BT Toyota Electric Forklift SWE120L, SWE16 Service Manual

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Service Manual SWE120L, SWE160D Valid from serial number: 922602-

Order number: 229101-040 Issued: 2006-03-13 ITS

© BT Europe AB

en

Document revisions:

Issue date

Order number

Changes

2005-04-05

220815

Completely new issue

2005-11-18

229101

P2, P3, P4, 5000, TruckCom (8700 - SEU tab (Extra I/O module)).

2006-03-13

229101

P2, P3, 0350, 0450, 5000, 7000, 8340

This manual covers following truck models:

T-code

Model

Serial number

702

SWE120L

922602-

702

SWE160D

922602-

© BT Europe AB

Service Manual

SWE120L, SWE160D

Approved by: L-G Andersson

Table of contents Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

1- Table of contents 1- Table of contents ................................................................................. 1-1 2- Technical data – M4 ............................................................................ 2-1 3- Introduction Maintenance – P1 .......................................................... 3-1 3.1 Safety regulations with maintenance work ..................................... 3-1 3.2 Cleaning and washing.................................................................... 3-3 3.2.1 External cleaning ............................................................. 3-3 3.2.2 Cleaning the motor compartment .................................... 3-3 3.2.3 Electrical components ..................................................... 3-3 3.3 Safe lifting ...................................................................................... 3-4 4- Preventive maintenance – P2 ............................................................. 4-1 4.1 Maintenance schedule ................................................................... 4-1 4.2 Lubrication schedule ...................................................................... 4-6 5- Oil and grease specification – P3 ...................................................... 5-1 6- Tools – P4 ............................................................................................ 6-1 6.1 Super Seal connectors................................................................... 6-1 6.2 AMP connectors............................................................................. 6-2 6.2.1 AMP Connectors, 040 series ........................................... 6-3 6.3 Molex connectors........................................................................... 6-3 6.4 Grease guns .................................................................................. 6-4 6.5 Other tools ..................................................................................... 6-5 7- Support arms – 0350 ........................................................................... 7-1 7.1 Greasable support arms................................................................. 7-1 8- Engine suspension– 0450 .................................................................. 8-1 8.1 Component parts ........................................................................... 8-1 8.1.1 Component List ............................................................... 8-2 8.1.2 Adjusting play, turning tube mounting ............................. 8-3 9- Electric drive motor – 1760 ................................................................. 9-1 9.1 Component parts ........................................................................... 9-1 9.1.1 Dismantling of motor from truck ....................................... 9-2 9.1.2 Assembling ...................................................................... 9-2 9.2 Service/Repairs.............................................................................. 9-3 9.2.1 Dismantling of motor ........................................................ 9-3 9.2.2 Assembling of motor ........................................................ 9-4 9.2.3 Cleaning .......................................................................... 9-4 10- Drive unit/gear – 2550 ..................................................................... 10-1 10.1 Component parts ......................................................................... 10-2 10.2 Leakage from top cover ............................................................... 10-3 10.3 Changing of the drive shaft’s sealing ring..................................... 10-4 10.3.1 Dismantling .................................................................... 10-4 10.3.2 Assembling .................................................................... 10-4

© BT Europe AB

Service Manual

SWE120L, SWE160D

1- 1

Table of contents T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

11- Electro magnetic brake – 3370 ....................................................... 11-1 11.1 Main components......................................................................... 11-1 11.1.1 Serial number 570989- .................................................. 11-1 11.2 Maintenance ................................................................................ 11-2 11.2.1 Exchange of brake disc ................................................. 11-2 12- Steering – 4000 ................................................................................ 12-1 12.1 Component parts, tiller arm.......................................................... 12-1 12.2 Adjustments ................................................................................. 12-2 12.2.1 Adjusting of brake microswitch ...................................... 12-2 12.3 Tiller arm handle .......................................................................... 12-3 12.3.1 Dismantling/Assembling ................................................ 12-5 Changing of signal button/switch (9, 10) ....................... 12-5 Changing of lift/lowering button (13) .............................. 12-6 Changing of pushbutton (16) ......................................... 12-6 13- Electrical systems – 5000 ............................................................... 13-1 13.1 General ........................................................................................ 13-1 13.1.1 Part numbers ................................................................. 13-1 13.2 Component identification ............................................................. 13-2 13.2.1 Component list ............................................................... 13-4 13.3 Electrical wiring diagram .............................................................. 13-6 13.3.1 Symbol list ..................................................................... 13-6 13.3.2 Overview ........................................................................ 13-7 13.3.3 Electrical wiring diagrams .............................................. 13-9 13.4 Functional description ................................................................ 13-15 13.4.1 Starting the truck ......................................................... 13-15 13.4.2 Driving ......................................................................... 13-15 13.4.3 Neutral speed reduction .............................................. 13-15 13.4.4 Neutral speed reduction on slopes .............................. 13-15 13.4.5 Braking ........................................................................ 13-15 13.4.6 Lifting the forks ............................................................ 13-16 13.4.7 Lifting the support arms ............................................... 13-16 13.4.8 Lowering the forks ....................................................... 13-16 13.4.9 Lowering the support arms .......................................... 13-16 13.4.10 Horn ............................................................................. 13-16 13.4.11 Hour meter ................................................................... 13-16 13.4.12 Transistor regulator ..................................................... 13-17 13.4.13 Spider expansion unit (SEU) (option) .......................... 13-17 13.4.14 TLS - Truck log system (optional) ................................ 13-20 General ........................................................................ 13-20 Registration ................................................................. 13-20 Logging in/out SD16 .................................................... 13-20 Logging in/out S16 ....................................................... 13-20 Collision sensor ........................................................... 13-21 Settings ........................................................................ 13-21 13.4.15 ID unit (optional) .......................................................... 13-22 General ........................................................................ 13-22 Installation ................................................................... 13-22 Settings ........................................................................ 13-23 13.5 Parameters ................................................................................ 13-25 13.5.1 General ........................................................................ 13-25 13.5.2 Viewing parameters - without the CAN service key ..... 13-25 13.5.3 Adjusting operator parameters - without the CAN service key 13-26 1- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Table of contents Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

13.5.4

13.6

13.7

© BT Europe AB

Viewing & changing parameters - CAN service key connected 13-27 Changing a parameter ................................................. 13-28 13.5.5 Operator parameters ................................................... 13-29 13.5.6 Parameter description ................................................. 13-29 Parameter 1 ................................................................. 13-29 Parameter 2 ................................................................. 13-29 Parameter 3 ................................................................. 13-29 Parameter 4 ................................................................. 13-29 Parameter 5 ................................................................. 13-30 13.5.7 Service parameters ..................................................... 13-31 13.5.8 Parameter description ................................................. 13-32 Parameter 10 ............................................................... 13-32 Parameter 14 ............................................................... 13-32 Parameter 15 - Non-configurable options .................... 13-32 Setting Non-configurable options ................................ 13-32 Parameter 16 - Configurable option #1 ....................... 13-33 Parameter 17 - Configurable option #2 ....................... 13-33 Parameter 18 - Configurable option #3 ....................... 13-33 Parameter 19 - Configurable option #4 ....................... 13-33 Parameter 20 ............................................................... 13-34 Parameter 21 ............................................................... 13-34 Recommendation on parameter setting for freely ventilated batteries ....................................................................... 13-35 Instructions for verifying parameter setting .................. 13-36 Recommendation on parameter setting for valve-controlled batteries (VRLA) .......................................................... 13-37 Instructions for verifying parameter setting .................. 13-38 Parameter 22 ............................................................... 13-38 Parameter 25 ............................................................... 13-38 Parameter 28 ............................................................... 13-38 Parameter 39 ............................................................... 13-39 Login method and driver parameter access ................ 13-39 Expanded keypad - General ........................................ 13-39 Expanded keypad - Programming ............................... 13-39 13.5.9 Configurable “Option” Parameters ............................... 13-42 General ........................................................................ 13-42 Summary of base options ............................................ 13-42 Convention for configurable options ............................ 13-43 Detailed option parameter tables ................................. 13-45 Diagnostic and troubleshooting.................................................. 13-56 13.6.1 General ........................................................................ 13-56 13.6.2 Error code history ........................................................ 13-56 13.6.3 Error codes .................................................................. 13-57 13.6.4 Transistor regulator errors ........................................... 13-69 Resetting errors ........................................................... 13-70 Safety .......................................................................... 13-70 13.6.5 Built-in Test Function ................................................... 13-71 Digital inputs/outputs test mode .................................. 13-72 Inputs check ................................................................ 13-72 Outputs check .............................................................. 13-73 Option buttons check ................................................... 13-74 Display test mode ........................................................ 13-74 Technical specifications – Curtis 1243 ....................................... 13-75

Service Manual

SWE120L, SWE160D

1- 3

Table of contents T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

14- Hydraulic system – 6000 ................................................................. 14-1 14.1 General ........................................................................................ 14-1 14.2 Hydraulic diagram and components............................................. 14-1 14.2.1 Main components .......................................................... 14-2 14.2.2 Description ..................................................................... 14-2 Lift .................................................................................. 14-2 Lowering ........................................................................ 14-2 Operating pressure ........................................................ 14-2 Relief valve .................................................................... 14-3 Pressure switch ............................................................. 14-3 15- Lifting mast – 7000 .......................................................................... 15-1 15.1 Adjusting the measurement between the guide and the mast...... 15-1 15.2 Grease the beam flanges and beam ribs ..................................... 15-2 15.3 Main lift chain system –................................................................ 15-3 15.3.1 General .......................................................................... 15-3 15.3.2 Checking the chain setting ............................................ 15-3 15.3.3 Chain inspection ............................................................ 15-3 15.3.4 Noise ............................................................................. 15-3 15.3.5 Surface rust ................................................................... 15-3 15.3.6 Rusty links ..................................................................... 15-3 15.3.7 Stiff links ........................................................................ 15-4 15.3.8 Bolt rotation ................................................................... 15-4 15.3.9 Loose bolts .................................................................... 15-4 15.3.10 Outline wear .................................................................. 15-5 15.3.11 Stretching ...................................................................... 15-6 15.3.12 Damage ......................................................................... 15-6 15.3.13 Damaged discs .............................................................. 15-7 15.3.14 Damaged bolts .............................................................. 15-7 15.3.15 Dirty chain ...................................................................... 15-7 15.3.16 Cleaning ........................................................................ 15-7 15.3.17 Lubrication ..................................................................... 15-7 16- Battery charger (built-in) – 8340 ..................................................... 16-1 16.1 General ........................................................................................ 16-1 16.2 Technical data – charger.............................................................. 16-2 16.3 Charging ...................................................................................... 16-2 Machine numbers 723984-936512 ................................ 16-2 Machine numbers 936513- ............................................ 16-3 16.4 Troubleshooting and service........................................................ 16-3 16.5 Setting the charger (applies to machine numbers 723984-936512) 16-4 Freely ventilated batteries ............................................. 16-4 Valve-regulated batteries ............................................... 16-4 16.5.1 Current levels at different charger settings (applies to machine numbers 936513-) 16-5 Freely ventilated batteries ............................................. 16-5 Valve-regulated batteries (Evolution type) ..................... 16-6 17- TruckCom ........................................................................................ 17-1 17.1 General ........................................................................................ 17-1 17.2 Connection................................................................................... 17-1 17.3 Layout .......................................................................................... 17-2 17.3.1 Main program screen ..................................................... 17-2 1- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Table of contents Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.3.2 Nodes ............................................................................ 17-2 17.3.3 Icons .............................................................................. 17-3 17.3.4 Tool buttons and menu bar ............................................ 17-3 17.3.5 Information window ........................................................ 17-4 17.3.6 Status bar ...................................................................... 17-4 17.4 Connection function .................................................................... 17-4 17.5 Disconnection function................................................................. 17-4 17.6 Downloading program function .................................................... 17-5 17.6.1 Normal downloading (truck with key) ............................. 17-5 17.6.2 Normal downloading (truck with keypad) ....................... 17-5 17.6.3 Emergency downloading (truck with keypad) ................ 17-6 17.6.4 Emergency downloading (truck with keypad) ................ 17-6 17.6.5 Downloading in old versions of logic card ..................... 17-6 17.7 Truck report function .................................................................... 17-7 17.8 Parameters function..................................................................... 17-8 17.9 Diagnostics function..................................................................... 17-8 17.9.1 Representation of signal colours ................................... 17-9 17.9.2 “Tiller arm” tab ............................................................... 17-9 17.9.3 “Drive Controller” tab (transistor regulator driving) ..... 17-10 17.9.4 “Pump controller” tab (transistor regulator pump) ....... 17-11 17.9.5 “EPS” (steering servo tab) ........................................... 17-12 17.9.6 SEU tab (Extra I/O module) ......................................... 17-13 17.10 Other menu functions................................................................. 17-13 17.10.1 Save to file ................................................................... 17-13 17.10.2 Download from file ....................................................... 17-13 17.10.3 Reset CAN adapter ..................................................... 17-14 17.10.4 Delete error code log ................................................... 17-14 17.10.5 Reset hour meter ......................................................... 17-14 17.10.6 Read error code log ..................................................... 17-14 17.10.7 Adjust date and time .................................................... 17-14 17.10.8 Adjusting the hour meter on older cards ...................... 17-14 17.10.9 Help ............................................................................. 17-14 About the TruckCom application ................................. 17-14 17.10.10 Exit ............................................................................. 17-14 17.11 Specifications............................................................................. 17-15 17.12 Installation.................................................................................. 17-15 17.12.1 Installation on a PC with Windows® 95/98 .................. 17-15 17.12.2 Installation on a PC with Windows XP/2000 ................ 17-16 Changes in Windows® Control Panel ......................... 17-18 17.12.3 Installation on a PC with Windows NT ......................... 17-21 17.12.4 In case of communication problems with CAN ............ 17-21 17.12.5 To uninstall .................................................................. 17-21

© BT Europe AB

Service Manual

SWE120L, SWE160D

1- 5

Table of contents T-code 702

Valid from serial number 922602-

1- 6

Service Manual

Date 2006-03-13

SWE120L, SWE160D

Order number 229101-040

© BT Europe AB

Technical data – M4 Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

2- Technical data – M4 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 Manual

SWE120L, SWE160D

2- 1

Technical data – M4 T-code 702

Valid from serial number 922602-

Model

Date 2006-03-13

Order number 229101-040

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

2- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Technical data – M4 Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

Model

T-code 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 Manual

SWE120L, SWE160D

2- 3

Technical data – M4 T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

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Service Manual

SWE120L, SWE160D

© BT Europe AB

Introduction Maintenance – P1 Safety regulations with maintenance work Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

3- Introduction Maintenance – P1 All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with BT’s minimum requirements.

