Steering bearings

Viscosity class

Recommended products ( Similar 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

Ambient temperature

© BT Europe AB

Service Guide

from other manufacturers may be used)

SWE100/120, SWE120S, SWE120L, SWE160D

7- 1

Oil and grease specification – P3 SWE120L, SWE160D T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

3

2

1

4

6

7- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

5

© BT Europe AB

Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D Super Seal connectors Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

8- Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D 8.1 Super Seal connectors 1

3 3 2 Figure

© BT Europe AB

Service Guide

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

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

159231

Tool for fitting secondary locks 3-6 poles (2)

159228

Tools for removing pins/sleeves (3)

SWE100/120, SWE120S, SWE120L, SWE160D

8- 1

Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D AMP connectors T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

8.2 AMP connectors PT = Power Timer (4,8. 5,8. 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

Figure

2

1

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2

8- 2

Tools for fitting pins For 0,5-2,5 mm2

1

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D Molex connectors Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

8.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

8.3 Molex connectors 16 9 8 1 Figure

© BT Europe AB

Service Guide

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

SWE100/120, SWE120S, SWE120L, SWE160D

8- 3

Tools – P4 SWE100/120, SWE120S, SWE120L, SWE160D Other tools T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

8.4 Other tools Figure

8- 4

Service Guide

Number

Application

156263

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Electrical parts Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9- Electrical systems – 5000 SWE100/120, SWE120S 9.1 Electrical parts S17

S10

X41

S21

X5 Y1

X1 F50

M3

F51 F1

P2 Y34 Y52 P1 Y41

R1 K10 F3 K30 A1

M1

H1

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 1

Electrical systems – 5000 SWE100/120, SWE120S Electrical parts T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

A17

9- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.2 List of symbols and electrical wiring diagram Symbol

Description

Function

Notes

A1

Transistor regulator

A2

Electronic card

A6

Display

A17

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10-S18

Speed control

Forwards/Reverse

M1

Motor

Drive motor

M3

Motor

Pump motor

P2

Pressure switch

Pressure switch fork lift

120 bar

R1

PTC-resistor

Power supply

15 Ohm

© BT Europe AB

Service Guide

24 V

SWE100/120, SWE120S, SWE120L, SWE160D

9- 3

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram T-code 700, 701, 702

9- 4

Valid from serial number 715612-

Date 2005-05-20

Symbol

Description

S111

Switch

Option

S112

Switch

Option

S113

Switch

Turtle button

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

A2:S17

Switch

Safety reversing

A2:S19

Switch

Fork lifting

A2:S20

Switch

Fork lowering

S21

Switch

Emergency switch off

S42

Switch

Manual fork lowering

Y1

Brake

Y34

Magnetic valve

Forks

Y41

Magnetic valve

Fork lowering

X1

Connector

Battery

X41

Connection point

CAN-communication

Service Guide

Function

Order number 225678-040

Notes

Brake lever

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.2.1 Electrical diagram 1(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 5

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.2.2 Electrical diagram 2(5)

9- 6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.2.3 Electrical diagram 3(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 7

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.2.4 Electrical diagram 4(5)

9- 8

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.2.5 Electrical diagram 5(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 9

Electrical systems – 5000 SWE100/120, SWE120S Functional description T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.3 Functional description 9.3.1 Starting the truck • To enable the truck to be started, the battery plug must be connected, the emergency switch (S21) closed and the start key (S17) in the ON position.

A1

9.3.2 Driving

BS1 T1

Ish

Ia

• The speed control activated in any direction.

MShunt

+

• S10 closed .

S2 A2

A A1

T2

K10

B+

9.3.3 Neutral speed reduction • The speed control to neutral position, motor starts to work as generator. Brake energy comes back to battery.

• Y1 will be applied when the truck comes to a stand still even if the tiller is in drive position.

• Energy is fed back to the battery (see diagram below).

• The transistors (T2) for the brake circuit generated are not live.

A1 BS1

T1 Ish

S2

MShunt

+ Ia

A2

A A1

T2 K10

B+

T

9.3.4 Neutral speed reduction on slopes If the driver release the speed control on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied by the system.

9.3.5 Braking The brake is always applied when the truck is started with the tiller in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck: • S10 open.

9- 10

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Hour meter Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.3.6 Lifting the forks • A2:S19 activated.

• Battery status OK (if battery capacity >20% left).

9.3.7 Lowering the forks • A2:S20 activated.

9.3.8 Horn • S18 activated.

9.4 Hour meter • Press S18 and turn S17 to “on” at the same time.

• Press S18 until you read H= hour meters.

• You have now choosen H=hourmeters the symbol “B” will be highlighted.

• You can now choose type of hourmeter by pressing the speed control.

A= Key time. b= Drive motor time. c= Pump motor time.

A

d= Activity time. s= Time to service.

E

D

© BT Europe AB

C

B

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 11

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.5 Fault codes • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred.

• The error codes are divided into two groups, C = caution and E = error.

• C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

9- 12

Service Guide

Code

C3

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck.

The TLS reset command activates the truck

Code

C4

Description

TLS: Use of the truck has been blocked

Possible error cause

Truck use can be “blocked” by a TLS command. / The truck cannot be used until a new TLS command cancels the blocking of the truck

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed.

When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

1. This means that the special parameters must be reset manually.

Code

C20

Description

Speed control caution.

Possible error cause

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card. (tiller arm head)

Action

1. Restart with the speed control in neutral position.

2. Replace the electronic card.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 13

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated.

No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51.

2. Check the emergency switch.

3. Check the cables from the battery and the battery contacts.

4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

9- 14

Service Guide

Code

C29

Description

Service warning

Possible error cause

Time for service.

The service counter has not been reset since the last service.

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor.

Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load).

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt.

The battery parameters are not correctly set.

Time to charge up the battery.

Action

1. Check parameter 21, battery size and type.

2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 15

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

9- 16

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt.

Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly.

2. Check the cabling, the battery contact and the contact points on main contactor K10.

Code

C43

Description

The travel regulator shuts off due to excess or subnormal temperature.

Possible error cause

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25oC or above +85oC reduce running speed.

Action

1. Check that the M12 fan is functioning. (Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis.

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

Data from extra I/0 box /(0) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

Data from extra I/0 box /(1) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 17

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

9- 18

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

Incorrect travel regulator or electronic card has been installed. The truck has a built-in control function that checks to ensure the wrong combination of travel regulator and electronic card has not been installed.

Action

Check travel regulator and electronic card.

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3.

Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake.

Value 13-15 ohm.

Check parameter 22

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current.

Internal monitoring error.

