BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040

BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040 - Image 2

BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040 - Image 3

BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040 - Image 4

BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040 - Image 5

bt swe100 swe120 swe120l swe120s swe140 swe140l swe200d repair manual 7588855 040 2

bt swe100 swe120 swe120l swe120s swe140 swe140l swe200d repair manual 7588855 040 3

BT SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D Repair Manual 7588855-040

$30.00

Type Of Manual: Repair Manual
Manual ID: 7588855-040
: Service Manual PDF
Number of Pages: 306
Size: 11.1MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- SWE100, SWE120, SWE120L, SWE120S, SWE140, SWE140L, SWE200D

1. Contents
2. General introduction
2.1. How to use this manual
2.2. Warning levels and symbols
2.3. Pictograms
3. General safety rules
3.1. Work safety
3.2. Electrical system
3.3. Safe lifting
3.4. Truck modifications
4. Operation and connection sequences
4.1. Symbols on keypad and display
4.2. Battery is connected
4.3. Login via keypad
4.4. Tiller arm lowered for driving
4.5. Driving in fork direction
4.6. Driving in the drive wheel direction
4.7. Neutral position braking
4.8. Reverse braking
4.9. Mechanical braking
4.10. Emergency reversal
4.11. Fork lifting
4.12. Fork lifting (SWE100)
4.13. Support arm lift (SWE120L, 140L, 200D)
4.14. Fork lowering
4.15. Support arm lowering (SWE120L, 140L, 200D)
4.16. Click-2-Creep
4.17. Turtle function (option)
5. Parameters
5.1. General
5.1.1. Show/change parameters
5.1.2. Operator parameters
5.1.3. Overview
5.1.4. Connection to logged-in operator
5.1.4.1. Description of operator parameters
5.1.4.2. Parameters 3 and 4 Acceleration/Deceleration
5.1.4.3. Parameters 6 and 7 Maximum travel speed
5.2. General service parameters
5.2.1. Overview
5.2.2. Description
5.2.2.1. Parameter 101/104 Service/Log-out
5.2.2.2. Parameter 102 – Operator access
5.2.2.3. Parameter 103 – Start-up display
5.2.2.4. Parameter 105/106 – Collision sensor sensitivity for X/Y (Optional)
5.2.2.5. Parameter 107 Battery size
5.2.2.6. Table applicable to LWE140, 160, 180, 200
5.2.2.7. Table concerning LWE250
5.2.2.8. Table concerning SWE
5.2.2.9. Verifying parameter settings for freely ventilated batteries (lead-acid batteries)
5.2.2.10. Verifying the parameter setting for valve-regulated batteries (Exide)
5.2.2.11. Parameters 109/110 – Built-in charger (option)
5.2.2.12. Parameter 111 – Reset procedure after collision (option)
5.2.2.13. Parameter 112 – Clear application data
5.3. Service parameters, travel functions
5.3.1. Overview
5.3.2. Description
5.3.2.1. Parameter 201 Deceleration when reversing
5.3.2.2. Parameter 202 Maximum speed Turtle mode activated
5.3.2.3. Parameter 203 – Maximum speed, forks above 1.8 m
5.3.2.4. Parameter 204 – Maximum acceleration, forks above 1.8 m
5.3.2.5. Parameter 205 – Maximum reversing, forks above 1.8 m
5.3.2.6. Parameter 206 – Automatic speed reduction, forks above 1.8 m
5.4. Service parameters, hydraulic functions
5.4.1. Description
5.4.1.1. Parameter 301 Ramping value for lowering stop
5.4.1.2. Parameter 302 – Fork, lowering speed
5.4.1.3. Parameter 303 – EVP start mode
5.4.1.4. Parameter 304 – EVP support arm lowering speed
5.4.1.5. Parameter 305 – EVP slow lowering speed
5.4.1.6. Parameter 306 – Activation of Click-2-Creep lifting/lowering
5.4.1.7. Parameter 307 – Automatic support arm lowering (On/Off)
5.4.1.8. Parameter 499 – (Not applicable)
5.5. Factory parameters
5.5.1. Overview
5.5.2. Description
5.5.2.1. Parameter 1001 – Truck type
5.5.2.2. Parameter 1002 – Non-configurable options