The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals: Day time:08.00-17.00 (20 hr./week) 2-shifts:06.00-14.00, 14.00-22.00 (40 hr./week) 3-shifts:06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week) Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.

Only use BT approved spare parts when service and repair work are carried out.

3.1 Safety regulations with maintenance work Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so • Keep the area where you carry out the service clean. Oil or water makes the floor slippery • Never wear loose objects or jewellery when working on the truck WARNING! Short-circuiting/Burns.

When working with the truck’s electrical system, short-circuiting/ burns can occur if a metal object comes into contact with live electrical connections.

Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual • Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system • Relieve the system pressure slowly before starting work on the truck’s hydraulic system © BT Europe AB

Service Manual

SWE120L, SWE160D

3- 1

Introduction Maintenance – P1 Safety regulations with maintenance work T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

• Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand • Bear in mind that the oil in the transmission or the hydraulic system can be hot WARNING! Risk of burns.

Hot transmission and hydraulic oil.

Let the truck cool before changing the oil.

• Only fill the hydraulic system with new and clean oil WARNING! The hydraulic system can be damaged.

If the oil is contaminated hydraulic components can be damaged.

Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives • Do not release solvents and the like, which are used for cleaning/ washing, into drains that are not intended for this purpose. Follow the local directives that apply for disposal • Disconnect the battery when welding on the truck NOTE! The battery can be damaged.

When welding using an electric power source the welding current can enter the battery.

The battery should therefore be disconnected.

• Remove at least 100 mm of paint around the welding/grinding area through sand-blasting or the use of a paint stripper when welding or grinding on painted surfaces CAUTION! Harmful gases.

Paint that is heated gives off harmful gases.

Remove 100 mm of paint from the work area.

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Service Manual

SWE120L, SWE160D

© BT Europe AB

Introduction Maintenance – P1 Cleaning and washing Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

3.2 Cleaning and washing Cleaning and washing of the truck is important to ensure the truck’s reliability.

• Carry out general cleaning and washing weekly NOTE! Risk of short-circuiting.

The electrical system can be damaged Disconnect the battery before washing by pulling out the battery connector.

3.2.1 External cleaning • Remove rubbish, etc. from the wheels daily • Use a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water NOTE! Jamming, corrosion.

Mechanical components can be damaged.

After washing, the truck should be lubricated as set out in the chapter Maintenance and lubrication chart.

3.2.2 Cleaning the motor compartment • Cover the electric motors, connections and valves before washing NOTE! Risk of short-circuiting.

The electrical system can be damaged.

Electrical components must not be cleaned with a high pressure washing unit.

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose grime using tepid water

3.2.3 Electrical components • Blow electric motors down using compressed air • Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent NOTE! Risk of short-circuiting.

Electrical components can be damaged.

Do not break the guarantee seal on the electronic board.

© BT Europe AB

Service Manual

SWE120L, SWE160D

3- 3

Introduction Maintenance – P1 Safe lifting T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

3.3 Safe lifting All lifting must be carried out on a flat, non-slip and firm surface. Avoid new laid asphalt or asphalt on a hot summer’s day.

• Activate the parking brake to prevent the truck from moving during the lift. If the lift applies to the brake wheel, chock the other wheels so that the truck stands still • Select a lifting point so that the lift is as easy as possible (one corner at a time). If the truck has marked lifting points on the under side of the chassis these can be used to obtain a well balanced lift • Ensure that the surface under the jack is clean and free from oil and grease • Ensure that your hands and the jack’s lever are free from oil and grease • Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a risk of the jack being overloaded • Support the truck: - as close as possible to the part of the chassis that is to be lifted.

This reduces the risk of the truck tipping over - so that the truck cannot roll • Never lift up the jack in order to lift higher • Never work under a lifted truck unless it is well supported WARNING! Risk of crushing.

A badly supported truck can fall.

Never work under a truck that is not supported on trestle-blocks and secured by a lifting device.

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Service Manual

SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 Maintenance schedule Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

4- Preventive maintenance – P2 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

500

1000

3000

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

1d

1w

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

Force grease into the lubricant nipples

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

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

© BT Europe AB

T

I/L6

I/T1

I/T

T2 I I

I3

Service Manual

L4

SWE120L, SWE160D

L

4- 1

Preventive maintenance – P2 Maintenance schedule T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

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

500

1000

3000

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

1d

1w

6m

12m

36m

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

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

4- 2

Service Manual

C

I

I I I I I

SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 Maintenance schedule Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 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

500

1000

3000

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

1d

1w

6m

12m

36m

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

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

© BT Europe AB

Service Manual

I C/T

TI I

I

I L5

SWE120L, SWE160D

L

4- 3

Preventive maintenance – P2 Maintenance schedule T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

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

500

1000

3000

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

1d

1w

6m

12m

36m

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

1 = The connections are re-tightened for the first time after 500 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 500 h/6 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 500 h/6 month, and then every 3000 h/36 months.

5 = The oil is changed and the filter cleaned for the first time after 500 h/ 6 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.

4- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 Maintenance schedule Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

6600 4110 7100

0380 5000 5700

0000

3100

5110

6000

5400 2550 3500 1700

© BT Europe AB

Service Manual

SWE120L, SWE160D

4- 5

Preventive maintenance – P2 Lubrication schedule T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

4.2 Lubrication schedule Pos no

Service point

Interval/Running hours 500h

1000h

Lubricant

3000h

1

Wheel bearings

L

A

2

Mast beam

L

F

2

Inside surfaces of beam ribs

S

I

2

Inside surfaces of beam flanges

S

A

3

Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear

C

7

Push rods and links

S

O

B

L

G O

C H

L = Lubrication C = Check O = Oil change

4- 6

Service Manual

SWE120L, SWE160D

© BT Europe AB

Preventive maintenance – P2 Lubrication schedule Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

3 2

1 7

4

6

© BT Europe AB

Service Manual

SWE120L, SWE160D

5

4- 7

Preventive maintenance – P2 Lubrication schedule T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

This page is intentionally left blank

4- 8

Service Manual

SWE120L, SWE160D

© BT Europe AB

Oil and grease specification – P3 Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

5- Oil and grease specification – P3 Table 1: Oil and grease specification Lubricant

Specification > - 15°C

Application area < - 15°C

A

Grease

223690 Q8 Rembrandt EP2

223690 Q8 Rembrandt EP2

B C

Hydraulic oil Transmission oil

D F G

Grease Grease Grease

H

Fett

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

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

I

Fett

Gleitmo 805

Gleitmo 805

Bearings and bushings Inside surfaces of beam flanges Hydraulic system Gears Chains Mast Pilot bearing Support arms, lubricant nipples of push rods and links Inside surfaces of beam ribs

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 Manual

from other manufacturers may be used)

SWE120L, SWE160D

5- 1

Oil and grease specification – P3 T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

3 2

1 7

4

6

5- 2

Service Manual

SWE120L, SWE160D

5

© BT Europe AB

Tools – P4 Super Seal connectors Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

6- Tools – P4 6.1 Super Seal connectors 1

3 3 2 Figure

© BT Europe AB

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)

Service Manual

SWE120L, SWE160D

6- 1

Tools – P4 AMP connectors T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

6.2 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

6- 2

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

1

Service Manual

SWE120L, SWE160D

© BT Europe AB

Tools – P4 Molex connectors Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

6.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

6.3 Molex connectors 16 9 8 1 Figure

© BT Europe AB

Service Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

SWE120L, SWE160D

6- 3

Tools – P4 Grease guns T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

6.4 Grease guns Figure

6- 4

Number

Application

24981

A tool with a pointed nozzle used to apply grease. Length 170 mm.

755132

Single-hand grease gun with straight discharge pipe and nozzle.

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

Pointed nozzle for grease guns used to apply grease in recessed nipples.

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

Nozzle for neck nipples. Fits grease guns with hose and discharge pipe.

Service Manual

SWE120L, SWE160D

© BT Europe AB

Tools – P4 Other tools Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

6.5 Other tools Figure

© BT Europe AB

Service Manual

Number

Application

156263

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

SWE120L, SWE160D

6- 5

Tools – P4 Other tools T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

This page is intentionally left blank

6- 6

Service Manual

SWE120L, SWE160D

© BT Europe AB

Support arms – 0350 Greasable support arms Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

7- Support arms – 0350 7.1 Greasable support arms Greasable support arms are an option on SWE120L and standard on SWE160D. Grease the lubricant nipples marked with arrows using S213366 according to the lubrication chart.

x2

© BT Europe AB

Service Manual

SWE120L, SWE160D

7- 1

Support arms – 0350 Greasable support arms T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

This page is intentionally left blank

7- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Engine suspension– 0450 Component parts Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

8- Engine suspension– 0450 8.1 Component parts

1

2

3 20

21 4

5

6

19 7 8 18

11

9 14

13 12

10

15

17 16

© BT Europe AB

Service Manual

SWE120L, SWE160D

8- 1

Engine suspension– 0450 Component parts T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

8.1.1 Component List

8- 2

Pos.

Description

Notes

1

Screw

2x M6S 8x30

2

Plate

3

Circlip

4

Console

5

Washer

8x

6

Screw

2x M6S 12x45

7

Lock bracket

8

Screw

9

Axle

10

Screw

2x M6S 12x90

11

Grease nipple

2x

12

Pivot pipe

13

Grease nipple

4x

14

Bushing

4x

15

Engine bracket

16

Screw

2x M6S 6x10

17

Axle

2x

18

Washer

(0.5 mm) Number as required

18

Washer

(1 mm) Number as required

19

Bushing

4x

20

Link

2x

21

Grease nipple

2x

Service Manual

SWE120L, SWE160D

MC6S 8x12

© BT Europe AB

Engine suspension– 0450 Component parts Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

8.1.2 Adjusting play, turning tube mounting When replacing the turning tube, or in case play has occurred between the turning tube mountings, shim the mountings of the turning tube as much as possible. The play should be 0

Shim the following four locations to achieve a play of 0.

© BT Europe AB

Service Manual

SWE120L, SWE160D

8- 3

Engine suspension– 0450 Component parts T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

This page is intentionally left blank

8- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electric drive motor – 1760 Component parts Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

9- Electric drive motor – 1760 9.1 Component parts 16 21 19

14

20

18

13

17 10

15

12 11

8

9

7 6 5 4 3 1 2

© BT Europe AB

Pos

Description

Note

1

Screw

M6x25

2

Bearing shield

3

Locking ring

4

Bearing

5

Carbon brush bridge

6

Screw

M5x12

7

Screw

M5x20

8

Carbon brush

9

Rotor

10

Key

11

Plug

12

Stator

13

Cable

Service Manual

SWE120L, SWE160D

9- 1

Electric drive motor – 1760 Component parts T-code 702

Valid from serial number 922602-

Pos

Description

14

Cable

15

Bearing shield

16

Screw

17

Seal

18

Bearing

19

Washer

20

Locking ring

21

Locking ring

Date 2006-03-13

Order number 229101-040

Note

M6x25

9.1.1 Dismantling of motor from truck • Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch. Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor. Remove the cover over the motor compartment together with the tiller arm.

• Carefully lift the motor straight up, without damaging the sealing surfaces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, e.g. with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

9.1.2 Assembling • Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm. • Fit and adjust the brakes as per the instructions. Screw tight the cover and tiller arm, and connect the cables that were previously removed. Check that the polarity is correct.

• The function of the brakes should be checked before the truck is moved.

9- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electric drive motor – 1760 Service/Repairs Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

9.2 Service/Repairs 9.2.1 Dismantling of motor 16 21 19

14

20

18

13

17 10

15

12 11

8

9

7 6 5 4 3 1 2

• Release the brake disc’s companion flange by first removing the locking ring together with the washer in the end of the rotor shaft.

The companion flange can now be lifted off. It may be necessary to unclamp it with an appropriate tool.

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

• Dismantle the commutator end’s bearing shield (2) together with the carbon brush bridge (5) and carbon brushes (8) by unscrewing the eight screws (1). Now put down the motor with a firm resting point against the edge of the bearing shield, and carefully tap on the rotor shaft’s end with a rubber mallet.

• Dismantle the drive end’s bearing shield (15) together with the rotor (9). Make sure not to damage the motor windings when the rotor is removed from the motor housing.

• After dismantling the motor’s bearing shields and removing the rotor from the motor housing, the gear wheel in the rotor’s drive end is removed. This is done by unscrewing the nuts on the gear wheel and then pulling the gear wheel off with a puller. Note that the gear wheel is locked with Loctite to the rotor shaft. © BT Europe AB

Service Manual

SWE120L, SWE160D

9- 3

Electric drive motor – 1760 Service/Repairs T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

• Now release the inner locking ring together with the underlying washer. Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

9.2.2 Assembling of motor Assemble the motor in the reverse order.

• Carefully check that the rotor can move freely in the direction of rotation and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing). For a new motor this should lie between 2 - 3 Mohm. When a used motor has been exposed to impurities an insulation resistance down to approx. 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

9.2.3 Cleaning An extremely critical factor to ensure correct functioning of the motor is that it is kept as clean as possible. The motor and the motor compartment must be regularly checked for dust, oil, and other impurities.

A vacuum cleaner with an appropriate nozzle can be used to clean the motor if the motor windings and inner compartment are dry Compressed air can be used in combination with a vacuum cleaner. In which case the compressed air must be clean and dry.