Action

1. Check the output for main contactor K10 (A1/ 4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm.

2. Check the output for horn (A1/7), check cabling and contacts.

3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 19

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

9- 20

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected.

Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated.

2. If the contactor is working, check the contact points and accompanying cabling.

3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm.

4. Check the travel regulator’s output, A1/4.

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded.

Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together.

2. Check that the R1 resistor is not shortcircuited.

3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine.

2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 21

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Code

E141

Description

Software problem.

Possible error cause

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Action

1. Restart the machine.

2. Download the program again.

3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts.

2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

w

9- 22

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Fault codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 23

Electrical systems – 5000 SWE100/120, SWE120S Fault codes T-code 700, 701, 702

9- 24

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E201

Description

M minus error.

Possible error cause

Problem with switch transistor in the armature circuit inside the travel regulator.

Action

1. Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

The motor monitor is reporting an unexpected data loss from the electronic card in the tiller arm head.

Action

1. Check cables 119 and 120 between electronic card and travel regulator.

2. Replace electronic card 3. Replace travel regulator.

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.6 Parameters • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

A

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

• Press L1 up or down and scroll to the parameter you want to change or view.

E

D

C

B

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

9.6.1 Operator parameters Parameter

Description

Unit

Min.

Max.

Step

Std.

Description

01

Speed, Turtle button

%

40

100

5

60

Speed, Turtle button 40: slow speed 100: maximum speed.

02

Max. speed

%

40

100

5

100

Max. speed 40: slow speed 100: maximum speed

03

Acceleration

10

100

5

70

10: slow acceleration 100: maximum acceleration

04

Braking in neutral mode

5

100

5

50

Specifies motor braking once the lever is put into neutral.

5: weak braking power 100: maximum breaking power

05

Logout

0

20

1

20

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours.

In steps of 1

© BT Europe AB

Service Guide

1min

SWE100/120, SWE120S, SWE120L, SWE160D

9- 25

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.6.2 Parameter description Parameter 1 The speed of use of the turtle button can be adjusted.

Parameter 2 The maximum speed can be adjusted.

Parameter 3 The lower the parameter value, the longer it takes for the truck to achieve maximum speed.

Parameter 4 Specifies the motor braking power when the lever (L1) is put into neutral. The lower the parameter value, the longer the braking time.

Parameter 5 The time it takes for the truck to switch off when the keypad is used.

The time counts down from the moment the last power-consuming unit is used.

Value = 0 gives 4 hours.

9- 26

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.6.3 Service parameters • • • • • • • • •

Connect the CAN key to X41.

Press and hold S18 while turning S17 to “ON” position.

Press and hold S18 until P = parameters is displayed.

You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

Press L1 up or down and scroll to the parameter you want to change or view.

Press S18 once to access the parameter.

Press L1 up or down to specify the parameter value.

Press S18 once to confirm the change.

Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

Parameter

Description

10

Min .

Max .

Step

Std .

Description

PIN-code

0

9999

1

1

Facility for specifying up to 10 PIN codes (10 different drivers).

14

Crawling speed

-10

10

1

-5

The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

15

Non-configurable option 0 to 9

See “Option parameters” on page 29,

16

Configurable option #1

See “Option parameters” on page 29,

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

20

Hour meter option

1

5

1

2

Select hour meter.

21

Battery size

1

20

1

5

Selection of battery size.

© BT Europe AB

Unit

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 27

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Parameter

Description

22

Inductive sensor

25

Service interval

28 39

Unit

Date 2005-05-20

Order number 225678-040

Min .

Max .

Step

Std .

Description

0

1

1

1

0: Mechanical switch 1: Inductive sensor

0

2000

50

100

Option for setting service timer

Lift button selection

0

3

1

1

Button selection

Password

1

12

1

1

States which level of authorization the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

1h

9.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section Expanded keypad - General on page 40 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck.

Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no. 1.

Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button numbered 1.

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

Parameter 14 Specifies the speed you will have when you reach the first speed sensor.

Parameter 15 - Non-configurable option See “Option parameters” on page 29,

Parameter 16 - Configurable option #1 See “Option parameters” on page 29,

9- 28

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Parameter 17 - Configurable option #2 See “Option parameters” on page 29,

Parameter 18 - Configurable option #3 See “Option parameters” on page 29,

Parameter 19 - Configurable option #4 See “Option parameters” on page 29,

Option parameters WARNING !

Do not try to change these parameter unless you have specific knowledge of the truck options or truck modifications. This service manual only covers the truck’s standard equipment. Specially modified trucks may require you to have access to particular service information. Incorrect adjustment of option parameters may result in incorrect function.

General Parameters #15 to #19 have been reserved in the truck control system for extra options and/or specific product modifications. These parameters are normally configured by the manufacturer on modification or customisation of the truck. It is recommended that the parameter settings be loaded up from the truck when carrying out any modification. If, for example, the main electronic card [A2] must be replaced, the original parameter settings can then be simply transferred to the new card, which ensures that all the special options function correctly.

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15.

Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

Changing non-configurable options • Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed.

The value of the sub-parameters is displayed after 1 second.

• Press the horn button S18. © BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 29

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

The parameter symbol flashes.

.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 3: for more information.

• Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

P

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 3: Parameter #15 Non-configurable option Value

Note!

1

"Turtle" function

1

0

0

2 to 9

For future use

-

-

-

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See “Table 4:List of configurable optional functions” on page 32. These are thus called the configurable optional functions.

• Each parameter can be programmed to cover a specific optional function.

• Each optional function can have up to 4 independent variables associated with it.

• Each independent variable has a value you can change to configure the function.

9- 30

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Parameter no. (range 16-19)

16 - 0 - 1

Independent variable: #0 is the option designation Independent variable value (range 0-63) 0= no option has been activated for this parameter 1 to 63 = Pre-programmed option number. See separate table.)

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected.

See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 1Summary – option parameter

Changing configurable optional functions In order to activate a configurable optional function, it must first be assigned a parameter from #16 to #19. This is done by changing independent variable #0 to the pre-programmed option number. Once this has been done, the independent variable for the option must be configured. This is done by changing the values for independent variables #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #16, #17, #18 or #19 using [L1].

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

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 4: • Press the S18 horn button once to confirm the new setting. © BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 31

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

The parameter symbol is lit (i.e. stops flashing).

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction. See the list of optional functions in Table 4: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing

on the keypad.

The optional function is now activated.

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

Table 4: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 1: The option button controls the spider output 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

0:high-speed range 1:low-speed range 2: both ranges

Independent variable #0 = 3:Activate the spider output for specific movements 0:Spider 0 1:Spider 1

9- 32

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4 Service Guide

Select movements.