5.5.2.3. Parameters 1003-1042 Optional functions
5.5.2.4. Parameter 1044 – Master maximum speed
5.5.2.5. Parameter 1045 – Type of battery in the truck
5.5.2.6. Parameter 1046 – Adapting to special trucks
5.5.2.7. Parameter 1101 – Built-in charger
5.5.2.8. Parameter 1102 – Controls for hydraulic function
5.5.2.9. Parameter 1110 Reset voltage for BDI
5.5.2.10. Parameter 1118 – Hardware version
6. Installation and commissioning
6.1. Transporting the truck
6.2. Transporting the mast
6.3. Safe lifting
6.4. Installing the battery
6.5. Using PIN codes
6.5.1. General
6.5.2. PIN code for resetting after a collision
6.5.3. Programming PIN codes
6.6. Programming PIN codes
6.6.1. PIN code defaults
6.7. Setting parameters
6.8. Function and safety checks
7. Maintenance
7.1. Introduction
7.2. Maintenance instructions
7.2.1. Cleaning and washing
7.2.2. High-pressure washers
7.2.3. Degreasing agents
7.2.4. Cleaning the exterior
7.2.5. Cleaning the chain
7.2.6. Cleaning the motor compartment
7.2.7. Electric components
7.3. Maintenance schedule
8. Troubleshooting
8.1. General
8.1.1. Software compatibility
8.2. Towing a defective truck
8.2.1. Tow using a tow truck and tow wagon
8.3. Emergency driving mode
8.4. Troubleshooting methods
8.4.1. General initial troubleshooting
8.4.2. Concluding troubleshooting
8.5. Error code history
8.6. Error code system
8.7. Error codes
8.8. Troubleshooting chart
8.8.1. The truck cannot be driven.
8.8.2. Truck only travels at reduced speed
8.8.3. The truck can be driven but behaves abnormally
8.8.4. The truck can be driven, but some functions do not work
8.8.4.1. Software compatibility
8.8.4.2. Hardware compatibility matrix
8.8.5. Defective hydraulic functions
8.9. Built-in test function
8.10. Digital input/output status
8.10.1. Test mode 9
8.10.2. Test function 10 Logic card
8.10.3. Test mode 12 Expansion unit SEU (option).
8.11. Built-in test function for the tiller arm
8.11.1. Display test
8.11.2. Speed control
8.11.3. Safety reversing
8.11.4. Controls for lifting/lowering
8.11.5. Sensilift
8.11.6. Keypad
8.12. Checking the built-in battery charger
9. Chassis 0000
9.1. Support arm 0350
9.1.1. Support arm lift, lateral adjustment
9.1.2. Adjusting the kneeling action
9.2. Motor mounts 0450
9.2.1. Replacing springs (not applicable for SWE120S)
9.3. Removing the platform
10. Electric drive motor 1700
10.1. Overview
10.2. Removing the motor from the truck
10.3. Removing the toothed wheel
10.4. Removing motor bearings
10.5. Removing the RPM sensor
10.6. Installing the temperature sensor
10.7. Drive motor tightening torques
10.8. Cleaning
11. Drive gear 2550
11.1. General
11.2. Overview
11.3. Removing the gear from the truck (not applicable for SWE120S)
11.4. Removing the drive gear from the truck (SWE120S)
11.5. Fitting grease nipples, steering bearings (Option)
11.6. Lubrication the steering bearings (Option)
11.7. Checking and changing the oil
11.7.1. Draining oil
11.7.2. Checking/refilling oil
11.8. Replacing the wheel hub seal
11.8.1. Removing the seal
11.8.2. Fitting the seal
11.8.3. Replacing studs
12. Brake system/Wheels C3000
12.1. Brake system – C3100
12.1.1. Description
12.1.1.1. Travel brake
12.1.1.2. Parking brake
12.1.1.3. Emergency brake
12.2. Parking brake 3180
12.2.1. Overview
12.2.2. Emergency release of the parking brake
12.3. Removing the parking brake
12.4. Fitting the parking brake
12.5. Checking the air gap
12.6. Drive wheel 3530
12.6.1. Replacing the drive wheel
12.7. Castor wheels 3540
12.7.1. Overview
12.7.2. Castor wheel mounting
12.7.3. Replacing the castor wheel
12.7.4. Disassembling the castor wheel cradle
12.8. Spring replacement
12.8.1. Removing springs
12.8.2. Fitting the spring
