BT SWE120XR Repair Manual 7605992
BT SWE120XR Repair Manual 7605992 - Image 2
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BT SWE120XR Repair Manual 7605992

$30.00

  • Type Of Manual: Repair Manual
  • Manual ID: 7605992
  • : Service Manual PDF
  • Number of Pages: 552
  • Size: 71.8MB
  • Format: PDF
Category:

Product details

  • Model List:

    • SWE120XR
  • 1. General introduction
  • 1.1. Warning levels and symbols
  • 1.2. Pictograms
  • 1.3. Abbreviations
  • 2. General safety rules
  • 2.1. Authorised personnel
  • 2.2. Work safety
  • 2.3. Electrical system
  • 2.3.1. Electrostatic risks
  • 2.3.2. Battery handling
  • 2.4. Safe lifting
  • 2.5. Product modification
  • 2.6. Software
  • 2.7. Hydraulic system
  • 3. Operating principle
  • 3.1. Description
  • 3.2. Description
  • 3.2.1. Battery is connected
  • 3.2.2. Login via keypad
  • 3.2.3. Login via ID key option
  • 3.2.4. Tiller arm lowered for driving
  • 3.2.5. Driving in fork direction
  • 3.2.6. Driving in the drive wheel direction
  • 3.2.7. Braking in neutral
  • 3.2.8. Reverse braking
  • 3.2.9. Mechanical braking
  • 3.2.10. Emergency reversal
  • 4. Parameters
  • 4.1. Display/change parameters
  • 4.2. Parameters in general
  • 4.3. Parameter list
  • 5. Installation
  • 5.1. Transport
  • 5.1.1. Transporting the mast
  • 5.2. Lifting the truck
  • 5.2.1. Lifting the truck
  • 5.2.2. Lift using a jack
  • 5.3. Commissioning
  • 5.3.1. Parameters on commissioning
  • 5.3.1.1. Setting parameters
  • 5.3.1.2. Setting collision sensor parameters (option)
  • 5.3.1.3. Setting battery parameters
  • 5.3.2. Battery
  • 5.3.2.1. Battery installation
  • 6. Maintenance
  • 6.1. Introduction
  • 6.2. Maintenance instructions
  • 6.2.1. Cleaning
  • 6.2.2. High-pressure washers
  • 6.2.3. Degreasing agents
  • 6.2.4. Cleaning the exterior
  • 6.2.5. Cleaning the chain
  • 6.2.6. Cleaning the motor compartment
  • 6.2.7. Electric components
  • 6.2.8. Hydraulic system
  • 6.2.9. Signs, warnings and adhesive labels
  • 6.2.9.1. Placement of signs
  • 6.3. Lubricants specification
  • 6.4. Periodic maintenance
  • 7. Troubleshooting
  • 7.1. Initial troubleshooting
  • 7.2. Concluding troubleshooting
  • 7.3. Auxiliary functions
  • 7.3.1. Towing a defective truck
  • 7.3.1.1. Towing and transporting a defective truck
  • 7.3.2. Emergency driving mode
  • 7.3.2.1. Emergency driving mode
  • 7.3.3. Error code history
  • 7.3.3.1. Error code history
  • 7.3.4. Extended error log
  • 7.3.4.1. Extended error log
  • 7.3.5. Built-in test function for the tiller arm
  • 7.3.5.1. General
  • 7.3.5.2. Display test
  • 7.3.5.3. Speed control
  • 7.3.5.4. Safety reversing
  • 7.3.5.5. Controls for lifting/lowering
  • 7.3.5.6. Sensilift
  • 7.3.5.7. Keypad
  • 7.3.6. Digital input/output status
  • 7.3.6.1. Test mode 9
  • 7.3.7. Service information
  • 7.3.7.1. Service information
  • 7.4. Troubleshooting using error codes
  • 7.4.1. List of error codes
  • 8. Chassis C0000
  • 8.1. Inspection of the rear chassis
  • 8.2. Frame, chassis C0300
  • 8.2.1. Inspection covers C0340
  • 8.2.1.1. Motor compartment covers
  • 8.2.2. Support arms, stabilizers C0350
  • 8.2.2.1. Checking the support arms
  • 8.2.2.2. Lubrication of the support arms
  • 8.2.3. Battery compartment parts C0390
  • 8.2.3.1. Overview
  • 8.2.3.2. Description
  • 8.2.3.3. Checking the battery lock
  • 8.3. Frame/chassis components C0400
  • 8.3.1. Motor mount/brackets C0450
  • 8.3.1.1. Checking the motor mounts
  • 8.3.1.2. Drive unit mountings
  • 8.4. Operator compartment, cab C0500
  • 8.4.1. Platform including fixing points C0560
  • 8.4.1.1. Overview
  • 8.4.1.2. Adjusting the position sensor B120
  • 8.4.1.3. Checking the platform
  • 8.4.1.4. Gas strut