A cloth of non-fluffing material should be used if the windings have a coating. The cloth can also be moistened with a grease-dissolving, organic and volatile detergent that does not damage the windings. Use detergent sparingly to avoid it penetrating into the parts of the motor.

Residual detergent should be removed with an appropriate solvent, if it leaves a greasy surface.

If the parts of the motor are heavily fouled it may be necessary to use a solvent that is sprayed onto the parts. It is important that the detergent is applied in a way to prevent dirt from penetrating into the parts of the motor, especially for the rotor.

One method of cleaning the rotor is to dip it in solvent. If this is done then the rotor must always be dried with the application of heat. There must be adequate ventilation during the drying process, and the drying should continue until a number of measurements of the insulation resistance provide equivalent and approved results.

9- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Drive unit/gear – 2550 Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

10- Drive unit/gear – 2550

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28

13 12 14 32 29

15

18

16

19

17 20

23 21

© BT Europe AB

30

31

Service Manual

SWE120L, SWE160D

22

10- 1

Drive unit/gear – 2550 Component parts T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

10.1 Component parts

10- 2

Pos

Description

01

Drive gear complete

2

Air valve

3

Cover

4

Dip stick

5

Washer

6

Gasket

7

Nut

8

Washer

9

Gear wheel

10

Conical roller bearing

11

Shims

12

Screw

13

Shims

14

Conical roller bearing

15

Pinion/ Crown gear

Cog clearance 0.09-0.15 mm Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

16

Nut

Tightening torque 300 Nm Locked with punch mark

17

Shims

18

Conical roller bearing

19

Shims

20

Screw

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

21

Screw

Bottom cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

22

Cover

23

Gasket

24

Gear wheel

Service Manual

Note

Tightening torque 70 Nm Locked with punch mark Primary gear

Top cover and gear housing Tightening torque 26.6 Nm Lock with Loctite 242

Motor gear

SWE120L, SWE160D

© BT Europe AB

Drive unit/gear – 2550 Leakage from top cover Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

Pos

Description

Note

25

Washer

26

Nut

Tightening torque 30 Nm Locked with punch mark Lock with Loctite 603

27

Screw

Motor and gear housing

28

Nut

Tightening torque 26.6 Nm Lock with Loctite 242

29

Conical roller bearing

30

Shims

31

Seal

32

Drive shaft

10.2 Leakage from top cover Dismantling • Lift up the truck, and block up to ensure that it is stable.

• Unscrew the drive wheel.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench. Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex socket wrench.

• Change the gasket (6).

Assembling is carried out in the reverse order • Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

© BT Europe AB

Service Manual

SWE120L, SWE160D

10- 3

Drive unit/gear – 2550 Changing of the drive shaft’s sealing ring T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

10.3 Changing of the drive shaft’s sealing ring The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

10.3.1 Dismantling • Unscrew the drive wheel (1).

• Remove the lower cover and drain off the oil (22).

• Release the drive shaft nut. Remove the nut and washer (16,17).

• Carefully tap out the drive shaft with a brass drift and hammer (32).

• Pull off the bearing from the drive shaft with tool 08-13022 (29).

• Check that the bearing washers are not damaged. If they have been damaged by the puller tool, measure the total thickness of the shim washers and change them before assembling (30).

• Remove the sealing ring from the drive shaft (31).

10.3.2 Assembling Assembling of the gear after changing the drive shaft’s sealing ring is carried out in the reverse order to dismantling.

Pay special attention to the following during assembling: • Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing’s shim washers.

• When fitting the drive shaft with bearing, shim washers and seal, make sure that the shaft keys correspond with the crown gear’s keys and that the bearing and seal are correctly positioned in the gear housing before the shaft is pressed in completely.

• Put the distance ring on the drive shaft end, and put on the shaft nut.

Always use a new nut. Tighten the shaft nut to a torque of 300 Nm and lock it with a punch mark in the middle. The drive shaft nut should be lubricated before it is put on the shaft.

• Change the gasket before fitting the bottom cover. Make sure that it is not damaged. Fit the cover and tighten the bolts to a torque of 26.6 Nm. The bolts should be lubricated before they are fitted. Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm.

10- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electro magnetic brake – 3370 Main components Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

11- Electro magnetic brake – 3370 11.1 Main components 11.1.1 Serial number 5709899

1 2

8

3

4

7

5

© BT Europe AB

Pos No

Description

1

Magnetic coil

2

Cap screws

3

Electrical wire

4

Pressure plate

5

Pressure springs

6

Flange

7

Mounting bolts

8

Brake disc

9

Hub

Service Manual

SWE120L, SWE160D

6

11- 1

Electro magnetic brake – 3370 Maintenance T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

11.2 Maintenance Basically the brake is maintenance free in normal work environments.

However it is recommended according to the preventive maintenance schedule to check the brake disc for wear.

11.2.1 Exchange of brake disc The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

• Undo and remove the three fastening bolts.

• Loosen the brake disc from the hub and check for wear and tear. Replace the brake disc if the surface is unevenly worn.

• Reassemble the brake.

• Reconnect the electrical wiring.

11- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Steering – 4000 Component parts, tiller arm Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

12- Steering – 4000 12.1 Component parts, tiller arm 1 2 3

4

5 6

7

8

9 10

14

12

13

16 18

11

15

17

19 20 21 22 23

© BT Europe AB

Pos

Description

Note

1

Screw

4

2

Washer

3

Handle

4

Screw

4

5

Washer

2

6

Cable holder

Service Manual

SWE120L, SWE160D

12- 1

Steering – 4000 Adjustments T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Pos

Description

Note

7

Nut

8

Gas damper

9

Bracket

10

Stop screw

11

Screw

12

Ball joint

13

Screw

14

Distance

15

Bush

2

16

Damper

2

17

Axle

18

Cam

19

Distance

20

Screw

21

Distance

22

Distance

23

Switch

4

S 10

12.2 Adjustments 12.2.1 Adjusting of brake microswitch Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

12- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Steering – 4000 Tiller arm handle Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

12.3 Tiller arm handle 28 29

27 26 24 25

14 23 22

17 18

21

16

20

19

15 14 14

30 31 10 9 8

32

35

14

12 11

13

33 34 5

6

7

4

1

2 3

© BT Europe AB

Pos

Description

1

Screw

2

Cover

3

Handle

4

Electronic circuit board

5

Screw

6

Display card

7

Top cover

8

Pushbutton

9

Signal switch

10

Signal button

11

Display glass

12

Arm

13

Pushbutton

14

Plate

15

Spring

16

Pushbutton

17

Arm

18

Holder

Service Manual

Note Keyboard option

SWE120L, SWE160D

Option

Lift/Lower

Not used

12- 3

Steering – 4000 Tiller arm handle T-code 702

12- 4

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Pos

Description

19

Spring

20

Control switch

21

Axle

22

Sliding bearing

23

Control stop

24

Arm

25

Spring holder

26

Spring

27

Spring holder

28

Sliding bearing

29

Control switch

30

Button for safe reversing

31

Arm

32

Spring

33

Lower cover

34

Screw

M4x40

35

Screw

2xM5x45 - 2xM5x60

Service Manual

SWE120L, SWE160D

Note

© BT Europe AB

Steering – 4000 Tiller arm handle Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

12.3.1 Dismantling/Assembling • Dismantle cover (2), (keyboard option).

• Remove the screws (35), hold top cover firm (7).

• Disconnect the cable connected to the electronic circuit board (4).

• Remove the screws (34).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place.

Assembling is carried out in the reverse order.

NOTE! Static electricity!

Risk of static discharge that can damage the electronics.

Make sure to take the necessary precautions before working with the electronics.

Changing of signal button/switch (9, 10) • Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic circuit board (4).

• Press out the switch from its mounting.

Assembling is carried out in the reverse order.

© BT Europe AB

Service Manual

SWE120L, SWE160D

12- 5

Steering – 4000 Tiller arm handle T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Changing of lift/lowering button (13) • Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

A

A

• Unscrew the holder (18) so that the arm (12) comes loose.

Assembling is carried out in the reverse order.

Changing of pushbutton (16) • Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

Assembling is carried out in the reverse order.

12- 6

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 General Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

13- Electrical systems – 5000 This chapter concerns the software182635-004 and later versions.

13.1 General The electrical system of the truck is based on the PowerDrive platform.

• The main energy source comprises a 24 V DC truck battery.

• The traction drive motor is a separate excitation type (SEM). The travel drive motor is operated by an enclosed transistor regulator relying on pulse width modulation (PWM) technology.

• The lift unit motor is a conventional DC motor without any external field winding connections. Switch-on of the hydraulic unit's electric motor is achieved using a contactor.

• All electric units communicate via a CAN bus with an IC card in the steering unit handle. This card contains a processor and software that controls and monitors truck functions. A set of parameters used to adjust truck functions and characteristics is stored in the card. The card also monitors error conditions that may occur.

13.1.1 Part numbers To select part number display mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “Pn” is displayed, then release S18. Fig. 1 Fig. 1

The display will now show the part numbers for the control program, the hardware part number and hardware serial number.

The part numbers are displayed by repeatedly operating speed control L1. The display will first show the starting portion of the number then the ending portion.

© BT Europe AB

Service Manual

SWE120L, SWE160D

13- 1

Electrical systems – 5000 Component identification T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.2 Component identification S10 S21

S17

X41 F51 K10

F50

F1

A1 Y1 F3 M1 R1 K30

H1 M3 P2 Y34 Y52 P1 Y41

S42

13- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Component identification Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

A2:S22 A2:S21 A2:S1-9

T-code 702

A2:S10-18

A2

9

1 10

18

A2:S17 A2:S20 A2:S19 A6 S113 S112 S111

S116 S115 S114

S18:1

S18:2 A2:S20 A2:S19 L1 A2:S22 A2:S21 A2:S17

A17

© BT Europe AB

Service Manual

SWE120L, SWE160D

13- 3

Electrical systems – 5000 Component identification T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.2.1 Component list 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

S111

Switch

Option

S112

Switch

Option

S113

Switch

Turtle button

S114

Switch

Option

S115

Switch

Option

13- 4

24 V

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Component identification Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

Symbol

Description

S116

Switch

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

© BT Europe AB

Function

T-code 702

Notes Option

Service Manual

SWE120L, SWE160D

Brake lever

13- 5

Electrical systems – 5000 Electrical wiring diagram T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.3 Electrical wiring diagram 13.3.1 Symbol list Table 2: Symbol list Symbol

A1

E1

M S

Description

Symbol

Description

Truck battery

Horn

Fuse

Emergency stop switch NC

Resistor (PTC)a

Brake coil (normally applied)

DC motorb (SEM type)c

Sensor, inductive NO

Contactor

Coil for hydraulic magnetic valve

Pressure switch, NC

Connector

A2

E2

p

Momentary switch, NO

NO = Normally Open, NC = Normally closed a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases) b. DC = Direct Current c. SEM = Separately Excited Motor

13- 6

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Electrical wiring diagram Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

13.3.2 Overview 2

ARMATURE (M)

6

A2

4

E2

1

F1

M1

R1 X1

A1

M S

+

3 24 (+) POWER 24VDC 40 (16) SUPPLY 24VDC (-) POWER 0VDC

E1

P1

63

FIELD (S1)

49

X1 CHARGER

MAIN CONTACTOR (4) P2

5

(10) SUPPORT ARM LOAD

p

(15) FORK LOAD

G1

-

FIELD (S2)

S170

K10

64

F51

A1

ONLY TRUCK WITH MAX LOAD 1200KG

40

21 S21

p

F3

S10

57

66

S33

(12) TILLER ARM

PUMP CONTACTOR (6) (13) LIFT LIMIT 1,6M

S90

A1

M3 A2 M

45 K30

H1

S32 ONLY TRUCK WITH MAX LOAD 1200KG

SIGNAL HORN (7) BRAKE RELEASE (5)

39 Y1 31 Y41

S42

65

LOWER VALVE (9) (11) MAN. LOWERING

38 34 58

FORK VALVE (2) Y52

53 SUPPORT ARM VALVE (3)

CAN HIGH/LOW (1/8) 24

24

X41 40

20 120 119

X9

S17

F50

CHARGER RED BLACK (+) OUT. POS. (-) OUT. NEG.

A30

ONLY KEYBOARD

(X3:3/7) CAN HIGH/LOW

22 40 (X3:2) +24VDC (X3:6) 0VDC

(X2:1/2) TURTLE (X1:1) HORN 2 (X4:1) HORN 1

S113

A2

S18:2 S18:1 (X4:2) (X1:2) (X2:1/3)

KEYBOARD A17 © BT Europe AB

1

A2:S17

Hall

F

A2:S19

EXT. EQUIP.

Hall A2:S20

Hall

A2:S1-S9 A2:S10-S18

Hall

(X11)

Service Manual

Hall

(X12)

DISPLAY A6

(X1)

SWE120L, SWE160D

13- 7

13- 8

Service Manual

40

24

21

20

1

7,5A

F51

7,5A

F50

1

A2

K10

A1

2

PTC 15~E

R1

F1

130A

F3

130A

+

9

-

SWE120L, SWE160D S

-

+

10

146

X1

1

13

X13

2

Y41

X12

A2

S33 14

X13

X10

X10 1

145

0:2

SWE120L

X10

21

13

S

M

S10

2

S90

Bn

Y1

E1

A1

22

14

Bl

X10

E2

A2

M1

M

M3 A1

DRIVE MOTOR

PUMP MOTOR

X12

X10

39

38

45

64

57

31

5

4

6

3

40

7

9

6

4

12

5

S1

S2

M

+

-

OUT. SIGNAL HORN

OUT. LOWER VALVE

OUT. PUMP CONTACTOR

OUT. MAIN CONTCTOR

218893 1/6, Prod C

INP. TILLER ARM IN DRIVE POS.