12.9. Support arm wheel 3550
12.9.1. Overview
12.10. Climber wheels
12.10.1. Overview
13. Tiller arm 4000
13.1. Overview
13.2. Removing the tiller arm
13.3. Replacing the gas spring
13.4. Replacing the safety sensor
13.4.1. Disassembly
13.4.2. Assembly
13.5. Electrical steering system 4000
13.5.1. Tiller arm handle C4110
13.5.2. Overview
13.5.3. Replacing the keypad C9420
13.5.4. Replacing the upper cover C4110
13.5.4.1. Removing the upper cover
13.5.5. Replacing the tiller arm handle
13.5.5.1. Removing the tiller arm handle
13.5.5.2. Fitting the tiller arm handle
13.5.6. Replacing the logic card
13.5.6.1. Removing the logic card
13.5.6.2. Fitting the logic card
13.5.7. Checking the handle
13.5.8. Update the software
13.5.9. Replacing the signal button/switch
13.5.10. Replacing the lift/lower button
13.5.11. Replacing the sensilift
13.5.12. Replacing the stomach button
13.5.13. Changing the position of the controls – support arm lift/ fork lift
14. Electrical components-5000
14.1. Li-ion battery (Hoppecke)
14.1.1. Resetting/restarting the battery
14.2. Inspecting the battery
14.3. Replacing the wiring harness
14.3.1. Replacing the transistor regulator wiring harness
14.4. Replacing the transistor regulator
15. Hydraulic system 6000
15.1. General
15.2. Hydraulic hygiene
15.2.1. Washing
15.2.2. Packaging
15.2.3. Handling
15.2.4. Storage
15.2.5. Work procedures
15.3. Hydraulic unit 6100
15.3.1. Emptying the hydraulic tank
15.3.2. Hydraulic system, bleeding
15.3.2.1. Cylinders with bleeding valve
15.3.2.2. Cylinders without bleeding valve
15.4. Hydraulic connections 6230
15.4.1. Quick change connectors
15.4.1.1. Connecting the quick change connector
15.4.1.2. Disassembly of the quick change connector
15.5. Hose rupture valve
15.5.1. Replacing the hose rupture valve
15.6. Hydraulic calibration
15.7. Adjusting the pressure limiting valve
15.8. Disassembling the hydraulic unit
15.9. Hydraulic unit tightening torques
16. Mast C7000
16.1. Main mast 7100
16.1.1. Components
16.1.2. Maintenance
16.1.2.1. Fixing point
16.1.2.2. Lubrication
16.2. Fork carriage 7420
16.2.1. Maintenance
16.3. Main lift chain system 7120
16.3.1. Checking the chain setting
16.3.2. Checking the chain
16.3.2.1. Surface rust
16.3.2.2. Rusty links
16.3.2.3. Stiff links
16.3.2.4. Bolt rotation
16.3.2.5. Loose bolts
16.3.2.6. Outline wear
16.3.2.7. Stretching
16.3.2.8. Damaged plates
16.3.2.9. Damaged bolts
16.3.2.10. Dirty chain
16.3.3. Cleaning
16.3.4. Lubrication
16.3.5. Adjustment
16.4. Replacing the fork carriage
16.5. Replacement of the mast
16.6. Adjusting the mast
17. Peripherals C8000
18. Accessories
18.1. Spider expansion unit
18.2. TLS – Truck log system
18.3. ID unit
18.4. I_Site
18.5. DC/DC converter
18.6. Collision sensor
18.7. Built-in battery charger
18.7.1. Technical data
18.7.2. Charging the battery
18.7.2.1. Main charging
18.7.2.2. Equalising charging
18.7.2.3. Charging completed
19. Instructions for disposal
19.1. General
19.2. Marking of plastics
19.2.1. General marking of products and packaging
19.2.2. Marking according to the manufacturers standards
19.2.2.1. Abbreviations
19.2.2.2. Marking examples
19.3. Pressure vessels
19.3.1. Gas struts
19.4. Sorting categories
20. Electrical components and wiring diagrams
20.1. Electric components
20.2. Wiring diagram
20.2.1. List of symbols
20.2.2. General wiring diagram
20.2.3. Wiring diagram
21. Hydraulics chart
22. Tools
22.1. MQS contacts
22.2. AMP connectors
22.2.1. AMP connectors, Multilock series 040
22.3. Molex connectors
22.4. Grease guns
22.5. Other tools
23. Oil and grease specification
23.1. General tightening torques
23.2. Oil and grease specification

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