See Table 5:

Initial position: 0: shines constantly 1: flashes 1 Hz 2: flashes 2 Hz

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Table 4: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital input 1 Lowering, digital input 2 Blocking of lowering, input 3 1: Lift, digital input 2 Lowering, digital input 3 Blocking of lowering, input 4 2: Lift, digital input 3 Lowering, digital input 4 Blocking of lowering, input 5 3: Lift, digital input 4 Lowering, digital input 5 Blocking of lowering, input 6 4: Lift, digital input 5 Lowering, digital input 6 Blocking of lowering, input 7 5: Lift, digital input 6 Lowering, digital input 7 Blocking of lowering, input 8

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/lowering

Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 1:Spider 1

© BT Europe AB

0-7: Limit switch for digital input 1-8

Service Guide

1-6: By-pass, option switch 1-6

Not used

SWE100/120, SWE120S, SWE120L, SWE160D

9- 33

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Table 5: Option 3 – Choice of movement

9- 34

Service Guide

Selected movement

Independent variable #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Fork lift

4

Fork lift or driving forward

5

Fork lift or driving backward

6

Fork lift or driving forward or driving backward

7

Fork lowering

8

Fork lowering or driving forward

9

Fork lowering or driving backward

10

Fork lowering or driving forward or driving backward

11

Fork lift or fork lowering

12

Fork lift or fork lowering or driving forward

13

Fork lift or fork lowering or driving backward

14

Fork lift or fork lowering or driving forward or driving backward

15

All other movements (AOM)

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or driving backward or AOM

19

Fork lift or AOM

20

Fork lift or driving forward or AOM

21

Fork lift or driving backward or AOM

22

Fork lift or driving forward or driving backward or AOM

23

Fork lowering or AOM

24

Fork lowering or driving forward or AOM

25

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Table 5: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or driving backward or AOM

26

Fork lowering or driving forward or driving backward or AOM

27

Fork lift or fork lowering or AOM

28

Fork lift or fork lowering or driving forward or AOM

29

Fork lift or fork lowering or driving backward or AOM

30

Fork lift or fork lowering or driving forward or driving backward or AOM

31

Parameter 20 You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 35

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size SWE100, SWE120, SWE120S 1

Less discharge

2 3 4 5

260Ah - 320Ah Standard value

6

190Ah - 250Ah

7

120Ah - 180Ah

8 9 10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

9- 36

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 37

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Recommendation on parameter setting for valve-controlled batteries (VRLA) Parameter 21

Battery size SWE100, SWE120, SWE120S 1

Less discharge

2

260Ah - 320Ah

3

190Ah - 250Ah

4

120Ah - 180Ah

5 6 7 8 9 10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

9- 38

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with.

Mechanical switch = 0 Inductive sensor= 1

Parameter 25 Using this parameter you can specify a limit for when the next service is to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for a service, warning 29 (C29) is shown in the display.

Parameter 28 Using this parameter you can select which button is to be used for lift/ lower.

0 = No lift/lower button activated 1 = Bottom lift/lower button activated (default) 2 = Top lift/lower button activated 3 = Both lift/lower buttons are activated

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 39

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes.

If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 7:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile.

The truck program stores a standard list of PIN codes as per Table 7: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

9- 40

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

To start programming the expanded keypad: • Connect an appropriate CAN service key to X41 • Enter code 341671 and press

on the keypad.

• Select the programming command from Table 6:

Table 6: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated. Original PIN codes reset as per Table 7: B= Block no. 0 - 9

Press “2” + B +

PIN codes in the block can be used

B= Block no. 0 - 9

Press “3” + B +

PIN codes in the block cannot be used Programming a new PIN code

B= Block no. 0 - 9 F= Driver profile no.

0-9 NNNN = PIN code

Press “1” +

Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid.

Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling.

Table 7: shows the PIN codes available as standard in the program.

These can be activated for use or changed according to the driver’s wishes.

One or more of these blocks can be activated.

A driver profile is activated, on normal login, by all PIN codes whose block no. is activated.

The truck program does not approve login using the PIN code “0000”.

Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles.

NOTE! Resetting the expanded keypad does NOT affect the driver profile settings.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 41

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Table 7: Standard PIN code assignment with the expanded keypad Driver profile

0

1

2

3

4

5

6

7

8

9

no.

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

_

Service indication A

• Connect CAN key to X41 and start the truck • Battery status is shown and symbol “D” is lit • Press S18 to go to display mode.

See the table below.

E

D

C

B

Flashing symbol

Data

B

A speed reference value has been sent to Curtis

C

Digital inputs to Curtis and hall sensors. * See explanation below

BC

Battery voltage (V)

D

Armature voltage (A)

BD

Field current (A)

CD

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

*These are displayed by segments of three of the figures being marked (A).

9- 42

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

• The figure with the highest value is active (marked with an arrow).

• Power amplifier, inputs.

A

T

Segment

Function

A

E

D

B

C A

B C

S31, input A1:15

D

S10, input A1:12

E

F

B

G

E

F

C DP

G

S10, input A1:5

DP

D

• The figure with the second highest value is active (marked with an arrow).

A

• Power amplifier, inputs

Segment

Function

A

E

D

B

C

A F

G

E D

© BT Europe AB

B C DP

B C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 43

Electrical systems – 5000 SWE100/120, SWE120S Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

• The figure with the third highest value is active (marked with an arrow).

A

• Digital input from control sensors.

Segment

Function

A

E

D

B

C

B C

A F

B

G

C DP

E D

D

Forks up

E

Forks down

F

Support arm up

G

Support arm down

DP

Horn

• The figure with the fourth highest value is active (marked with an arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

9- 44

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Part numbers Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.7 Part numbers • Press S18 and turn S17 to “on” at the same time.

A

• Press S18 until you Pn= partnumbers.

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

E

D

C

• By scrolling with the speed control you can get the following information:

B

• SPn= Software part number.

• HPn= Hardware part number.

• HSn= Hardware serial number.

9.8 Transistor panel

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

9.8.1 General B+

A1

S1

© BT Europe AB

M

M-

Curtis 1243 is a regulator for controlling shunt motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

A2

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

S2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 45

Electrical systems – 5000 SWE100/120, SWE120S Diagnostic and troubleshooting T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.9 Diagnostic and troubleshooting 9.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that may be shown by the STATUS LED or read using the handheld terminal.