  • 8.4.1.5. Platform suspension
  • 8.4.1.6. Safety switch, platform B119
  • 8.4.1.7. Safety switch, platform B119/B120
  • 8.4.1.8. Replacing the platform
  • 8.5. Safety equipment C0800
  • 8.5.1. Operator protection C0840
  • 8.5.1.1. Gate
  • 8.5.2. Signs, warnings, labels C0850
  • 8.5.2.1. Checking signs and labels
  • 8.5.2.2. Placement of signs
  • 9. Motors C1000
  • 9.1. Electric motors C1700
  • 9.1.1. Electric pump motor C1710
  • 9.1.1.1. Overview
  • 9.1.1.2. Replacing the pump motor
  • 9.1.2. Electric steering motor C1730
  • 9.1.2.1. Overview
  • 9.1.2.2. Description
  • 9.1.2.3. Cleaning the ring gear
  • 9.1.2.4. Checking the electrical connections
  • 9.1.2.5. Checking the steering motor gears
  • 9.1.2.6. Checking the steering motor
  • 9.1.2.7. Lubricating the ring gear
  • 9.1.2.8. Check the drive gears attachment
  • 9.1.2.9. Replacing the steering motor
  • 9.1.3. Electric fan motor/fan C1740
  • 9.1.3.1. Overview
  • 9.1.3.2. Description
  • 9.1.3.3. Replacing the motor control fan
  • 9.1.4. Electric drive motor C1760
  • 9.1.4.1. Overview 1.8 kW
  • 9.1.4.2. Description
  • 9.1.4.3. Checking the electrical connections
  • 9.1.4.4. Checking the drive motor
  • 9.1.4.5. Listen for any abnormal noise in the drive motor bearings
  • 9.1.4.6. Check the drive motor mountings
  • 9.1.4.7. Checking the rotational speed sensor
  • 9.1.4.8. Check the rotational speed sensor fitting
  • 9.1.4.9. Replacing the drive motor
  • 9.1.4.10. Replacing the temperature sensor
  • 9.1.4.11. Replacing the rotational speed sensor
  • 9.1.4.12. Replacing the toothed wheel
  • 10. Transmission/Drive gear C2000
  • 10.1. Drive unit, final gear C2500
  • 10.1.1. Drive unit/gear C2550
  • 10.1.1.1. Overview
  • 10.1.1.2. Description
  • 10.1.1.3. Check the drive gears attachment
  • 10.1.1.4. Checking for leaks in the drive gear
  • 10.1.1.5. Checking for noise in the drive gear
  • 10.1.1.6. Replacing the drive gear
  • 10.1.1.7. Replacing the wheel hub seal
  • 10.1.1.8. Drive gear oil change
  • 10.1.1.9. Drive gear oil change
  • 10.1.1.10. Replacing the drive gear steering bearing
  • 10.1.1.11. Stud replacement
  • 11. Brake/wheel/track system C3000
  • 11.1. Travel brake system C3100
  • 11.1.1. Description
  • 11.1.1.1. Brake types
  • 11.2. Parking brake details C3300
  • 11.2.1. Electrical parking brake, magnet brake C3370
  • 11.2.1.1. Overview
  • 11.2.1.2. Description
  • 11.2.1.3. Cleaning the parking brake
  • 11.2.1.4. Adjusting the parking brake gap
  • 11.2.1.5. Tighten the parking brake mounting bolts
  • 11.2.1.6. Checking the parking brake
  • 11.2.1.7. Replacing the brake hub
  • 11.2.1.8. Replacing the friction disc
  • 11.3. Wheels C3500
  • 11.3.1. Drive wheel C3530
  • 11.3.1.1. Overview
  • 11.3.1.2. Description
  • 11.3.1.3. Measuring the drive wheel tread
  • 11.3.1.4. Check the drive wheel mountings
  • 11.3.1.5. Replacing the drive wheel
  • 11.3.2. Support arm wheels/castor wheels C3540
  • 11.3.2.1. Replacing the castor wheel
  • 11.3.2.2. Replacing the castor wheel assembly
  • 11.3.3. Fork wheels/support arm wheels C3550
  • 11.3.3.1. Replacing the support arm wheels
  • 12. Steering system C4000
  • 12.1. Description
  • 12.1.1. Power steering
  • 12.2. Mechanical steering system C4100
  • 12.2.1. Steering arm/wheel/lever C4110
  • 12.2.1.1. Overview tiller arm
  • 12.2.1.2. Operating panel
  • 12.2.1.3. Tiller arm handle
  • 12.2.1.4. Tiller arm
  • 12.2.1.5. Steering yoke
  • 12.2.1.6. Steering adapter
  • 12.2.1.7. Tiller arm wiring harness
  • 12.2.1.8. Replacing the steering bearing
  • 12.3. Electric steering system C4300
  • 12.3.1. Overview
  • 12.3.2. Steering angle sensor C4350
  • 12.3.2.1. Description
  • 12.3.2.2. Replacing the steering angle sensor servo unit.