OUT. BRAKE

OUT. FIELD

OUT. FIELD

OUT ARMATURE

INP. POWER SUPPLY +24V DC

INP. POWER SUPPLY 0V DC

Date 2006-03-13

H1

2

A2

K30 A1

1

G1 24V

FEXTERNAL EQUIPMENT

2

X1

Valid from serial number 922602-

Sh. 3

Sh. 2

Sh. 2

Sh. 3

Sh. 6

T-code 702

Bu

TRANSISTOR REGULATOR A1

Electrical systems – 5000

Electrical wiring diagram Order number 229101-040

13.3.3 Electrical wiring diagrams

© BT Europe AB

© BT Europe AB

Service Manual

SWE120L, SWE160D

Sh. 3

Y34

S32 14

2

Y52

S42 3

53

58

65

66

120

13

p

49

120

37

SWE120L X200 50

P2

63

119

X200

p

P1

24

8

8

3

2

11

13

15

10

16

CAN LOW

CAN HIGH

218893 2/6, Prod C

OUT. SUPPORT ARM VALVE

OUT. FORK VALVE

INP. MAN. LOWERING

INP. LIFT LIMIT 1.6 M

INP. FORK LOAD

INP. SUPPORT ARM LOAD

INP. SUPPLY +24V DC

Valid from serial number 922602-

119

2

Date 2006-03-13

Sh. 3

24

1

EMERGENCY SWITCH OFF S21

Order number 229101-040

Sh. 1 6

Sh. 1

21

TRANSISTOR REGULATOR A1

Electrical systems – 5000 Electrical wiring diagram

T-code 702

13- 9

13- 10

Sh. 1 6

40

120

Service Manual

X41

4

120 CAN, CONNECTION

40

119

120

3

119

2

40

X9

20

1

20

S17

X5

X5

X5

X5

X5

X5

X5

X5

40

120

119

22

X3 6

X3 7

X3 3

X3 2

SWE120L, SWE160D

218893 3/6, Prod C

FORK LOWER

FORK LIFT

SUPPORT ARM LOWER

SUPPORT ARM LIFT

SPEED REF. VALUE

BELLY BUTTON

Date 2006-03-13

A2:S20

A2:S19

A2:S22

A2:S21

A2:S1-S9 A2:S10-S18

A2:S17

INP. OV DC

CAN LOW

CAN HIGH

INP. +24V DC

Valid from serial number 922602-

CAN, SERVICE CONNECTOR

Sh. 2

119

20

ELECTRONIC CARD TILLER ARM A2

T-code 702

Sh. 2

Sh. 1

KEY

ONLY KEY BOARD

Electrical systems – 5000

Electrical wiring diagram Order number 229101-040

© BT Europe AB

© BT Europe AB S18:1

Service Manual

OPTION

S113

SWE120L, SWE160D 2

OUT. 0V DC HORN 2 X1 2

X2:1/3 TURTLE

X2:1/2 TURTLE

INP. HORN 2

OUT. OV DC HORN 1 X4 2

X1 1

INP. HORN 1 X4 1

0V DC

218893 4/6, Prod C

Valid from serial number 922602-

1

2

S18:2 1

2

X12 6

X1 6

LCLK

ENABLE

SCK

SI

+5V DC

Date 2006-03-13

1

X12 5

X12 4

X1 4

X1 5

X12 3

X12 2

X1 2

X1 3

X12 1

X1 1

ELECTRONIC CARD A2

Order number 229101-040

8 8 8 8

DISPLAY A6

DISPLAY A6

Electrical systems – 5000 Electrical wiring diagram

T-code 702

13- 11

Electrical systems – 5000 Electrical wiring diagram Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

I 0

LED_GREEN

LED_RED

X11 8

X11 9

X11 10 0V DC

-0# X11 7

789

9 7

8

X11 6

456

5 4

6

X11 5

123

2 KEY BOARD A17

1

3

X11 4

369#

2580 X11 2

X11 3

147X11 1

ELECTRONIC CARD A2

218893 5/6, Prod C

T-code 702

13- 12

Service Manual

SWE120L, SWE160D

© BT Europe AB

© BT Europe AB

Service Manual

Sh. 3

(RED)

40 (BLACK)

1

K10 A1 A2

OUT. MAIN CONTACTOR

+

-

(BLACK)

SWE120L, SWE160D

MAINS, EARTH

MAINS, VAC

MAINS, VAC

218893 6/6, Prod C

OUT. NEGATIVE CHARGER VOLTAGE

OUT. POSITIVE CHARGER VOLTAGE

ONBOARD CHARGER A30

4

(RED)

64

Valid from serial number 922602-

PLUG. B

PLUG. A

ONBOARD CHARGER, PLUG. A/B

23

Date 2006-03-13

S170

ELECTRONIC CARD A5

Order number 229101-040

Sh. 1

Sh. 2

24

START INTERLOCK ONBOARD CHARGER

ONBOARD CHARGER

OPTION

Electrical systems – 5000 Electrical wiring diagram

T-code 702

13- 13

Electrical systems – 5000 Functional description T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.4 Functional description 13.4.1 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.

13.4.2 Driving

A1 B-

• S10 closed .

S1 T1

Ish

Ia

Shunt

+

• The speed control activated in any direction.

S2

MA2

A A1

T2

K10

B+

13.4.3 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

13.4.4 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.

13.4.5 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.

13- 14

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Functional description Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

13.4.6 Lifting the forks • A2:S19 activated.

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

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

13.4.8 Lowering the forks • A2:S20 activated.

13.4.9 Lowering the support arms • A2:S22 activated.

13.4.10 Horn • S18 activated.

13.4.11 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 Manual

SWE120L, SWE160D

13- 15

Electrical systems – 5000 Functional description T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.4.12 Transistor regulator

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

Curtis 1243 is a regulator [A1] for controlling separately excited motors (SEM). 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.

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.

13.4.13 Spider expansion unit (SEU) (option) The Spider expansion unit, referred to as the SEU, allows the main control card to handle a greater number of inputs & outputs. The SEU allows up to 8 extra digital inputs and 4 digital outputs which can be addressed and controlled via the CAN bus. Up to two SEU units can be fitted in the truck to handle more complex options. The SEU contains firmware but this is only for internal configuration. No truck control logic is present in the SEU. This means a faulty SEU can be exchanged without affecting the truck’s functions in any way.

There are 3 cases covering the usage of SEU: a) The SEU can be fitted if the truck is modified according to a customer special request, including certain standard options. In this case, correct operation of the modification/option is achieved by adjustment of service parameters 16 to 19. b) The SEU is fitted as standard in certain truck models, to allow control of standard features. Such trucks do not require that service parameters 16 to 19 be activated. (Parameters 16 to 19 shall be set to “0”.) c) Trucks already fitted with an SEU as standard can also have additional modifications using “configurable options”. These additional modifications are controlled by the setting of service parameters 16 to 19.

Refer to section Configurable “Option” Parameters on page 42 for more detailed information.

13- 16

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Functional description Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

A2 Electronic card TLS Extra / Customised function(s)

CAN bus

A36 SEU

X41 CAN service connector

A1 Traction controller Fig. 2 Connection architecture for SEU Fig. 2 shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus. The SEU has one 42-pin multipin connector which handles all inputs, outputs, CAN and supply signals.

© BT Europe AB

Service Manual

SWE120L, SWE160D

13- 17

Electrical systems – 5000 Functional description T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Table 3: SEU 42-p connector Pin

Connection

Pin

Connection

Pin

Connection

14

AGND

28

AGND

42

CAN_L

13

+5V EXT

27

CAN_H

41

AGND

12

ANALOG IN 4 (5V)

26

ANALOG IN 5 (30V)

40

ANALOG IN 6 (30V)

11

ANALOG IN 1 (5V)

25

ANALOG IN 2 (30V)

39

ANALOG IN 3 (30V)

10

RS-232 +12V

24

RS-232 TxD

38

9

RS-232 GND

23

RS-232 RxD

37

8

22

36

7

DIGITAL IN 7 (H)a

21

DIGITAL IN 8 (H)

35

6

DIGITAL IN 4 (L)b

20

DIGITAL IN 5 (H)

34

DIGITAL IN 6 (H)

5

DIGITAL IN 1 (L)

19

DIGITAL IN 2 (L)

33

DIGITAL IN 3 (L)

18

BOX ADDRESS 1

32

BOX ADDRESS 2

4 3

DIGITAL OUT 4 (PWM OUT 2)

17

GND

31

GND

2

DIGITAL OUT 3 (PWM OUT 1)

16

DIGITAL OUT 1

30

DIGITAL OUT 2

1

B+ (+24V)

15

GND

29

GND (0V)

a.H = high-current (7 mA) b.L = low-current (1 mA)

13- 18

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Functional description Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

13.4.14 TLS - Truck log system (optional) General The truck log system, which is CAN based, is either an integrated system (SD16) or a freestanding supplementary system (S16). A collision sensor can also be connected.

The TLS communicates wirelessly with a base station (RG3) once the truck is within range. The base station then receives information on what the truck has done since they last communicated with one another.

PC

Built-in system

A2 Electronic card

RG3

TLS SD16 CAN bus

CAN bus

Add-on system

Shock sensor

A1 Traction controller

TLS S16

Shock sensor

I/O-unit

Registration To register the truck with the base station, follow the instructions below: • Position the truck close to the base station.

• Press and hold the green button for approx. 5-10 seconds until three LEDs on the base station start flashing at the same time.

The base station can now communicate with the truck whenever it is within range.

Logging in/out SD16 Logging in and out is performed as usual via the keyboard on the handle (or by using an ID unit). The difference is that communication passes through the TLS, which makes all the decisions.

Logging in/out S16 Logging in and out is performed using the keyboard on the TLS. © BT Europe AB

Service Manual

SWE120L, SWE160D

13- 19

Electrical systems – 5000 Functional description T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Collision sensor If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into something. If the impact exceeds a certain level, it is classified as a collision and the truck comes to a halt. It can be reset by entering the PIN code for “resetting the collision sensor” (see table below).

Settings Additional equipment (software and wiring) from Davis Derby is required to change the TLS settings.

Table 4: Settings TLS Function

Description

Default setting

PIN code

PIN code for different driver profiles.

00001 (profile 1) 00002 (profile 2) 00003 (profile 3) 11111 (resetting the collision sensor)

Logoff time

Time in minutes (1-254) that the truck is inactive before it is switched off.

255 (not switched off)

Impact level

Determines how sensitive the truck is to an impact.

5 % (sideways) 5 % (forwards/backwards)

Department

Only applies when ID unit is installed.

14

Type of truck

Only applies when ID unit is installed.

16

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13.4.15 ID unit (optional) General The ID unit is used to start the truck. A smart card or an ID key (see image below) is used instead of a PIN code. It is standard for 2 ID keys to be enclosed with the unit. These have standard settings for use with all types of truck and departments.

Login is performed by pressing the green button and then holding the smart card/ID key close to the ID unit. If the information on the card is confirmed, the truck starts with the correct driver profile and the green LED lights up. If the information on the card is not confirmed, a red LED lights up for 0.7-0.8 seconds. If no information is detected within 5 seconds, the procedure must be repeated.

Logging off is performed by pressing the red button. The red LED then lights up for 0.7-0.8 seconds.

A2 Electronic card

Installation NOTE: During commissioning of the truck (or the ID unit), the ID unit should be programmed with a specific department and truck type. To avoid unauthorised use, rider-controlled trucks and ‘walkie’ trucks, at the very least, must be programmed as different types of truck.

• Connect the service key.

• Set the ID unit to parameter 39. See “13.5.7 Service parameters” on page 31. (If values 9-12 are not available, the software must be upgraded with the aid of TruckCom.) • Remove the service key.

• Disconnect the battery contact.

• Replace the keypad with the ID unit. Take care during connection and disconnection.

• Connect the battery contact.

• Start the truck by pressing the green button and then, within 5 seconds, holding a smart card or ID key close to the scanner on the ID unit. (If the service key is connected, you need only press the green

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Electrical systems – 5000 Functional description T-code 702

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Order number 229101-040

button.) The green LED lights up if login was approved, and the red LED lights up if an invalid smart card/ID key has been used. (Smart cards/ID keys are preprogrammed with a standardised start code.)

• Switch off the truck by pressing the red button. The red LED lights up.

Settings Up to 16 types of truck and 14 departments can be used with the system. A smart card/ID key can be programmed for several departments and types of truck, depending on what the driver is authorised to use.

A smart card/ID key can also be used to program the ID unit if the type of card is changed (see table below). The truck then detects the department and type of truck selected on the smart card/ID key. When the ID unit is programmed, a red LED lights up for 0.7-0.8 seconds.

Table 5: Settings ID unit Truck

Description

Default

Department

Up to 14 departments in any combination (1-14)

All

Type of truck

Up to 16 types of truck in any combination (1-16)

All

Smart card/ID key

Description

Default

Department

Up to 14 departments in any combination (1-14)

14

Type of truck

Up to 16 types of truck in any combination (1-16)

16

Type of card

Driver card (1) or programming card (3)

1

Driver profile

Profile for different driver parameters (0-9)

0

Driver ID

-

-

A programming unit from Davis Derby (see image below) is required in order to be able to program a smart card/ID key. The unit is connected to a normal PC.

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• Connect the programming unit to the PC’s Com port using the accompanying cable.

• Turn on the PC and open the programming software.

• Connect the programming unit to the mains power.

See separate manual (232629) for more information on programming.

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Electrical systems – 5000 Parameters T-code 702

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13.5 Parameters 13.5.1 General The truck’s control system stores a number of parameters. These parameters are used to configure the truck for correct operation in the particular application for which it was designed. The parameters are divided into two groups, Driver parameters and Service parameters.

• Driver parameters (1 to 9) - These parameters are used to tailor the driving characteristics of a truck for a specific driver or operation. Up to 10 sets of driver parameters can be stored. Driver parameters can be adjusted directly without the requirement for a suitable CAN service key.1 • Service parameters (10 to 39) - These parameters are used to tailor the truck’s performance / operation characteristics and include all other parameters not designated as driver parameters. Service parameters can ONLY be adjusted when a suitable CAN service key is plugged into the truck.2

13.5.2 Viewing parameters - without the CAN service key Proceed as follows to display parameters when a CAN service key is not connected: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN code and then press

on the keypad.