STATUS LED

Handheld terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

9- 46

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE100/120, SWE120S Diagnostic and troubleshooting Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

9.9.2 Resetting errors To reset an error turn S17 to off and then on again.

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

9.9.3 Safety The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only.

WARNING! Risk of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

9- 47

Electrical systems – 5000 SWE100/120, SWE120S Technical specifications – Curtis 1243 T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

9.10 Technical specifications – Curtis 1243 Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

150

Amps

for 2 minutes

100

Amps

for 1 hour

20

Amps

for 2 minutes

Max. current of field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

9- 48

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Component identification Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10- Electrical systems – 5000 SWE120L, SWE160D 10.1 Component identification S17

S10

X41

S21

X5 Y1

X1 F50

M3

F51 F1

P2 Y34 Y52 P1 Y41

R1 K10 F3 K30 A1

M1

H1

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 1

Electrical systems – 5000 SWE120L, SWE160D Component identification T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

A17

10- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.2 List of symbols and electrical wiring diagram Symbol

Description

Function

Notes

A1

Transistor regulator

A2

Electronic card

A6

Display

A17

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10-S18

Speed control

Forwards/Reverse

M1

Motor

Drive motor

M3

Motor

Pump motor

P1

Pressure switch

Pressure switch support arm lift

70 bar

P2

Pressure switch

Pressure switch fork lift

120 bar

R1

PTC-resistor

Power supply

15 Ohm

© BT Europe AB

Service Guide

24 V

SWE100/120, SWE120S, SWE120L, SWE160D

10- 3

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Symbol

Description

S111

Switch

Option

S112

Switch

Option

S113

Switch

Turtle button

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

A2:S17

Switch

Safety reversing

A2:S19

Switch

Fork lifting

A2:S20

Switch

Fork lowering

S21

Switch

Emergency switch off

A2:S21

Switch

Support arm, lifting

A2:S22

Switch

Support arm, lowering

S32

Switch

Lift height limiting, 1.6 m

S33

Switch

Lift height limiting

S42

Switch

Manual fork lowering

S90

Switch

Lift height limiting

Y1

Brake

Y34

Magnetic valve

Forks

Y41

Magnetic valve

Fork lowering

Y52

Magnetic valve

Support arm lifting

X1

Connector

Battery

X41

Connection point

CAN-communication

10- 4

Service Guide

Function

Order number 225678-040

Notes

Brake lever

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.2.1 Electrical diagram 1(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 5

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.2.2 Electrical diagram 2(5)

10- 6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.2.3 Electrical diagram 3(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 7

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.2.4 Electrical diagram 4(5)

10- 8

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D List of symbols and electrical wiring diagram Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.2.5 Electrical diagram 5(5)

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 9

Electrical systems – 5000 SWE120L, SWE160D Functional description T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.3 Functional description 10.3.1 Starting the truck • To enable the truck to be started, the battery plug must be connected, the emergency switch (S21) closed and the start key (S17) in the ON position.

10.3.2 Driving

A1 B-

• S10 closed .

S1 T1

Ish

Ia

Shunt

+

• The speed control activated in any direction.

S2

MA2

A A1

T2

K10

B+

10.3.3 Neutral speed reduction • The speed control to neutral position, motor starts to work as generator. Brake energy comes back to battery.

• The brake will be activated when the truck comes to a stand still even if the tiller is in drive position.

• Energy back to the battery.

• The transistors (T2) for the generated brake current are not live.

A1 BS1

T1 Ish

Ia

MShunt

+

S2 A2

A A1

T2 K10

B+

T

10.3.4 Neutral speed reduction on slopes If the driver release the speed control on a slope and the truck doesn’t come to a stop within a certain time the electrical brake will be applied by the system.

10.3.5 Braking The brake is always applied when the truck is started with the tiller in it’s upper or lower position (S10 open). The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move.

Conditions to brake the truck: • S10 open.

10- 10

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Hour meter Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.3.6 Lifting the forks • A2:S19 activated.

• Battery status OK (if battery capacity >20% left).

10.3.7 Lifting the support arms • A2:S21 activated • Battery status OK (if battery capacity >20% left).

10.3.8 Lowering the forks • A2:S20 activated.

10.3.9 Lowering the support arms • A2:S22 activated.

10.3.10 Horn • S18 activated.

10.4 Hour meter • Press S18 and turn S17 to “on” at the same time.

• Press S18 until you read H= hour meters.

• You have now choosen H=hourmeters the symbol “B” will be highlighted.

• You can now choose type of hourmeter by pressing the speed controlt.

A= Key time. b= Drive motor time.

A

c= Pump motor time. d= Activity time. s= Time to service.

E

D

© BT Europe AB

C

B

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 11

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.5 Error codes • Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored. The latest error is displayed first. The display shows the error code first, followed by the time when the error occurred.

• The error codes are divided into two groups, C = caution and E = error.

• C codes are not stored. They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - - .

10- 12

Service Guide

Code

C3

Description

TLS: Shock sensors registered values outside the limits

Possible error cause

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck.

The TLS reset command activates the truck

Code

C4

Description

TLS: Use of the truck has been blocked

Possible error cause

Truck use can be “blocked” by a TLS command. / The truck cannot be used until a new TLS command cancels the blocking of the truck

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C19

Description

Parameter caution. Displayed for 5 seconds.

Possible error cause

The parameters have probably been changed.

When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action

1. This means that the special parameters must be reset manually.

Code

C20

Description

Speed control caution.

Possible error cause

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card. (tiller arm head)

Action

1. Restart with the speed control in neutral position.

2. Replace the electronic card.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 13

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Code

C28

Description

Emergency switch caution

Possible error cause

The emergency switch has been activated.

No current to the travel regulator, input. A1/16.

Action

1. Check fuse F51.

2. Check the emergency switch.

3. Check the cables from the battery and the battery contacts.

4. If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

Restart.

10- 14

Service Guide

Code

C29

Description

Service warning

Possible error cause

Time for service.

The service counter has not been reset since the last service.

Code

C31

Description

Pressure switch warning.

Possible error cause

A problem with the pressure switch. Check that the voltage is approximately 24 V between cables 24 and 40 connected to the pressure sensor.

Check the voltage between cable 40 and 63 connected to the pressure sensor. The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load).

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C41

Description

Warning of low battery voltage

Possible error cause

Battery voltage < 17 volt.

The battery parameters are not correctly set.

Time to charge up the battery.

Action

1. Check parameter 21, battery size and type.

2. Check the battery contact and the pole connections on the battery 3. Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

© BT Europe AB

Code

C42

Description

Warning of high battery voltage

Possible error cause

Battery voltage > 33 volt.

Energy return feed to battery during motor braking with a fully-charged battery.

Action

1. The fault disappears after a few lifts, once the battery has been run down slightly.

2. Check the cabling, the battery contact and the contact points on main contactor K10.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 15

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

10- 16

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

C43

Description

The travel regulator shuts off due to excess or subnormal temperature.