  • 12.3.2.3. Checking the reference sensor
  • 13. Electrical system C5000
  • 13.1. Description
  • 13.1.1. Using the anti-static carpet
  • 13.2. Programming tools
  • 13.2.1. TruckCom
  • 13.2.1.1. Connect the CAN interface to the truck
  • 13.3. General electric equipment C5100
  • 13.3.1. Battery C5110
  • 13.3.1.1. Description
  • 13.3.1.2. Cleaning the battery
  • 13.3.1.3. Checking the connections
  • 13.3.1.4. Checking the battery cables
  • 13.3.1.5. Checking the battery
  • 13.3.1.6. Checking cell and terminal protectors
  • 13.3.1.7. Checking the level of the electrolyte
  • 13.3.1.8. Checking the electrolyte density
  • 13.3.1.9. Checking the battery parameters
  • 13.3.1.10. Checking the battery voltage
  • 13.3.1.11. Resetting/restarting the battery
  • 13.3.1.12. Charging the battery
  • 13.3.1.13. Replacing a battery using a lifting device
  • 13.3.1.14. Replacing a battery using a battery changing table
  • 13.3.2. General alarm signals (audible/visual) C5160
  • 13.3.2.1. Horn
  • 13.3.3. Battery charger (built-in) C5170
  • 13.3.3.1. Checking the battery charger cables
  • 13.3.3.2. Checking the battery charger parameters
  • 13.3.4. Battery cut out switch, main contactor C5190
  • 13.3.4.1. Main contactor
  • 13.4. Instrument panel, display C5200
  • 13.4.1. Menu
  • 13.4.1.1. Menus
  • 13.4.1.2. Menu navigation
  • 13.4.1.3. Menu overview
  • 13.4.1.4. Menu list
  • 13.4.1.5. Menu information
  • 13.4.1.6. Show hour meter values
  • 13.4.1.7. Show error codes
  • 13.4.1.8. Show part numbers for software/hardware
  • 13.4.1.9. Built-in test ICH
  • 13.4.1.10. Show collisions
  • 13.4.1.11. Show/change parameters
  • 13.4.1.12. Emergency driving mode
  • 13.4.1.13. Calibration
  • 13.4.1.14. Show/change PIN code
  • 13.4.1.15. PIN codes
  • 13.4.2. Hour counter, tachograph C5290
  • 13.4.2.1. Checking error log and operating hours
  • 13.5. Control system travel function C5300
  • 13.5.1. Direction selector/speed regulator
  • 13.5.2. Pressure equalization
  • 13.5.3. Weighing system
  • 13.5.4. Display
  • 13.5.5. Symbols on keypad and display
  • 13.5.6. Option buttons
  • 13.5.7. Signal buttons
  • 13.5.8. Lifting and lowering control
  • 13.5.9. Hour meter
  • 13.5.10. Battery indicator
  • 13.5.11. Safety reversing
  • 13.6. Power system travel function C5400
  • 13.6.1. Overview
  • 13.6.2. Transistor panel C5460
  • 13.6.2.1. Description
  • 13.6.2.2. Checking the contactors
  • 13.6.2.3. Checking the cable connections
  • 13.6.2.4. Checking the electric panel mounting
  • 13.6.2.5. Cleaning the electric panel heatsink
  • 13.6.2.6. Replacing the motor control panel
  • 13.7. Control system, working function C5500
  • 13.7.1. Work function harnesses/fuse C5590
  • 13.7.1.1. Checking the wiring harnesses
  • 13.8. Protective sensors, position sensors C5800
  • 13.8.1. Description
  • 13.8.1.1. Inductive sensors
  • 13.8.1.2. Pressure sensor
  • 13.8.1.3. Pulse transducer
  • 13.8.2. Safety probes/sensors C5830
  • 13.8.2.1. Emergency switch off