• Hold S18 depressed until “P” is displayed (Fig. 3), then release S18.

Fig. 3

Parameters symbol lights.

The different parameters are now displayed by repeatedly operating speed control L1. Operator parameters can be both viewed and changed.1

1.Driver parameters can only be set without a CAN key if parameter #39 is set to value 1,3,5,7,9 & 11. See “ Login method and driver parameter access” on page 39.

2.Service parameters can be viewed without a CAN key being plugged in but they cannot be adjusted.

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Electrical systems – 5000 Parameters Order number 229101-040

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13.5.3 Adjusting operator parameters without the CAN service key NOTE! Operator parameters can only be set without a CAN key if parameter #39 is set to value 1, 3, 5, 7, 9 or 11. See Login method and driver parameter access on page 39.

To change the value of a particular operator parameter carry out the following: • Switch on the truck and log in with the appropriate PIN-code. This is important if the truck has more than one set of Operator parameters active. Any changes made will only be in effect when that particular “operator” is logged in.

• Select the required parameter.

• Press Horn button S18.

Parameter symbol flashes.

• Set parameter value by repeatedly operating speed control L1 up or down.

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

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing

on the keypad.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

For detailed descriptions and effects of these parameters, see the section Parameter description on page 29.

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Electrical systems – 5000 Parameters T-code 702

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13.5.4 Viewing & changing parameters - CAN service key connected • Ensure the battery is connected.

• Connect a suitable CAN-service key to X41.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second and then press on the keypad.

• Hold S18 depressed until “P” is displayed (Fig. 4), then release S18.

Fig. 4 Parameters symbol lights.

When pressing the speed control L1 forwards repeatedly, the first operator profile will be displayed. Continue to press L1 in the forward direction and the next operator profile will be displayed (operator no. 2), etc. until the last operator (operator no. 10). See Fig. 5.

Operator parameter no.

Profile no.

Fig. 5

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Once the 10 operator profile have been displayed, the truck service parameters will be displayed as L1 is repeatedly pressed in the forward direction.

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Electrical systems – 5000 Parameters Order number 229101-040

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T-code 702

Changing a parameter • Select the required parameter.

• Press Horn button S18.

Parameter symbol flashes.

• Set the parameter value by repeatedly operating speed control L1 up or down.

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

Parameters symbol lights (stops flashing).

• Switch off the truck by pressing

on the keypad.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

The truck’s service parameters can be displayed first by operating speed control L1 in the backward direction. This will cause parameter #40 to be displayed and then parameter #39 etc.1 For detailed descriptions and effects of these parameters see the section Service parameters on page 31.

NOTE! Truck handling.

Modifying specific truck parameters will change the driving characteristics of the truck.

Do not change any parameters without the necessary know how.

1.Certain parameters numbers displayed are not active in this truck model. © BT Europe AB

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13.5.5 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

1min

13.5.6 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.

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T-code 702

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.

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13.5.7 Service parameters 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 “ Parameter 15 - Non-configurable options” on page 32.

16

Configurable option #1

17

Configurable option #2

18

Configurable option #3

These parameters provide correct operation of trucks which have been modified with an approved special request modification. If no such modifications are present on the truck, these parameters shall all be set to “0” See “13.5.9 Configurable “Option” Parameters” on page 42.

19

Configurable option #4

20

Hour meter option

1

5

1

2

Select hour meter.

21

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

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Unit

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13.5.8 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 39 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 options Up to 10 so called sub-parameters are stored and accessed via parameter #15. These options are either switched ON or switched OFF and require no other adjustments. They are therefore called non-configurable options. The number of available options is dependant on the truck type. Consult table Parameter #15 Non-configurable options on page 33 for available options.

Setting Non-configurable options • Ensure the truck is in the parameter mode.

The parameters symbol lights.

• Select parameter #15 using [L1].

The first sub-parameter will be displayed.

Continued operation of the speed control L1 will display the next subparameter. Note also that only relevant sub-parameters will be displayed.

After 1 second the value of the sub-parameter will be displayed. © BT Europe AB

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• Press horn button S18.

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control L1 up or down. See Table 6: for details.

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

The parameters symbol lights (stops flashing).

• Switch off the truck by pressing

on the keypad.

The non-configurable option will now be activated.

• Ensure the option operates correctly before returning the truck for normal use.

P

Sub-parameter No.

Option name

Function ON

Function OFF

Default setting

Table 6: Parameter #15 Non-configurable options Value

NOTE!

0

Click-2-creep

1

0

0

1

Turtle

1

0

0

Parameter 16 - Configurable option #1 See “13.5.9 Configurable “Option” Parameters” on page 42,

Parameter 17 - Configurable option #2 See “13.5.9 Configurable “Option” Parameters” on page 42,

Parameter 18 - Configurable option #3 See “13.5.9 Configurable “Option” Parameters” on page 42,

Parameter 19 - Configurable option #4 See “13.5.9 Configurable “Option” Parameters” on page 42,

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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.

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Recommendation on parameter setting for freely ventilated batteries Parameter 21

Battery size SWE120L, SWE160D 1 2

Less discharge

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.

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

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

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

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

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Electrical systems – 5000 Parameters T-code 702

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Recommendation on parameter setting for valvecontrolled 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 13 14 Greater discharge

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.

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

• 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.

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Electrical systems – 5000 Parameters T-code 702

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Parameter 39 Login method and driver parameter access This parameter determines which function will used for log-in and whether or not the operator is allowed to adjust the operator parameter settings.

• Value 1 - Key switch installed - Operator parameters accessible without CAN service key.

• Value 2 - Key switch installed - Operator parameters NOT accessible without CAN service key.

• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters accessible without CAN service key.

• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters NOT accessible without CAN service key.

• Value 5 - Extended keypad (100 PIN codes) - Operator parameters accessible without CAN service key.

• Value 6 - Extended keypad (100 PIN codes) - Operator parameters NOT accessible without CAN service key.

• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator parameters accessible without CAN service key.

• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator parameters NOT accessible without CAN service key.

• Value 9 – ID unit – Driver parameters accessible without CAN service key.

• Value 10 – ID unit – Driver parameters NOT accessible without CAN service key.

• Value 11 – ID unit + TLS – Driver parameters accessible without CAN service key.

• Value 12 – ID unit + 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 13- 38

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blocks means that all PIN codes for the block are accessible (See Table 8:). 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 8: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles.

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 7:

Table 7: Programming command - expanded keypad Progamming

Function

Notes

Reset to factory settings

Block 1 - 9 is deactivated. Original PIN codes reset as per Table 8: 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 8: 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. © BT Europe AB

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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.

Table 8: Standard PIN code assignment with the expanded keypad Driver profile

0

1

2

3

4

5

6

7

8

9

Block 0

0000

0001

0002

0003

0000

0000

0000

0000

0000

0000

Block 1

5421

7901

1437

3731

1049

9439

7265

1322

2869

1574

Block 2

1787

4854

2907

9175

5799

1490

3031

7392

5622

5023

Block 3

4659

3174

1026

3815

6703

1179

5152

7514

5668

3215

Block 4

9197

7110

5477

3846

9491

5918

8222

6923

8139

7025

Block 5

2549

6276

9879

9658

1690

4042

5201

9807

4332

9715

Block 6

7474

4142

8620

3754

8432

8788

7430

1948

2595

8527

Block 7

1930

1482

7135

2395

7365

7092

4611

2831

4185

6067

Block 8

2876

4731

1022

5377

3257

7334

9009

7881

8843

7436

Block 9

3242

3162

5878

2828

1910

6907

2136

5730

2957

7691

no.

_

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13.5.9 Configurable “Option” Parameters WARNING! The information in this section is not intended as a programming reference and is included solely to allow the reader to gain a thorough understanding of parameter setting / checking.

Do not attempt to make any adjustments to these parameters unless you have sufficient knowledge of the truck’s options / modified functions. This manual only covers the truck’s standard equipment. Specially modified trucks may require that you have access to special service information. Improper adjustment of the option service parameters may compromise safe operation and / or result in a malfunction.

General Parameters #16 to #19 are reserved in the truck’s control system for extra truck options and/or special product modifications. The parameters configure and control the behaviour of the Spider expansion unit (SEU) which must be fitted in the truck. See “13.4.13 Spider expansion unit (SEU) (option)” on page 17. This method of implementation allows the standard software program to be used without the need for a specialised software. Normally, these parameters are configured by the manufacturer when the truck is modified or customized. It is advisable to up-load the parameter settings from trucks which are modified. In the event the main control card [A2] is changed, the original parameter settings can then be transferred to the new card thus ensuring the special option functions correctly.

Summary of base options Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a maximum of 4 preprogrammed “base options” to be activated and configured to suit a specific special option or customization. See table below.

Table 9: Summary of base options Base Function option

Refer to...

1

Pressing an option button controls a digital o/p.

table 10 on page 45

2

Activating a digital input will reduce maximum drive speed.

table 11 on page 46

3

Specific truck movement(s) activates a digital o/p.

table 12 on page 47

4

Activating a digital input causes main contactor to close.

table 13 on page 50

5

Activating digital inputs will operate lift /lower.

table 14 on page 51

6

Lift height can be restricted by activating a digital input + ability to override by pressing an option button.

table 15 on page 53

11

Automatic control of fork lifting/lowering.

table 16 on page 54

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Convention for configurable options • Each parameter can be designated to hold a particular base option.

• Each designated option has up to 4 arguments associated with it.

• Each argument holds a value which configures that option.

16 - 0 - 1

Parameter no. (range 16-19) Argument: #0 holds option designator (displayed for 2 s only) Argument value (range 0 - 63) 0= no base option is activated for this parameter 1 to 6 = Base option no. See separate tables)

OPTION ASSIGNATION

16 - 1- 1

Argument: #1, #2, #3 & #4 hold configurable values for the option Argument value (range depends on argument) Value depends on option and argument selected See separate table OPTION CONFIGURATION

Fig. 6 Configurable option layout

Setting Configurable options To activate a configurable option the base option must first be assigned to one of the parameters #16 to #19. This is achieved by setting argument #0 to the base option number. Once it is assigned, the option’s arguments must be configured. This is achieved by setting a value for arguments #1, #2, #3 and #4.

• Ensure the truck is in parameter mode.

Parameters symbol lights.

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

Argument #0 will be displayed

After 1 second the argument’s value will be displayed. A value of “0” indicates no option is assigned to this parameter, in which case continued operation of the speed control L1 will display the next parameter.

• Press Horn button S18.

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Electrical systems – 5000 Parameters Order number 229101-040

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Parameter symbol flashes.

• Set argument #0 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 9:.

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

Parameters symbol lights (stops flashing).

• Select argument #1 by operating speed control L1.

After 1 second the value of argument #1 will be displayed.

• Press Horn button S18.

Parameter symbol flashes.

• Set argument #1 value by repeatedly operating speed control L1 up or down. Refer to base option list Table 9:.

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

Parameters symbol lights (stops flashing).

Adjust arguments #2, #3 and #4 using the same method as above.

• Switch off the truck by pressing

on the keypad.

The special option shall now be activated.

• Ensure the special option operates correctly before returning the truck for normal use.

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Electrical systems – 5000 Parameters T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Detailed option parameter tables

Table 10: Base option 1 - Option button controls SEU output Argument #0

Option designator Values

Meaning

Initial display (value shown after 2 s delay)

1

Sets relevant parameter to handle base option 1

Argument #1

Selection of SEU unit 1 or 2

Initial display (value shown after 2 s delay)

Argument #2

Initial display (value shown after 2 s delay)

Argument #3

Initial display (value shown after 2 s delay)

Argument #4

Initial display (value shown after 2 s delay)

13- 44

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

Selection of SEU digital output Values

Meaning

Pin no.

0

activate SEU digital o/p 1 (1,6A)

16

1

activate SEU digital o/p 2 (1,6A)

30

2

activate SEU digital o/p 3 (1,6A)

3

3

activate SEU digital o/p 4 (1,6A)

4

Selection of option button Values

Meaning

1

activated by option button 1

2

activated by option button 2

3

activated by option button 3

4

activated by option button 4

5

activated by option button 5

6

activated by option button 6

Type of switching Values

Meaning

0

activated when button is depressed

1

option is toggled when button is pressed

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Electrical systems – 5000 Parameters Order number 229101-040

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T-code 702

Table 11: Base option 2 - Reduced drive speed by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

2

Sets relevant option parameter to handle base option 2

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

activate SEU digital i/p 1 (1mA)

5

1

activate SEU digital i/p 2 (1mA)

19

2

activate SEU digital i/p 3 (1mA)

33

3

activate SEU digital i/p 4 (1mA)

6

4

activate SEU digital i/p 5 (7mA)

20

5

activate SEU digital i/p 6 (7mA)

34

6

activate SEU digital i/p 7 (7mA)

7

7

activate SEU digital i/p 8 (7mA)

21

(value shown after 2 s delay)

Argument #3

Speed limitation as a percentage of max. speed

Initial display

Values

Meaning

0-12

Max. speed adjustable from 40-100% formula: =40+5*Arg.3 e.g. 40+5*4=60%

(value shown after 2 s delay)

Argument #4

Speed range

Initial display

Values

Meaning

0

Affects only high speed range

1

Affects only low speed range

2

Affects both speed ranges

(value shown after 2 s delay)

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Electrical systems – 5000 Parameters T-code 702

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Date 2006-03-13

Order number 229101-040

Table 12: Base option 3 - Truck movement activates SEU o/p Argument #0

Option designator

Initial display (value displayed after 2 s)

Values

Meaning

3

Sets relevant option parameter to handle base option 3

Argument #1

Selection of SEU unit 1 or 2

Initial display (value displayed after 2 s)

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

Argument #2

Selection of SEU digital output

Initial display (value displayed after 2 s)

Values

Meaning

Pin no.