Possible error cause

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25oC or above +85oC reduce running speed.

Action

1. Check that the M12 fan is functioning.

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

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

C90 (Option)

Description

Extra I/0 (0) CAN communication error

Possible error cause

Data from extra I/0 box /(0) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C91 (Option)

Description

Extra I/0 (1) CAN communication error

Possible error cause

Data from extra I/0 box /(1) not being received by [A2]/ Check the CAN-bus cable and the connections. [A2] Restart the truck.

Code

C92 (Option)

Description

Configuration error Extra I/0 (0)

Possible error cause

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Code

C93 (Option)

Description

Configuration error Extra I/0 (1)

Possible error cause

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 17

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

10- 18

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E101

Description

Travel regulator does not correspond with the type of truck

Possible error cause

Incorrect travel regulator or electronic card has been installed. The truck has a built-in control function that checks to ensure the wrong combination of travel regulator and electronic card has not been installed.

Action

Check travel regulator and electronic card.

Code

E104

Description

Switch-transistor to brake is short-circuited

Possible error cause

Error in the travel regulator, output. A1/3.

Incorrect value on parameter 22

Action

Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake.

Value 13-15 ohm.

Check parameter 22

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E106

Description

Digital outputs short-circuited or exceeding field current limit.

Possible error cause

Problem regulating the field current.

Internal monitoring error.

Action

1. Check the output for main contactor K10 (A1/ 4), check cabling and contacts and measure ohms for the coil. Value 25-30 ohm. Check the output for the brake coil K10 (A1/3), check cabling and contacts and measure ohms for the coil. Value 13-15 ohm.

2. Check the output for horn (A1/7), check cabling and contacts.

3. Check the drive motor’s shunt winding and cabling and contacts. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 19

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

10- 20

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E107

Description

Contactor K10 does not close.

Possible error cause

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected.

Interruption in the travel regulator’s output, A1/4.

Action

1. Check if the contactor is activated.

2. If the contactor is working, check the contact points and accompanying cabling.

3. If the contactor is not working, check the coil and accompanying cabling. Measure Ohms for the coil. Value 25-30 ohm.

4. Check the travel regulator’s output, A1/4.

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E108

Description

Contactor K10 does not open.

Possible error cause

Main contactor points welded.

Short circuit in the travel regulator’s output A1/4.

Action

1. Check that the contactor’s contact points are not welded together.

2. Check that the R1 resistor is not shortcircuited.

3. If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Code

E110

Description

System error.

Possible error cause

Temporary error/error in the travel regulator.

Action

1. Restart the machine.

2. Replace travel regulator.

Code

E140

Description

Error in control total.

Possible error cause

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 21

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Code

E141

Description

Software problem.

Possible error cause

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Action

1. Restart the machine.

2. Download the program again.

3. Replace the electronic card

Code

E150

Description

Fault in the data communication.

Possible error cause

Break on the CAN cable.

Action

1. Check the 119 and 120 cables and their contacts.

2. Replace travel regulator.

Code

E151

Description

Tx error in data communication.

Possible error cause

Travel regulator not responding.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

Code

E157

Description

Bus shut off.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

w

10- 22

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Error codes Order number 225678-040

© BT Europe AB

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Code

E159

Description

Transgression error.

Possible error cause

CAN bus problem.

Action

1. Check 119 and 120 cables and the connections on the travel regulator.

2. Replace travel regulator.

3. Replace the electronic card

Code

E160

Description

Error in safety reversing function

Possible error cause

Error in important sensor part.

Action

1. Replace the electronic card

Code

E200

Description

Open field.

Possible error cause

Shunt field’s circuit open.

Action

1. Check the field winding connections E1 and E2. Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 23

Electrical systems – 5000 SWE120L, SWE160D Error codes T-code 700, 701, 702

10- 24

Valid from serial number 715612-

Service Guide

Date 2005-05-20

Order number 225678-040

Code

E201

Description

M minus error.

Possible error cause

Problem with switch transistor in the armature circuit inside the travel regulator.

Action

1. Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

2. Replace travel regulator.

Code

E202

Description

Fault on sensor in travel regulator

Possible error cause

Fault on armature current sensor in travel regulator

Action

Replace travel regulator

Code

E214

Description

CAN timeout in power amplifier.

Possible error cause

The motor monitor is reporting an unexpected data loss from the electronic card in the tiller arm head.

Action

1. Check cables 119 and 120 between electronic card and travel regulator.

2. Replace electronic card 3. Replace travel regulator.

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.6 Parameters A

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

E

D

C

B

• Press L1 up or down and scroll to the parameter you want to change or view.

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

10.6.1 Operator parameters Parameter

Description

Unit

Min.

Max.

Step

Std.

Description

01

Speed, Turtle button

%

40

100

5

60

Speed, Turtle button 40: slow speed 100: maximum speed.

02

Max. speed

%

40

100

5

100

Max. speed 40: slow speed 100: maximum speed

03

Acceleration

10

100

5

70

10: slow acceleration 100: maximum acceleration

04

Braking in neutral mode

5

100

5

50

Specifies motor braking once the lever is put into neutral.

5: weak braking power 100: maximum breaking power

05

Logout

0

20

1

20

The time it takes for the truck to switch off when the keypad is used. The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours.

In steps of 1

© BT Europe AB

Service Guide

1min

SWE100/120, SWE120S, SWE120L, SWE160D

10- 25

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.6.2 Parameter description Parameter 1 The speed of use of the turtle button can be adjusted.

Parameter 2 The maximum speed can be adjusted.

Parameter 3 The lower the parameter value, the longer it takes for the truck to achieve maximum speed.

Parameter 4 Specifies the motor braking power when the lever (L1) is put into neutral. The lower the parameter value, the longer the braking time.

Parameter 5 The time it takes for the truck to switch off when the keypad is used.

The time counts down from the moment the last power-consuming unit is used.

Value = 0 gives 4 hours.

10- 26

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.6.3 Service parameters • Connect the CAN key to X41.

A

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

E

D

C

B

• Press L1 up or down and scroll to the parameter you want to change or view.

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine.

NOTE: Truck handling When you change specific truck parameters, the truck’s driving characteristics are also changed.

Do not change any parameters unless you really know what you are doing.

Parameter

Description

10

Min

Max

Step

Std

Description

PIN-code

0

9999

1

1

Facility for specifying up to 10 PIN codes (10 different drivers).

14

Crawling speed

-10

10

1

-5

The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

15

Non-configurable option 0 to 9

See “Option parameters” on page 29,

16

Configurable option #1

See “Option parameters” on page 29,

17

Configurable option #2

18

Configurable option #3

19

Configurable option #4

20

Hour meter option

© BT Europe AB

Unit

Service Guide

1

5

1

2

Select hour meter.