  • 13.8.2.2. Gate switches B121/B122
  • 13.9. Calibrations
  • 13.9.1. Steering angle calibration
  • 13.9.2. Hydraulic valve calibration
  • 13.9.2.1. Proportional valve calibration
  • 13.9.2.2. Calibrating the tilt sensor
  • 13.9.3. Pressure sensor calibration
  • 13.9.3.1. Steering angle manual steering
  • 13.9.3.2. Weight measuring calibration
  • 13.9.3.3. Calibrating the reach sensor
  • 13.9.3.4. Overload calibration
  • 13.9.3.5. Overload calibration
  • 14. Hydraulics/Pneumatics C6000
  • 14.1. Overview
  • 14.2. Description
  • 14.2.1. Hydraulic hygiene
  • 14.2.1.1. Inside cleaning
  • 14.2.1.2. Packaging
  • 14.2.1.3. Handling
  • 14.2.1.4. Storage
  • 14.2.1.5. Work procedures
  • 14.2.1.6. Definitions hydraulic parts
  • 14.2.2. Erroneous hydraulic system pressure
  • 14.3. Quick change connectors
  • 14.3.1. Overview quick change connectors
  • 14.3.2. Removing female quick change connectors
  • 14.3.3. Installing female quick change connectors
  • 14.3.4. Removing a quick change connector (male)
  • 14.3.5. Installing a quick change connector (male)
  • 14.4. Hydraulic unit C6100
  • 14.4.1. Description
  • 14.4.1.1. Pressure limiting valve
  • 14.4.2. Hydraulic oil tank C6110
  • 14.4.2.1. Tank
  • 14.4.2.2. Description
  • 14.4.2.3. Cleaning the tank
  • 14.4.2.4. Cleaning the tank
  • 14.4.2.5. Checking the tank
  • 14.4.2.6. Oil change
  • 14.4.2.7. Oil change
  • 14.4.2.8. Replacing the tank
  • 14.4.3. Filter, filter housing C6130
  • 14.4.3.1. Air filter
  • 14.4.3.2.
  • 14.4.3.3. Oil filter replacement
  • 14.4.4.
  • 14.4.4.1. Description
  • 14.4.4.2. Replacing the flow control valve
  • 14.4.4.3. Replacing the pressure limiting valve
  • 14.4.5. Replacing the valve coil
  • 14.4.5.1. Removing the valve coil
  • 14.4.5.2. Fitting the valve coil
  • 14.4.6. Replacing the pressure sensor
  • 14.4.6.1. Removing the pressure sensor
  • 14.4.6.2. Fitting the pressure sensor
  • 14.5. Hydraulic system, fitted on the mast C6300
  • 14.5.1. Mast hydraulic conduits C6320
  • 14.5.1.1. Replacing the hose rupture valve
  • 14.5.1.2. Checks for leaks from hydraulic conduits and connections, hydraulic unit
  • 14.6. Hydraulic cylinder C6600
  • 14.6.1. Main lift cylinders C6610
  • 14.6.1.1. Checking for leaks in the lift cylinder
  • 14.6.1.2. Replacing the main lift cylinders
  • 14.6.2. Reach/telescoping cylinder C6650
  • 14.6.2.1. Lubricate the reach cylinder attachment points
  • 14.6.2.2. Replacing the reach cylinder
  • 15. Work function – lifting masts C7000
  • 15.1. Description
  • 15.1.1. Ordering a replacement mast
  • 15.2. Chain system, general
  • 15.2.1. General
  • 15.2.2. Adjusting the chain
  • 15.2.3. Lubrication
  • 15.2.4. Checking the chains
  • 15.2.4.1. Noise
  • 15.2.4.2. Surface rust
  • 15.2.4.3. Rusty links
  • 15.2.4.4. Stiff links
  • 15.2.4.5. Bolt rotation
  • 15.2.4.6. Loose bolts
  • 15.2.4.7. Outline wear
  • 15.2.4.8. Chain gauge
  • 15.2.4.9. Stretching
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