0

activate SEU digital o/p 1 (1.6 A)

16

1

activate SEU digital o/p 2 (1.6 A)

30

2

activate SEU digital o/p 3 (1.6 A)

2

3

activate SEU digital o/p 4 (1.6 A)

3

...table continued on next page

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Table 12: Base option 3 - Truck movement activates SEU o/p ...continued from previous page

Argument #3

Selection of activating movement

Initial display (value displayed

Values

after 2 s)

1

Drive forward

X

X

X X

X X

X

X

X

8 9

X X

10 11

X

X X

X

X

X

12 13

X

X

X

X

X

X

X

X

X

X

X

14 15

X

16 17

X X

18 19

X

X X

X

X

X

20 21

X

X

X

X

X

X

X

X

X

X

X

22 23

X

24 25

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

26 27

X

28 29

X

30 31

Any other movement

X

6 7

Lower forks

X

4 5

Lift forks

X

2 3

Drive backward

X

...table continued on next page

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Date 2006-03-13

Order number 229101-040

Table 12: Base option 3 - Truck movement activates SEU o/p ...continued from previous page

Argument #4

Output switching mode

Initial display (value displayed after 2 s)

Values

Meaning

0

Output continuously on

1

Output switches at 1 Hz

2

Output switches at 2 Hz

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Table 13: Base option 4 - Activate main contactor by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

4

Sets relevant option parameter to handle base option 4

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input

Initial display

Values

Meaning

Pin no.

0

activated by SEU digital i/p 1 (1 mA)

5

1

activated by SEU digital i/p 2 (1 mA)

19

2

activated by SEU digital i/p 3 (1 mA)

33

3

activated by SEU digital i/p 4 (1 mA)

6

4

activated by SEU digital i/p 5 (7 mA)

20

5

activated by SEU digital i/p 6 (7 mA)

34

6

activated by SEU digital i/p 7 (7 mA)

7

7

activated by SEU digital i/p 8 (7 mA)

21

(value shown after 2 s delay)

Argument #3

Hold time in minutes

Initial display

Values

Meaning

0-30

Contactor is held on from 0 to 30 minutes after digital i/p is activated

(value shown after 2 s delay)

Argument #4

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Not used

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Electrical systems – 5000 Parameters T-code 702

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Order number 229101-040

Table 14: Base option 5 - Activate lift/lower by SEU i/p Argument #0

Option designator

Initial display

Values

Meaning

5

Sets relevant option parameter to handle base option 5

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1 (A36)

1

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2 s delay)

Argument #2

Selection of SEU digital inputs

Initial display

Values

Meaning

Pin no.

0

Lift - SEU digital i/p 1 Lower - SEU digital i/p 2 Lower inhibit - SEU digital i/p 3

5 19 33

1

Lift - SEU digital i/p 2 Lower - SEU digital i/p 3 Lower inhibit - SEU digital i/p 4

19 33 6

2

Lift - SEU digital i/p 3 Lower - SEU digital i/p 4 Lower inhibit - SEU digital i/p 5

33 6 20

3

Lift - SEU digital i/p 4 Lower - SEU digital i/p 5 Lower inhibit - SEU digital i/p 6

6 20 34

4

Lift - SEU digital i/p 5 Lower - SEU digital i/p 6 Lower inhibit - SEU digital i/p 7

20 34 7

5

Lift - SEU digital i/p 6 Lower - SEU digital i/p 7 Lower inhibit - SEU digital i/p 8

34 7 21

(value shown after 2 s delay)

...table continued on next page

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Table 14: Base option 5 - Activate lift/lower by SEU i/p ...continued from previous page

Argument #3

Enable / Disable lower inhibit

Initial display

Values

Meaning

0

Lower inhibit disabled

1

Lower inhibit enabled

(value shown after 2 s delay)

Argument #4

Selection of fork / support arm

Initial display

Values

Meaning

0

Selects fork lift / Lower

1

Selects support arm lift / lower

(value shown after 2 s delay)

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Table 15: Base option 6 - Lift height restriction by SEU i/p & override Argument #0

Option designator

Initial display

Values

Meaning

6

Sets relevant option parameter to handle base option 6

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2 s delay)

Argument #2

Selection of SEU digital input for restriction switch

Initial display

Values

Meaning

Pin no.

0

activate SEU digital i/p 1 (1 mA)

5

1

activate SEU digital i/p 2 (1 mA)

19

2

activate SEU digital i/p 3 (1 mA)

33

3

activate SEU digital i/p 4 (1 mA)

6

4

activate SEU digital i/p 5 (7 mA)

20

5

activate SEU digital i/p 6 (7 mA)

34

6

activate SEU digital i/p 7 (7 mA)

7

7

activate SEU digital i/p 8 (7 mA)

21

(value shown after 2 s delay)

Argument #3

Selection of option button to override

Initial display

Values

Meaning

1

activated by option button 1

2

activated by option button 2

3

activated by option button 3

4

activated by option button 4

5

activated by option button 5

6

activated by option button 6

(value shown after 2 s delay)

Argument #4

13- 52

Not used

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Table 16: Base option 11 - Automatic lift/lower function Argument #0

Option designator

Initial display

Values

Meaning

11

Sets relevant option parameter to handle base option 11

(value shown after 2 s delay)

Argument #1

Selection of SEU unit 1 or 2

Initial display

Values

Meaning

0

option is handled by SEU unit 1(A36)

1

option is handled by SEU unit 2 (second SEU unit)

(value shown after 2 s delay)

Argument #2

Selection of option buttons

Initial display

Values

Meaning

0

No option buttons used

1

Option button 1 & 2 used (left side of handle)

2

Option button 2 & 3 used (left side of handle)

3

Option button 3 & 4 used (one on each side of handle)

4

Option button 4 & 5 used (right side of handle)

5

Option button 5 & 6 used (right side of handle)

6

Option button 1, 6, 2 & 5 used (Duplicate switches on both sides of handle)

7

Option button 2, 5, 3 & 4 used (Duplicate switches on both sides of handle)

(value shown after 2 s delay)

...table continued on next page

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Table 16: Base option 11 - Automatic lift/lower function ...continued from previous page

Argument #3

Selection of input & output signals

Initial display

Values

Meaning

Pin no.

0

Photocell -SEU digital i/p 1 (1 mA) Lower limit -SEU digital i/p 2 (1 mA) upper limit -SEU digital i/p 3 (1 mA) External lift button -SEU digital i/p 4 (1 mA) External lower button -SEU digital i/p 5 (7 mA) Auto lamp o/p - SEU digital o/p 1 (1,6 A)

5 19 33 6 20 16

1

Photocell -SEU digital i/p 2 (1 mA) Lower limit -SEU digital i/p 3 (1 mA) upper limit -SEU digital i/p 4 (1 mA) External lift button -SEU digital i/p 5 (1 mA) External lower button -SEU digital i/p 6 (7 mA) Auto lamp o/p - SEU digital o/p 2 (1,6 A)

19 33 6 20 34 30

2

Photocell -SEU digital i/p 3 (1 mA) Lower limit -SEU digital i/p 4 (1 mA) upper limit -SEU digital i/p 5 (1 mA) External lift button -SEU digital i/p 6 (1 mA) External lower button -SEU digital i/p 7 (7 mA) Auto lamp o/p - SEU digital o/p 3 (1,6 A)

33 6 20 34 7 2

3

Photocell -SEU digital i/p 4 (1 mA) Lower limit -SEU digital i/p 5 (1 mA) upper limit -SEU digital i/p 6 (1 mA) External lift button -SEU digital i/p 7 (1 mA) External lower button -SEU digital i/p 8 (7 mA) Auto lamp o/p - SEU digital o/p 4 (1,6 A)

6 20 34 7 21 3

(value shown after 2 s delay)

Argument #4

Activation of external lift & lower buttons

Initial display

Values

Meaning

0

Disabled

1

Enabled

(value shown after 2 s delay)

13.6 Diagnostic and troubleshooting means constantly on

means flashing

13.6.1 General Fig. 7 13- 54

The trucks’s electronic control system incorporates built-in fault code display and logging. This capability works as a powerful complement in Service Manual

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assessing the cause of eventual truck malfunctions. When a fault code occurs the code number is displayed and the fault condition LED flashes (Fig. 7).

The codes can be broadly divided into two groups: • Caution codes - denoted by prefix “C”. These codes alert the operator to the presence of a caution condition. Caution codes in the range C50 to C99 will limit the truck’s maximum speed to creepspeed. The conditions which cause such codes can usually be easily remedied without further attention. Caution codes C19 to C43 are not stored in the code history log.

• Error codes - denoted by prefix “E”. These codes alert the operator to the presence of a fault condition in the truck. Error codes E100 and higher will stop all truck driving functions until the error code is cleared.

The first time any fault code is displayed it is advisable to check if the condition persists by switching the truck off completely. i.e. disconnect the battery and then switch back on. Check to see if the fault code is again displayed.

13.6.2 Error code history Up to 50 of the most recently occurred fault codes will be stored in a log along with the hour meter reading when the fault occurred. When the fault code log is displayed, it shows the fault codes in chronological order with the newest code first.

Carry out the following to display the fault code log: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid PIN-code and then press

on the keypad.

• Hold S18 depressed until “E” is displayed (Fig. 8), then release S18.

Fig. 8

Fault symbol lights.

The most recently occurred error will be displayed. The display will alternate between the fault code and the hour meter reading when the fault occurred. If the fault code log contains more than one fault code, these can be displayed by repeatedly operating the speed control L1.

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

• Press and hold S18 until E = error codes is displayed. © BT Europe AB

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• 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: - - - - .

13- 56

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

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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.

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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.

13- 58

Code

C29

Description

Service warning

Possible error cause

Time for service.

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

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.

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Code

C41

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.

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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.

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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.

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)

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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

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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.

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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.

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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 Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

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

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SWE120L, SWE160D

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13- 65

Electrical systems – 5000 Diagnostic and troubleshooting T-code 702

13- 66

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

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 Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229101-040

© BT Europe AB

Date 2006-03-13

Valid from serial number 922602-

T-code 702

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.

Service Manual

SWE120L, SWE160D

13- 67

Electrical systems – 5000 Diagnostic and troubleshooting T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.6.4 Transistor regulator errors All errors generated by or within the transistor regulator [A1] are communicated to the main control card [A2]. The fault conditions are then displayed as error or caution codes according to the Error codes on page 57. However, there is a status LED on the transistor regulator which displays the current status of the regulator.

The table below depicts the error codes that may be shown by the STATUS LED or read using the hand-held terminal.

STATUS MODEL

VOLTAGE

SERIAL

CURRENT

Table 17: Transistor regulator error code STATUS LED

Curtis 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 current.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding.

Shunt field 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. > 85 oC or < -25 oC. 2. Truck overloaded.

3. Wrong installation of transistor regulator.

4. Operation under extreme conditions.

13- 68

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

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.

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 Manual

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13- 69

Electrical systems – 5000 Diagnostic and troubleshooting T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.6.5 Built-in Test Function The truck’s control system provides a number of useful built-in test functions • Connect CAN-key in X41 and press

[A17].

• Battery status is shown.

• Press Horn S18 repeatedly to choose Built-in Test mode.

NOTE! All truck functions operate as normal in this mode. Care should be taken when operating the truck and reading the display at the same time!

Table 18: Built-in test modes Mode

Flashing symbol

Displayed data

1

Speed reference value sent to Curtis.

2

Digital inputs/outputs can be tested. See “ Digital inputs/outputs test mode” on page 72.

3

Battery voltage (V).

4

Armature current (A).

5

Field current (A).

6

PWM Armature in %.

7

Status Curtis.

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© BT Europe AB

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

Digital inputs/outputs test mode In the digital inputs/outputs mode, the operation of both inputs and outputs can be checked by checking the individual segments of the main display as given in the following tables.

Inputs check

Table 19: Inputs check Element

© BT Europe AB

Segment

Function

[S31]

Segment on when support arms not at top.

[S10]

Segment on when tiller arm is in drive position.

[A2:S19]

Segment on when forks lift button is depressed.

[A2:S20]

Segment on when forks lower button is depressed.

[A2:S21]

Segment on when support arms lift button is depressed.

[A2:S22]

Segment on when support arm lower button is depressed.

[S18]

Segment on when signal horn button(s) pressed.

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13- 71

Electrical systems – 5000 Diagnostic and troubleshooting T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Outputs check

Table 20: Outputs check Element

13- 72

Segment

Function

[Y1]

Segment on when Brake solenoid output activated.

Complement [Y1]

Segment on when Brake solenoid NOT activated.

[K10]

Segment on main contactor output is activated.

[K30]

Segment on when pump contactor output is activated.

[Y34]

Segment on when fork cylinder selection valve output is activated.

[Y52]

Segment on when support arm selection valve output is activated.

[Y41]

Segment on when lower valve output is activated.

Service Manual

SWE120L, SWE160D

© BT Europe AB

Electrical systems – 5000 Diagnostic and troubleshooting Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

Option buttons check

Table 21: Option buttons check Element

Segment

Function

[S116]

Segment on when option button 6 is pressed.

[S115]

Segment on when option button 5 is pressed.

[S114]

Segment on when option button 4 is pressed.

[S111]

Segment on when option button 3 is pressed.

[S112]

Segment on when option button 2 is pressed.

[S113]

Segment on when option button 1 is pressed.

Display test mode The digital display [A6] itself can be tested to verify all the segments of the display function correctly.

To select Display test mode carry out the following procedure: • Ensure the battery is connected.

• Ensure the truck is switched off. Press

on the keypad.

• Press and hold horn button S18 for at least 1 second, enter a valid Fig. 9

PIN-code and then press

on the keypad.

• Hold S18 depressed until “d” is displayed (Fig. 9), then release S18.

All number segments on the display and symbol lamps should flash sequentially (Fig. 10).

Fig. 10

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13- 73

Electrical systems – 5000 Technical specifications – Curtis 1243 T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

13.7 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.

13- 74

Service Manual

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© BT Europe AB

Hydraulic system – 6000 General Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

14- Hydraulic system – 6000 14.1 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

14.2 Hydraulic diagram and components n

2

4

1

G K

J

3

B

H

C

A E D P

F

F

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Service Manual

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14- 1

Hydraulic system – 6000 Hydraulic diagram and components T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

14.2.1 Main components 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

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

14.2.2 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

14- 2

Service Manual

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© BT Europe AB

Hydraulic system – 6000 Hydraulic diagram and components Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

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.