SWE100/120, SWE120S, SWE120L, SWE160D

10- 27

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Parameter

Description

21

Unit

Date 2005-05-20

Order number 225678-040

Min

Max

Step

Std

Description

Battery size

1

20

1

95

Selection of battery size.

22

Inductive sensor

0

1

1

1

0: Mechanical switch 1: Inductive sensor

25

Service interval

0

2000

50

100

Option for setting service timer

28

Lift button selection

1

3

1

1

Button selection

39

Password

1

12

1

1

States which level of authorization the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

1h

10.6.4 Parameter description Parameter 10 NOTE! The functionality of parameter #10 is set aside if the value of parameter #39 is set to 5,6,7 or 8. The PIN codes are managed using the socalled expanded keypad. See section Expanded keypad - General on page 40 for more detailed information.

Ten drivers can have their own PIN code to gain access to the truck.

Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no. 1.

Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button numbered 1.

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1. Switch off by pressing the red button numbered 0.

Parameter 14 Specifies the speed you will have when you reach the first speed sensor.

Parameter 15 - Non-configurable option See “Option parameters” on page 29,

Parameter 16 - Configurable option #1 See “Option parameters” on page 29, 10- 28

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Parameter 17 - Configurable option #2 See “Option parameters” on page 29,

Parameter 18 - Configurable option #3 See “Option parameters” on page 29,

Parameter 19 - Configurable option #4 See “Option parameters” on page 29,

Option parameters WARNING !

Do not try to change these parameter unless you have specific knowledge of the truck options or truck modifications. This service manual only covers the truck’s standard equipment. Specially modified trucks may require you to have access to particular service information. Incorrect adjustment of option parameters may result in incorrect function.

General Parameters #15 to #19 have been reserved in the truck control system for extra options and/or specific product modifications. These parameters are normally configured by the manufacturer on modification or customisation of the truck. It is recommended that the parameter settings be loaded up from the truck when carrying out any modification. If, for example, the main electronic card [A2] must be replaced, the original parameter settings can then be simply transferred to the new card, which ensures that all the special options function correctly.

Parameter #15 Non-configurable options Up to 16 so-called sub-parameters are stored under parameter #15.

Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options.

Changing non-configurable options • Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed The next set-up of sub-parameters is displayed if you continue to activate the speed control L1. Ensure that only the relevant sub-parameters are displayed.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 29

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

The value of the sub-parameters is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction. See Table 8: for more information.

• Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

P

Sub-parameter no.

Function name

Function ON

Function OFF

Basic setting

Table 8: Parameter #15 Non-configurable option Value

Note!

1

"Turtle" function

1

0

0

2 to 9

For future use

-

-

-

Parameter #16 to 19 configurable optional functions Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a maximum of 4 pre-programmed functions and configure these to suit optional equipment or customisation of the truck. See “Table 9:List of configurable optional functions” on page 32. These are thus called the configurable optional functions.

• Each parameter can be programmed to cover a specific optional function.

• Each optional function can have up to 4 independent variables associated with it.

• Each independent variable has a value you can change to configure the function.

10- 30

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Parameter no. (range 16-19)

16 - 0 - 1

Independent variable: #0 is the option designation Independent variable value (range 0-63) 0= no option has been activated for this parameter 1 to 63 = Pre-programmed option number. See separate table.)

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu

16 - 1- 1

Independent variable value (the range depends on the function referred The value depends on the option and independent variable selected.

See separate table CONFIGURING THE OPTIONAL FUNCTION

Fig. 2Summary – option parameter

Changing configurable optional functions In order to activate a configurable optional function, it must first be assigned a parameter from #16 to #19. This is done by changing independent variable #0 to the pre-programmed option number. Once this has been done, the independent variable for the option must be configured. This is done by changing the values for independent variables #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #16, #17, #18 or #19 using [L1].

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

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 9: • Press the S18 horn button once to confirm the new setting. © BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 31

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

The parameter symbol is lit (i.e. stops flashing).

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction. See the list of optional functions in Table 9: • Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e. stops flashing).

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing

on the keypad.

The optional function is now activated.

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

Table 9: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 1: The option button controls the spider output 0:Spider 0 1:Spider 1

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6

Type of function: 0:instantaneous 1:butterfly switch

Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-12:reduced speed 40-100% (i.e. 40+5*arg3 e.g.

4: 40+5*4=60%)

0:high-speed range 1:low-speed range 2: both ranges

Independent variable #0 = 3:Activate the spider output for specific movements 0:Spider 0 1:Spider 1

10- 32

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4 Service Guide

Select movements.

See Table 10:

Initial position: 0: shines constantly 1: flashes 1 Hz 2: flashes 2 Hz

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Table 9: List of configurable optional functions Independent variable #1

Independent variable #2

Independent variable #3

Independent variable #4

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input 0:Spider 0 1:Spider 1

0-7:Digital input 1-8

0-30:Holding time 030 minutes

Not used

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs 0:Spider 0 1:Spider 1

0: Lift, digital input 1 Lowering, digital input 2 Blocking of lowering, input 3 1: Lift, digital input 2 Lowering, digital input 3 Blocking of lowering, input 4 2: Lift, digital input 3 Lowering, digital input 4 Blocking of lowering, input 5 3: Lift, digital input 4 Lowering, digital input 5 Blocking of lowering, input 6 4: Lift, digital input 5 Lowering, digital input 6 Blocking of lowering, input 7 5: Lift, digital input 6 Lowering, digital input 7 Blocking of lowering, input 8

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/lowering

Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 1:Spider 1

© BT Europe AB

0-7: Limit switch for digital input 1-8

Service Guide

1-6: By-pass, option switch 1-6

Not used

SWE100/120, SWE120S, SWE120L, SWE160D

10- 33

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Table 10: Option 3 – Choice of movement

10- 34

Service Guide

Selected movement

Independent variable #3

-

0

Driving forward

1

Driving backward

2

Driving forward or backward

3

Fork lift

4

Fork lift or driving forward

5

Fork lift or driving backward

6

Fork lift or driving forward or driving backward

7

Fork lowering

8

Fork lowering or driving forward

9

Fork lowering or driving backward

10

Fork lowering or driving forward or driving backward

11

Fork lift or fork lowering

12

Fork lift or fork lowering or driving forward

13

Fork lift or fork lowering or driving backward

14

Fork lift or fork lowering or driving forward or driving backward

15

All other movements (AOM)

