BT SWE120XR Repair Manual 7605992 - Image 2

BT SWE120XR Repair Manual 7605992 - Image 3

BT SWE120XR Repair Manual 7605992 - Image 4

BT SWE120XR Repair Manual 7605992 - Image 5

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: BT Service Manual PDF

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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