© BT Europe AB

Service Manual

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14- 3

Hydraulic system – 6000 Hydraulic diagram and components T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

This page is intentionally left blank

14- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Lifting mast – 7000 Adjusting the measurement between the guide and the mast Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

15- Lifting mast – 7000 15.1 Adjusting the measurement between the guide and the mast The measurement between the guide and the mast (A) must be max.

13 mm. When replacing the mast, be sure to set the distance correctly and check whether adjustment of the measurement is required.

Use the screw (B) to adjust play between the guide and mast and thus correcting the distance (A). Following adjustment, be sure to grease the beam ribs with Gleitmo 805.

B A

B

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Service Manual

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15- 1

Lifting mast – 7000 Grease the beam flanges and beam ribs T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

15.2 Grease the beam flanges and beam ribs Grease the inside surfaces of the beam flanges with Q8 Rembrandt EP2 (see the lubrication chart).

Grease the inside surfaces of the beam ribs with Gleitmo 805 (see the lubrication chart).

15- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

Lifting mast – 7000 Main lift chain system – Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

15.3 Main lift chain system – 15.3.1 General Applies to all machines with a mast.

15.3.2 Checking the chain setting The lift chains must be adjusted at regular periods due to stretching, see below. The chain setting is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

15.3.3 Chain inspection The chains are exposed to two types of wear, outline wear and stretching. Wear to the bolts and disc holes is caused by stretching. The chains are also affected by the environment they are used in.

15.3.4 Noise If lubrication has been insufficient there will be metallic friction on the chain and this will result in noise.

The chain should be replaced.

15.3.5 Surface rust Surface rust is easy to recognize as the chain will be reddish brown.

Deep-seated rust has generally started and the chain has impaired strength.

The chain should be replaced

15.3.6 Rusty links Fretting corrosion results in a reddish brown powder being visible by the outer discs. It can also appear as if the chain is bleeding when lubricated.

The chain should be replaced.

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Service Manual

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15- 3

Lifting mast – 7000 Main lift chain system – T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

15.3.7 Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

The chain should be replaced.

15.3.8 Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain. .

The chain should be replaced

15.3.9 Loose bolts If a bolt is loose it will protrude from the side of the chain, which is due to a stiff link or bolt rotation.

The chain should be replaced

15- 4

Service Manual

SWE120L, SWE160D

© BT Europe AB

Lifting mast – 7000 Main lift chain system – Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

15.3.10 Outline wear P

H2

H3

P = Pitch H2 = Nominal disc height.

H3 = Minimum disc height.

A new lift chain has a specific nominal disc height, defined as H2 in the figure. As the truck is used the lift chain wears radically, on the side that runs over the chain sprocket. The minimum disc height is define as H3 in the figure and denotes the minimum permitted value of the disc height.

Maximal permitted outline wear is 5% of the height H2. If a lift chain reaches the maximum level of wear, the chain should be replaced.

The nominal and minimum disc heights for respective lift chains are stated in the table in the chapter “Stretching”.

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Service Manual

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15- 5

Lifting mast – 7000 Main lift chain system – T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

15.3.11 Stretching The amount of stretch on a lift chain is measured on the part of the chain that runs over the chain sprocket. The amount of stretch may, at the most, be 2% on the most worn section of the chain. Measurement is suitably made over 300-1000 mm of the chain.

The nominal and maximum permitted chain lengths for lift chains are stated in the table below.

Type of chain

Nominal disc height H2 ( mm)

Minimum disc height H3 (mm)

Pitch P (mm)

Nominal chain length for 20/30/ 50 discs (mm)

Maximum permitted chain length for 20/ 30/50 discs (mm)

3/4”, 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4”, 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1”, 4x4

23,6

22,4

25,4

508/762/1270

518/777/1295

1”, 6x6

23,6

22,4

25,4

508/762/1270

518/777/1295

Wear to the bolts and around the holes on the discs are a reason why the chain stretches. The chain should be replaced if stretching is more than 2%.

15.3.12 Damage

The chain should be replaced if damaged in any way.

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Service Manual

SWE120L, SWE160D

© BT Europe AB

Lifting mast – 7000 Main lift chain system – Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

15.3.13 Damaged discs If a disc has broken on the chain, this can be due to overloading or corrosion.

The chain should be replaced.

15.3.14 Damaged bolts It can be difficult to discover whether a bolt has broken. It can appear as bolt rotation and/or that the outer disc is loose.

The chain should be replaced.

15.3.15 Dirty chain If a chain is very dirty it is first and foremost recommended that it is replaced. It can also be dismantled and cleaned as set out in the chapter “Cleaning”.

15.3.16 Cleaning If a chain is very dirty it is recommended that it is replaced.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

The chain should be blown dry using compressed air and lubricated directly after cleaning NOTE! Exercise care with degreasing agent as these can contain abrasives.

15.3.17 Lubrication Mineral and synthetic oils can be used to relubricate Rexnord chains.

NOTE! Lubricant must not contain substances such as molybdenum disulphide, PTFE or the like.

A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated. © BT Europe AB

Service Manual

SWE120L, SWE160D

15- 7

Lifting mast – 7000 Main lift chain system – T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

• Lubrication intervals: - 500 hours with normal operations - 100 hours when driving in rugged environments such as cold stores and corrosive environments.

The chains are sprayed with lubricant. Note the entire chain must be lubricated, even the fastening bolts. It is especially important that the part of the chain which runs over the chain sprocket is well lubricated.

The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

Ambient temperature

Viscosity class

Recommended Products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

> + 5°C < + 45°C

VG 150

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette Klüberoil 4UH 1-220N, Klüber Lubrication

* Equivalent products from another manufacturer may be used.

NOTE! Do not use a special rust protective agent to prevent rust on the lift chains.

These agents impair the lubrication of the chains. Regular lubrication is the best method to prevent rust attack.

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SWE120L, SWE160D

© BT Europe AB

Battery charger (built-in) – 8340 General Order number 229101-040

A

B

Date 2006-03-13

Valid from serial number 922602-

T-code 702

16- Battery charger (built-in) – 8340 16.1 General The SMCI 300 is a 24 V battery charger with firmware designed to charge freely ventilated or valve-regulated plumbic acid batteries (Evolution type). Chargers on trucks with machine numbers 723984-936512 are designed for battery sizes ranging from approx. 100 Ah up to 320 Ah. Chargers on trucks with machine numbers from 936513- are designed for freely ventilated batteries with sizes ranging from approx.

100 Ah to 350 Ah and for valve-regulated batteries in sizes 134 Ah, 174 Ah and 201 Ah.

C

The charger relies on state-of-the-art switching technology and should be connected to an earthed 220-240 V single phase wall socket (B).

The built-in microcomputer controls the charging process according to the pre-programmed charging curve. During charging, the charging process is displayed using a status indicator on the charger panel (A).

The micro-controller also supervises charging with regard to the charging time and temperature. This enables interruption of charging, for example if a fault is detected in a battery cell or in case of insufficient cooling of the charger.

The battery size and battery type can be selected with the switch located on the ventilation panel (C). Set the switch using a flat screwdriver.

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Service Manual

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16- 1

Battery charger (built-in) – 8340 Technical data – charger T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

16.2 Technical data – charger Dimensions

250x115x67 mm

Weight

1.6 kg

Ambient temperature

-25° C to +40° C

Line voltage

90-255 V AC 45-400 Hz Note! The charging current is reduced in case of a line voltage below 200 V

Rated voltage

24 V DC

Rated current

30 A

Max. output power

800 W

Efficiency

> 86%

Battery types

Freely ventilated lead batteries with water filling, Valve-regulated (VR) lead batteries

Protection class

IP 20

Other

Temperature regulated cooling fan Protected against incorrect polarisation.

In order for chargers on trucks with machine numbers from 936513- to switch on, the battery voltage must be between 19.8 and 34.7 V

16.3 Charging WARNING!

A

B

Please note that when charging valve-regulated batteries (Evolution type), the SMCI300 has been designed to charge batteries that are used in normal room temperature, i.e. +15°C to +30°C. For other temperatures, the charger must be loaded with different firmware, available from the charger dealer.

Machine numbers 723984-936512 Connect the charger to the mains (B). A few seconds after charging starts, the orange status indicator on the parking device (A) lights up.

This indicator remains lit until the battery has been fully charged, at which time it changes colour to green.

The charging duration varies depending on the battery type and degree of discharge. Normally, the charger would be started after the work shift and the battery should then be fully charged the next morning. A deeply

C 16- 2

Service Manual

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© BT Europe AB

Battery charger (built-in) – 8340 Troubleshooting and service Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

discharged freely ventilated 320 Ah battery may need up to 14 hours of recharging, while a VR battery may require even longer time.

Once charging has been completed, after a certain time depending e.g. on the battery type, the SMCI 300 switches to trickle charging. The green indication remains lit to indicate the battery has been completely charged.

Following completed charging, return the power plug to the parking device (B).

Machine numbers 936513Connect the charger to the mains (B). Before charging starts, the battery type will be indicated for three seconds. Continuous green indication is used for valve-regulated batteries (Evolution type) and continuous orange indication for freely ventilated batteries.

After this, the charger setting is indicated through a number of blinks corresponding to the selected setting (see table on page 5) Charging begins once the charger setting has been indicated. Charging in progress is displayed by the orange status indicator lighting up next to the parking device. This indicator remains lit until the battery has been fully charged, at which time it changes colour to green.

The charging duration varies depending on the battery type and degree of discharge. Normally, the charger would be started after the work shift and the battery should then be fully charged the next morning. A deeply discharged freely ventilated 320 Ah battery may need up to 14 hours of recharging, while a VR battery may require even longer time. A 201 Ah Evolution battery, for example, may require up to 14 hours or recharging.

Once charging has been completed, after a certain time depending e.g. on the battery type, the SMCI300 switches to trickle charging. The green indication remains lit to indicate the battery has been completely charged.

Following completed charging, return the power plug to the parking device.

16.4 Troubleshooting and service First check whether the charger indicates an error. A red blinking indicator means that the charger has not detected any connected battery or that a battery has not been set with the selection switch. Check the switch position, cables, terminals and other battery connections. Measure the battery voltage.

If the charger still does not operate, contact the supplier for service.

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Service Manual

SWE120L, SWE160D

16- 3

Battery charger (built-in) – 8340 Setting the charger (applies to machine numbers 723984-936512) T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

16.5 Setting the charger (applies to machine numbers 723984-936512) Freely ventilated batteries Switch

Battery size

I2 current

Max. current, trickle charging

Output current 0

No charging (red LED lit)

-

-

-

1

100-119 Ah

22 A

5.5 A

0.6 A

2

120-144 Ah

26 A

6.6 A

0.7 A

3

145-174 Ah

30 A

8.0 A

0.8 A

4

175-209 Ah

30 A

9.6 A

1.0 A

5

210-249 Ah

30 A

11.5 A

1.2 A

6

250-299 Ah

30 A

13.7 A

1.4 A

7

300-350 Ah

30 A

16.2 A

1.6 A

Valve-regulated batteries

16- 4

Switch

Battery size

Output current

I2 current

Max. current, trickle charging

8

No charging

-

-

-

9

300-350 Ah

30 A

3.8 A

1.6 A

A

250-299 Ah

30 A

3.4 A

1.4 A

B

210-249 Ah

30 A

2.8 A

1.2 A

C

175-209 Ah

28 A

2.4 A

1.0 A

D

145-174 Ah

22 AA

1.9 A

0.8 A

E

120-144 Ah

18 A

1.5 A

0.6 A

F

100-119 Ah

15 A

1.3 A

0.6 A

Service Manual

SWE120L, SWE160D

© BT Europe AB

Battery charger (built-in) – 8340 Setting the charger (applies to machine numbers 723984-936512) Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

16.5.1 Current levels at different charger settings (applies to machine numbers 936513-) Freely ventilated batteries Switch position

Battery voltage

Battery type

Battery size

Indication

Max. charging current = I1

0

No charging

-

-

Continuous red

-

1

24 V

Freely ventilated

100-119Ah

1 blink, Orange

22 A

2

24 V

Freely ventilated

120-144 Ah

2 blinks, Orange

26 A

3

24 V

Freely ventilated

145-174 Ah

3 blinks, Orange

30 A

4

24 V

Freely ventilated

175-209 Ah

4 blinks, Orange

30 A

5

24 V

Freely ventilated

210-249 Ah

5 blinks, Orange

30 A

6

24 V

Freely ventilated

250-299 Ah

6 blinks, Orange

30 A

7

24 V

Freely ventilated

300-350 Ah

7 blinks, Orange

30 A

8

No charging

-

-

Continuous red

-

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Service Manual

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16- 5

Battery charger (built-in) – 8340 Setting the charger (applies to machine numbers 723984-936512) T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

Valve-regulated batteries (Evolution type)

16- 6

Switch position

Battery voltage

Battery type

Battery size

Indication

Max. charging current = I1

9

24 V

Valve-regulated

134 Ah

1 blink, green

23 A

A

24 V

Valve-regulated

174 Ah

2 blinks, green

30 A

B

24 V

Valve-regulated

201 Ah

3 blinks, green

30 A

C

No charging

-

-

Continuous red

-

D

No charging

-

-

Continuous red

-

E

No charging

-

-

Continuous red

-

F

No charging

-

-

Continuous red

-

Service Manual

SWE120L, SWE160D

© BT Europe AB

TruckCom General Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17- TruckCom User Manual for trucks using the “PowerDrive” platform. This Manual is valid for version 3.5 of TruckCom p/n 182145-008.

17.1 General TruckCom is a communication program which communicates with trucks equipped with CAN (Controller Area Network) communication.

It enables the following tasks to be performed: • downloading truck control software.

• viewing and adjusting operator / truck parameters and hour meters.

Additionally, the truck’s parameter set (including hour meter values) can be saved to file and reloaded later.