16

Driving forward or AOM

17

Driving backward or AOM

18

Driving forward or driving backward or AOM

19

Fork lift or AOM

20

Fork lift or driving forward or AOM

21

Fork lift or driving backward or AOM

22

Fork lift or driving forward or driving backward or AOM

23

Fork lowering or AOM

24

Fork lowering or driving forward or AOM

25

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Table 10: Option 3 – Choice of movement Selected movement

Independent variable #3

Fork lowering or driving backward or AOM

26

Fork lowering or driving forward or driving backward or AOM

27

Fork lift or fork lowering or AOM

28

Fork lift or fork lowering or driving forward or AOM

29

Fork lift or fork lowering or driving backward or AOM

30

Fork lift or fork lowering or driving forward or driving backward or AOM

31

Parameter 20 You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

Parameter 21 You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid concentration when the battery is fully charged, to check the grade of the battery. Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % discharged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 35

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size SWE120L, SWE160D 1

Less discharge

2 3 4 5

260 Ah - 320 Ah Standard value

6

190 Ah - 250 Ah

7

120 Ah - 180 Ah

8 9 10 11 Greater discharge

12 13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

10- 36

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 37

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Recommendation on parameter setting for valve-controlled batteries (VRLA) Parameter 21

Battery size SWE120L, SWE160D 1

Less discharge

2

260 Ah - 320 Ah

3

190 Ah - 250 Ah

4

120 Ah - 180 Ah

5 6 7 8 9 10 11 12 Greater discharge

13 14 15 16 17 18 19 20

WARNING !

The service life of the battery will be reduced if the value of parameter 21 is set at too high a value. The standard setting of parameter 21 is set for normal truck handling. Other applications may require a different setting of parameter 21. Check that the parameter setting is the correct one using the instructions below.

10- 38

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

Instructions for verifying parameter setting • Charge up the battery • Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours. NB! No charging or discharging during this period.

• Measure the battery voltage at room temperature. If the voltage is less than Uend, see the table below, the parameter value must be reduced. If the value significantly exceeds Uend, the risk of damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be increased. Maximum one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Battery type

Battery voltage at rest, Uend

Hawker Evolution

24,24 V

Parameter 22 You must specify the type of brake switch the truck is equipped with.

Mechanical switch = 0 Inductive sensor= 1

Parameter 25 Using this parameter you can specify a limit for when the next service is to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for a service, warning 29 (C29) is shown in the display.

Parameter 28 Using this parameter you can select which button is to be used for lift/lower.

0 = No lift / lower button activated.

1 = Bottom lift / lower button activated (default).

2 = Top lift / lower button activated.

3 = Both lift / lower buttons are activated.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 39

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Parameter 39 Login method and driver parameter access This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key) • Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key) • Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key) • Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Expanded keypad - General The truck can contain a maximum of 10 individual driver profiles. The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles. This allows you to manage a maximum of 100 unique PIN codes.

If the expanded keypad function is activated, the standard management of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming A number of PIN codes can be made accessible by activating the socalled block. Block no. 0 is activated as standard. This means that 3 different driver profiles are available from the start. Activation of other blocks means that all PIN codes for the block are accessible (See Table 12:). If all 10 blocks are activated, there will be 10 PIN codes available for the driver profile.

The truck program stores a standard list of PIN codes as per Table 12: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

10- 40

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

To start programming the expanded keypad: • Connect an appropriate CAN service key to X41 • Enter code 341671 and press

on the keypad.

• Select the programming command from Table 11:

Table 11: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated. Original PIN codes reset as per Table 12: B= Block no. 0 - 9

Press “2” + B +

PIN codes in the block can be used

B= Block no. 0 - 9

Press “3” + B +

PIN codes in the block cannot be used Programming a new PIN code

B= Block no. 0 - 9 F= Driver profile no.

0-9 NNNN = PIN code

Press “1” +

Press “4” + B + F + NNNN +

• Switch off the truck by pressing

on the keypad.

The expanded keypad programming is now complete Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN codes to be valid.

Carry out a practical test by logging in using some of the new PIN codes. It is important to establish that the correct driver profile has been activated when a certain PIN code has been entered, especially if a specific driver profile has been set for a specific application/goods handling.

Table 12: shows the PIN codes available as standard in the program.

These can be activated for use or changed according to the driver’s wishes.

One or more of these blocks can be activated.

A driver profile is activated, on normal login, by all PIN codes whose block no. is activated.

The truck program does not approve login using the PIN code “0000”.

Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles.

NOTE! Resetting the expanded keypad does NOT affect the driver profile settings.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 41

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Table 12: Standard PIN code assignment with the expanded keypad Driver profile

0

1

2

3

4

5

6

7

8

9

no.

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

_

Service indication A

• Connect CAN key to X41 and start the truck • Battery status is shown and symbol “D” is lit • Press S18 to go to display mode.

See the table below.

E

D

C

B

Flashing symbol

Data

B

A speed reference value has been sent to Curtis

C

Digital inputs to Curtis and hall sensors. * See explanation below

BC

Battery voltage (V)

D

Armature voltage (A)

BD

Field current (A)

CD

PWM (pulse width modulation) armature in percentage

BCD

Status of Curtis

*These are displayed by segments of three of the figures being marked (A).

10- 42

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Parameters Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

• The figure with the highest value is active (marked with an arrow).

• Power amplifier, inputs.

A

T

Segment

Function

A

E

D

B

C A

B C

S31, input A1:15

D

S10, input A1:12

E

F

B

G

E

F

C DP

G

S10, input A1:5

DP

D

• The figure with the second highest value is active (marked with an arrow).

A

• Power amplifier, inputs

Segment

Function

A

E

D

B

C

A F

G

E D

© BT Europe AB

B C DP

B C

Y41, output A1:2

D

Y1, output A1:3

E

K10, output A1:4

F

H1, output A1:7

G

Y1, output A1:5

DP

K30, output A1:6

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 43

Electrical systems – 5000 SWE120L, SWE160D Parameters T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

• The figure with the third highest value is active (marked with an arrow).

A

• Digital input from control sensors.

Segment

Function

A

E

D

B

C

B C

A F

B

G

C DP

E D

D

Forks up

E

Forks down

F

Support arm up

G

Support arm down

DP

Horn

• The figure with the fourth highest value is active (marked with an arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

Extra function 3

E

Extra function 2

F

Extra function 1

G DP

10- 44

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Part numbers Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.7 Part numbers • Press S18 and turn S17 to “on” at the same time.

A

• Press S18 until you Pn= partnumbers.

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

E

D

C

• By scrolling with the speed control you can get the following information:

B

• SPn= Software part number.

• HPn= Hardware part number.

• HSn= Hardware serial number.