• viewing diagnostic data for various digital inputs / outputs and analogue data including voltages, currents and certain temperatures.

The program is a Windows program running under Windows® 95/98, Windows® XP/2000 and Windows® NT.

17.2 Connection A CAN interface of the CPC-PP type is needed to connect it to the truck, with attendant cable. Connect the interface via the printer port on a PC. Connect the cable between the interface and the truck's CAN terminal.

The CAN interface is supplied with power from the truck electronics and is protected from any high voltages in the truck if a fault should occur.

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Service Manual

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17- 1

TruckCom Layout T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.3 Layout 17.3.1 Main program screen Information window

Menu bar

Tool buttons

Nodes Icons

Tool button bar

Fig. 11 Main TruckCom program screen The Main window opens when the program is started. This shows the menu bar, tool buttons, workspace, log window and status window.

17.3.2 Nodes Devices which are connected to and communicate via the CAN interface are called nodes. The nodes detected on the bus are shown in the node window. The current node status and input component/information is shown with different icons.

Fig. 12 A typical node window display 17- 2

Service Manual

SWE120L, SWE160D

© BT Europe AB

TruckCom Layout Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.3.3 Icons Icon

Description Node OK is shown when contact is made with a node and no errors have been reported.

Node not connected is shown when there is no contact with a node in the network.

Node not OK is shown when an error has been reported by a node. Click on node to obtain more information.

Program version is shown when information is available on which software is installed. Click to obtain more information.

Information is shown when a node has information on, for example, error codes.

Truck report GB“17.7 Truck report function” on page 7 Parameters is shown when a node has information on a parameter.

Diagnostics

Exit

17.3.4 Tool buttons and menu bar The tool button bar allows direct access to the program’s most common functions. The menu bar allows access to all the program functions.

Explanations of each menu bar item are given in the relevant section.

Search for units

Disconnect Download from PC

Truck report

Parameters Diagnostics Information Fig. 13 Tool button bar

© BT Europe AB

Service Manual

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Exit

17- 3

TruckCom Connection function T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.3.5 Information window The right section of the main window contains a status window where different messages are shown.To see previous messages, use the scroll arrows in the right margin.

17.3.6 Status bar There is a status bar at the bottom of the main window, which shows variable status when the program is run.

1

2

3

HELPTEXT

REC

MACHINE

4

5

The following are shown from the left: Help text "pop-up" via the mouse cursor, connected/not connected to network, truck type connected, initiation result of CAN interface and the present time.

17.4 Connection function To connect the PC the network, select the Scan units function. This can be done with the menu <Nodes | Scan units> or with the tool button [Scan nodes].

This should also be done when the truck is supplied with voltage and in normal drive mode.The program will now run a check and installation of the CAN interface. A diagnosis will also be carried out to check which units are connected in the system. The result of this diagnosis is shown in the Node window.

17.5 Disconnection function Select the Disconnect function to disconnect from the network. This can be done with the menu <Nodes | Set PC off-Line> or with the tool button [Set PC off-Line].

The CAN interface is then reset and the CAN cable can be disconnected if so required. This enables connection to another truck without having to close the program.

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© BT Europe AB

TruckCom Downloading program function Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.6 Downloading program function To download a new program to one of the nodes, select the Download software function. This can be done with the menu <Tools | Download software... > or with the tool button [Download].

Type 123456

17.6.1 Normal downloading (truck with key) Select Open.. to open the file to be downloaded into a node. The file name, file type and version number are shown in the window for file information. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by selecting Start... and by restarting the truck by turning the key off and on twice.

Restart must be made within 20 seconds from when the Start button has been activated.

Close the download window when the download is ready, and then disconnect the PC from the network. A new connection can now be made to verify the new program.

17.6.2 Normal downloading (truck with keypad) Select Open to open the file to be downloaded into a node. The file name, file type and version number are shown in the file information dialogue box. If it is file for a controller, indicate which type of controller is to receive the file. Start downloading by depressing and then releasing the red key on the keypad.

The truck must be restarted within 20 seconds from when the Start key has been activated. © BT Europe AB

Service Manual

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17- 5

TruckCom Downloading program function T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

When downloading has been completed, close the download dialogue box and then disconnect the PC from the network. It is now possible to reconnect to verify the new application.

17.6.3 Emergency downloading (truck with keypad) • Disconnect the battery connector.

• Select OK in the dialogue box.

• Keep the red key on the keypad depressed while reconnecting the battery connector.

• Release the red key to commence downloading.

17.6.4 Emergency downloading (truck with keypad) E141 will be shown in the truck’s display when starting, if for any reason there is no program in the electronics card (interrupted downloading).

Communication with the truck via the PC will then be minimised. Use “E141” to download the program in the card.

On some trucks, a counter, which continuously counts up, is displayed.

NOTE! Once programmed, the logic cards in some trucks can only be upgraded with the same basic firmware. In other words, it is not possible to replace the basic firmware (other machine type).

17.6.5 Downloading in old versions of logic card To download to older versions of electronic cards which do not support restart with key, the button Old card... should be used instead of Start...

Downloading is carried out in the same way, except that restart is done by using the battery lug instead of the key.

17- 6

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SWE120L, SWE160D

© BT Europe AB

TruckCom Truck report function Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.7 Truck report function It is possible to generate a report to a file or disk with the truck’s configuration and status. Select menu <Tools | Generate truck report...> or with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report: [GENERAL] REPORT DATE-TIME=2004-01-19 11:11:58 CPC-PP SERIAL No=8002041 MACHINE NUMBER=555555 CUSTOMER=CUSTOMER 1 TECHNICIAN=NONAME COMPANY=Other NOTES=Test report [CAN NODES] MAIN CARD=0 CURTIS DRIVE CONTROLLER=16 [MAIN CARD CONFIGURATION] SOFTWARE=181179-001 HARDWARE=167833-004 SERIAL NO=53676 [DRIVE CONTROLLER CONFIGURATION] SOFTWARE=5 DRIVE CURRENT LIMIT (A)=300 FIELD MAXIMUM (A)=34 SERIAL NO=52857 MFG Date:=26/05/03 HOUR METERS] A IGNITION TIME=81 B TOTAL MOVEMENT=7 C DRIVE MOTOR TIME=7 D PUMP MOTOR TIME=0 S SERVICE TIME=7

[ERROR LOG] 01=104 00007.5 02=104 00007.5 03=104 00007.5 04=104 00007.5 05=104 00007.5 09=104 00005.0

[DRIVER PARAMETERS] 1=100 2=100 3=75 100=0

[TRUCK PARAMETERS] 11=0 12=0 13=0

The contents of certain rows can vary according to truck type.

© BT Europe AB

Service Manual

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17- 7

TruckCom Parameters function T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.8 Parameters function To change the truck parameters, select the Parameter function. This can be done with the menu <Tools | Change parameters > or with the tool button Parameters.

NOTE! The truck must in Normal mode (i.e. not Parameter mode) when connecting TruckCom. Otherwise TruckCom will report “Unable to determine truck brand”

The parameter numbers follow the description in the respective truck Service Manuals, section 5000.

The parameter window shows the information and the current settings for all parameters. The parameters are divided into 4 tabs.

• [Driver] - Driver; driver parameters and PIN code storing • [Truck] - Truck; service parameters • [Time] - Time; time-related service parameters • [Option parameters] - Option parameters. (no. 15 to 19) WARNING! Do not attempt to make any adjustments to the option parameters unless you have sufficient knowledge of the truck’s options/ modified functions. Specially modified trucks may require that you have access to special service information.

Improper adjustment of the option service parameters may result in a malfunction.

17.9 Diagnostics function To access diagnostics, select the Diagnostic function. This can be done with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.

NOTE! If the value “---” is shown in a field, or a “read status LED” is red, the communication has been interrupted for some reason and error data cannot be shown.

NOTE! The tab information displayed in the diagnostics mode depends on the type of truck connected.

17- 8

Service Manual

SWE120L, SWE160D

© BT Europe AB

TruckCom Diagnostics function Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.9.1 Representation of signal colours The screen dumps shown in the following section have been modified to improve legibility in black & white print.

WHITE GREEN RED

17.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following: • Speed lever -The status of the speed control and travel direction selector. The status of each individual hall element is displayed.

• Buttons -The status of the control buttons is displayed. “Sxx” refers to the switch designations as given in the circuit diagram.

• Option - Status of option buttons • Battery - The measured battery voltage • R14 - Shows the measured signal voltage from the lift/lower control • R15 - Not used at present

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Service Manual

SWE120L, SWE160D

17- 9

TruckCom Diagnostics function T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.9.3 “Drive Controller” tab (transistor regulator driving)

Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM - The effective power output supplied to the field circuit as a percentage.

• Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes.

• Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage.

• Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 -The input voltage from the man-on platform sensor. “digital O” indicates the digital status of the input.

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© BT Europe AB

TruckCom Diagnostics function Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.9.4 “Pump controller” tab (transistor regulator pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator. pin refers to the motor controller pin designations as given in the circuit diagram.

• Field PWM, Armature PWM, Field current, Armature current, Temperature - See explanation in 17.9.3 • Raw throttle data - The received lift/lower signal as a percentage.

• Out pin9 - The output signal to the proportional lowering valve as a percentage.

• Inp pin 10 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

• Inp pin 11 - The input voltage from the pressure sensor. “digital O” indicates the digital status of the input.

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Service Manual

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17- 11

TruckCom Diagnostics function T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.9.5 “EPS” (steering servo tab)

Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output.

• “Reference switch reached” - indicates status of drive wheel in centre reference switch.

• “Reference position found” - indicates whether a successful steering in centre has been performed.

• “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity).

“Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius.

• “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel.

• “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer.

• “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer.

• “Current” - The measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m.

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© BT Europe AB

TruckCom Other menu functions Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.9.6 SEU tab (Extra I/O module)

When the truck is equiped with a Spider Extension Unit (former Extra I/ O module) the SEU tab shows following: • “INP X” - Shows the logical status for the digital inputs.

• “OUT X” - Shows the logical status for the digital outputs.

• “Analog input X” - Shows the voltage level on the analog inputs.

See chapter 5000 for more information about the SEU and how the inputs and outputs are connected.

17.10 Other menu functions 17.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date.Select <File | Save to file | Parameters>. All parameters in the nodes which are connected to the bus will be scanned in and saved in a file.If only the hour meters are needed, select <File | Save to file | Hour meters>.

17.10.2 Download from file A set of parameters can be downloaded from the PC to the truck. Select <File | Load from file | Parameters >. The parameters in the file will be copied to the nodes connected to the bus. If only the hour meter settings are needed, select <File | Load from file | Hour meters >.

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Service Manual

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17- 13

TruckCom Other menu functions T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.10.3 Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting <Nodes | Reset CPC-PP>.

17.10.4 Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select <Tools | Erase error log>.

17.10.5 Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select <Tools | Reset hour meters >.

17.10.6 Read error code log To show the truck’s error code log, select <Tools | Read error log >.

17.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time >. The time given in the PC will now be downloaded into the truck.

NOTE! This does not apply to trucks without a real-time clock.

17.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select <Tools | Adjust Hour meters>. The time given in the PC will now be downloaded into the truck.

17.10.9 Help About the TruckCom application To see program information, select <Help | About TruckCom...> or use the tool button [Information].

17.10.10 Exit To exit the program, select <File | Exit > or use the tool button [Exit].

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Service Manual

SWE120L, SWE160D

© BT Europe AB

TruckCom Specifications Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.11 Specifications Table 22: CAN interface specification Description

Value

Power consumption

40-120 mA

Supply voltage

11-28 V

Transfer rate

125 kbit/s

Storage temperature

-20-80 °C

Operating temperature

0-60 °C

17.12 Installation NOTE! The program must be installed from the hard disk.

NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge. BT does not accept any responsibility for any errors that occur during the installation.

NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows®.

17.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file.

Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig.

• Click on System.ini and open the folder (386Enh).

• Unmark the option at Device=C:\Windows\Cpcppvd.vxd.

• Save the change and close the application.

Now continue with installationThe software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found.Then follow the on-screen instructions.

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Service Manual

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17- 15

TruckCom Installation T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

17.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to enter a value in the Windows® Registry and then make a few alterations in the Windows® Control panel.

Due to the built-in Windows® security, this must be done manually.

The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000.The changes can be made either before or after TruckCom is installed.

• Open the Registry Editor. To do this, select the Start button, then Run, type regedit and hit Enter.

• Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor.

• Select the Edit option, then Find and type PortName to search for the correct folder.

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© BT Europe AB

TruckCom Installation Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

NOTE! The location of the folder differs between different computers (some may be \Enum\Root\.., while others could be \Enum\ACPI\ etc.).

Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters.

• Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name

EnableConnectInterruptIoctl.

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Service Manual

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17- 17

TruckCom Installation T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

• Change the value in data field 1 by right-clicking on the name and selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

The Registry change is now complete. Close the Registry Editor.

Changes in Windows® Control Panel • Select the Start button.

• Choose Settings, then Control Panel and double-click on System.

• Select Hardware.

• Click on Device Manager and open Ports (Com & LPT).

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© BT Europe AB

TruckCom Installation Order number 229101-040

© BT Europe AB

Date 2006-03-13

Valid from serial number 922602-

Service Manual

SWE120L, SWE160D

T-code 702

17- 19

TruckCom Installation T-code 702

Valid from serial number 922602-

Date 2006-03-13

Order number 229101-040

• Double-click on the LPT port to be changed, and select the Port Settings tab.

• Check the "Use any Interrupt assigned to the port" option and click on OK.

The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

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© BT Europe AB

TruckCom Installation Order number 229101-040

Date 2006-03-13

Valid from serial number 922602-

T-code 702

17.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network. Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found. Then follow the on-screen instructions.

17.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ:7 Mode:Output only For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer.

17.12.5 To uninstall To uninstall TruckCom under Windows®: • Select the Start button, Settings, Control Panel, Add/Remove Programs.

• Then select the TruckCom Program and click Change/Remove.

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Service Manual

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17- 21

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