10.8 Transistor panel

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

10.8.1 General B+

A1

S1

© BT Europe AB

M

M-

Curtis 1243 is a regulator for controlling shunt motors. Varying the voltage applied through the armature primarily controls the speed. The voltage is varied through use of pulse-width modulation (PWM). This involves varying the “on” time of the MOS-FET transistors regulating the armature current.

A2

Switching of the rotational direction is achieved by switching the polarity on the field winding (S1-S2). The regulator is fitted with a four-quadrant transistor bridge for the field winding and a single-quadrant transistor bridge for the armature winding.

S2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 45

Electrical systems – 5000 SWE120L, SWE160D Diagnostic and troubleshooting T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.9 Diagnostic and troubleshooting 10.9.1 Error codes and troubleshooting

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

The table below describes the error codes that may be shown by the STATUS LED or read using the handheld terminal.

STATUS LED

Handheld terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

10- 46

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 SWE120L, SWE160D Diagnostic and troubleshooting Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

10.9.2 Resetting errors To reset an error turn S17 to off and then on again.

Error

Reset when

OVERVOLTAGE

Battery voltage falls below 33 V

THERMAL CUTBACK

The temperature is within allowed range

THROTTLE FAULT 1, 2

Error has been fixed

LOW BATTERY VOLTAGE

When battery voltage exceeds 16 V

10.9.3 Safety The regulator is a high-power component. When working on a battery operated vehicle, necessary precautions should be taken. This includes, but is not limited to, correct training, use of eye protectors, avoiding use of lose-fitting clothes, removal of watches and jewellery, and use of insulated tools only.

WARNING! Risk of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

10- 47

Electrical systems – 5000 SWE120L, SWE160D Technical specifications – Curtis 1243 T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

10.10 Technical specifications – Curtis 1243 Value

Unit

Rated operating voltage

24

Volts

Overvoltage limit

33

Volts

Undervoltage limit

16

Volts

Minimum operating voltage

Electrical insulation towards cold body

500

V AC

Minimum

PWM frequency

16

kHz

Max. current of armature winding *

150

Amps

for 2 minutes

100

Amps

for 1 hour

20

Amps

for 2 minutes

Max. current of field winding

20

Explanation

for 1 hour

Contactor voltage

24

Volts

Same as battery voltage

Contactor current

2

Amps

Max (current limit at 2.5 amps)

KSI input voltage, Min.

16.8

Volts

KSI input current

50

mA

Logic input voltage

>7.5; High <1; Low

Volts

Logic input current

15

mA

Operating temperature

-40 to +50

°C

Overtemperature, reduction

85

°C

Undertemperature, reduction

-25

°C

* During specific test conditions.

10- 48

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Hydraulic system – 6000 SWE100/120, SWE120S General Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

11- Hydraulic system – 6000 SWE100/120, SWE120S 11.1 General To avoid functional problems with the lowering valve, such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve.

11.2 Hydraulic diagram and components n

1

3

C

2

B A

D

P

E

F

F

11.2.1 Main components

© BT Europe AB

Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Non return valve B = Lowering valve, manual C = Lowering valve, el D = Overflow valve E = Flow control valve F = Filter M = Pump motor P = Pump

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

11- 1

Hydraulic system – 6000 SWE100/120, SWE120S Hydraulic diagram and components T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Pos No

Description

Remark

3

Pressure switch

Load >750 kg Speed = 5,3 km/h

11.2.2 Description Lift When the pump motor starts, the oil flows through the non return valve to the lift cylinders.

Lowering When the lowering valve is actuated by the lowering lever on the chassis, or the lowering button on the tiller arm, the valve opens to allow the oil in the pressure lines to return to the oil tank. The lowering speed can be regulated by the movement of the lowering lever on the chassis.

Lowering using the button on the tiller arm gives a constant lower speed.

Operating pressure The operating pressures at rated load are: • SWE100: 150 bar.

• SWE120: 180 bar.

• SWE120S: 190 bar.

Relief valve The relief valve opens at the following pressures: • SWE100: 170 bar.

• SWE120: 200 bar.

• SWE120S: 210 bar.

Pressure switch The pressure switch is used to regulate the speed and is influenced by the load. It only has an off/on operation.

Load > 750 kg. Speed = 5,3 km/h Load < 750 kg. Speed = 6,0 km/h

11- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Hydraulic system – 6000 SWE120L, SWE160D General Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

12- Hydraulic system – 6000 SWE120L, SWE160D 12.1 General To avoid functional problems with the lowering valve, such as unintentional lowering of forks, the valve must be cleaned and the function checked before replacing the valve

12.2 Hydraulic diagram and components n

2

4

1

G J

3

H

K

C

B A E D P

F

F

12.2.1 Main components

© BT Europe AB

Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Lift Cylinders

Support arm lift

3

Hydraulic Unit

A = Non return valve B = Lowering valve, manual C = Lowering valve, el D = Overflow valve E = Flow control valve F = Filter M = Pump motor P = Pump

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

12- 1

Hydraulic system – 6000 SWE120L, SWE160D Hydraulic diagram and components T-code 700, 701, 702

Valid from serial number 715612-

Date 2005-05-20

Order number 225678-040

Pos No

Description

Remark

4

Pressure switches/lift functions

G = Support arm lift Load >750 kg Speed = 5,3 km/h Load > 1200 kg Speed = 4,4 km/h H = Fork lift Load > 750 kg Speed = 5,3 km/h J = Valve, support arm lift K = Valve, fork lift

12.2.2 Description Lift When the pump motor starts, the oil flows through the non return valve to the lift cylinders.

Lowering When the lowering valve is actuated by the lowering lever on the chassis, or the lowering button on the tiller arm, the valve opens to allow the oil in the pressure lines to return to the oil tank. The lowering speed can be regulated by the movement of the lowering lever on the chassis.

Lowering using the button on the tiller arm gives a constant lower speed.

Operating pressure The operating pressures at rated load are: • SWE120L: 191 bar • SWE160D: 191 bar

Relief valve The relief valve opens at the following pressures: • SWE120L: 220 bar • SWE160D: 220 bar

Pressure switch The pressure switch is used to regulate the speed and is influenced by the load. It only has an off/on operation.

Load < 750 kg. Speed = 6,0 km/h Load > 750 kg. Speed = 5,3 km/h Load > 1200 kg – support arms. Speed = 4,4 km/h.

12- 2

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

© BT Europe AB

Hydraulic system – 6000 SWE120L, SWE160D Hydraulic diagram and components Order number 225678-040

Date 2005-05-20

Valid from serial number 715612-

T-code 700, 701, 702

This page is intentionally left blank

© BT Europe AB

Service Guide

SWE100/120, SWE120S, SWE120L, SWE160D

12- 3

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