BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354

BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354 - Image 2

BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354 - Image 3

BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354 - Image 4

BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354 - Image 5

bt swe140s swe145 swe145l swe160 swe160l swe200 swe200l repair manual 7590354 2

bt swe140s swe145 swe145l swe160 swe160l swe200 swe200l repair manual 7590354 3

BT SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L Repair Manual 7590354

$30.00

Type Of Manual: Repair Manual
Manual ID: 7590354
: Service Manual PDF
Number of Pages: 532
Size: 73.5MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- SWE140S, SWE145, SWE145L, SWE160, SWE160L, SWE200, SWE200L

1. General introduction
1.1. How to use this manual
1.2. Warning levels and symbols
1.3. Pictograms
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. Truck modifications
2.6. Software
2.7. Hydraulic system
3. Operating principle
3.1. Description
3.1.1. Battery is connected
3.1.2. Login via keypad
3.1.3. Login via ID key option
3.1.4. Tiller arm lowered for driving
3.1.5. Driving in fork direction
3.1.6. Driving in the drive wheel direction
3.1.7. Braking in neutral
3.1.8. Reverse braking
3.1.9. Mechanical braking
3.1.10. Emergency reversal
3.1.11. Fork lowering
4. Parameters
4.1. Display/change parameters
4.2. Parameters in general
4.3. Parameter list
4.4. Parameter list
5. Installation
5.1. Transport
5.1.1. Transporting the truck
5.1.2. 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
5.3.2.2. Placement of signs
5.3.2.3. Placement of signs
5.3.2.4. Placement of signs
6. Troubleshooting
6.1. Auxiliary functions
6.1.1. Towing a defective truck
6.1.1.1. Towing and transporting a defective truck
6.1.2. Emergency driving mode
6.1.2.1. Emergency driving mode
6.1.3. Error code history
6.1.3.1. Error code history
6.1.4. Extended error log
6.1.4.1. Extended error log
6.1.5. Built-in test function for the tiller arm
6.1.5.1. General
6.1.5.2. Display test
6.1.5.3. Speed control
6.1.5.4. Safety reversing
6.1.5.5. Controls for lifting/lowering
6.1.5.6. Sensilift
6.1.5.7. Keypad
6.2. Initial troubleshooting
6.3. Concluding troubleshooting
6.4. Troubleshooting using error codes
6.4.1. List of error codes
7. Chassis C0000
7.1. Overview
7.2. Frame, chassis C0300
7.2.1. Inspection covers C0340
7.2.1.1. Motor compartment covers
7.2.2. Support arms, stabilizers C0350
7.2.2.1. Overview
7.2.2.2. Checking the linkage
7.2.2.3. Checking the wheel fork flexibility
7.2.2.4. Replacing the pressure rod
7.2.2.5. Replacing torsion tubes
7.2.2.6. Replacing the roller on the torsion tube
7.2.2.7. Replacing a wheel fork
7.2.2.8. Replacing a bogie link, fork wheel
7.2.2.9. Replacing a bogie link, support arm
7.2.2.10. Replacing the wheel fork bushing
7.2.2.11. Replacing the support arm bushing
7.2.3. Fork structure (low-lifter) C0380
7.2.3.1. Checking the fork lift height limitation
7.2.4. Battery compartment parts C0390
7.2.4.1. Overview
7.2.4.2. Overview
7.2.4.3. Description
7.3. Frame/chassis components C0400
7.3.1. Motor mount/brackets C0450
7.3.1.1. Checking the motor mounts
7.3.1.2. Drive unit mountings
7.3.1.3. PowerTrak
7.3.1.4. Decompression locking
7.4. Operator compartment, cab C0500
7.4.1. Platform including fixing points C0560
7.4.1.1. Replacing the platform
7.5. Safety equipment C0800
7.5.1. Signs, warnings, labels C0850
7.5.1.1. Checking signs and labels
7.5.1.2. Placement of signs
7.5.1.3. Placement of signs
7.5.1.4. Placement of signs
8. Motors C1000
8.1. Electric motors C1700
8.1.1. Electric pump motor C1710
8.1.1.1. Overview
8.1.1.2. Replacing the pump motor
8.1.2. Electric fan motor/fan C1740
8.1.2.1. Overview
8.1.2.2. Description
8.1.2.3. Replacing the motor control fan
8.1.3. Electric drive motor C1760
8.1.3.1. Overview 1.8, 2.5 kW
8.1.3.2. Description
8.1.3.3. Check the rotational speed sensor fitting
8.1.3.4. Checking the electrical connections
8.1.3.5. Checking the drive motor
8.1.3.6. Listen for any abnormal noise in the drive motor bearings
8.1.3.7. Check the drive motor fitting (1.8 and 2.5 kW)
8.1.3.8. Checking the rotational speed sensor
8.1.3.9. Replacing the drive motor
8.1.3.10. Replacing the temperature sensor
8.1.3.11. Replacing the rotational speed sensor
8.1.3.12. Replacing the toothed wheel
9. Transmission/Drive gear C2000
9.1. Drive unit, final gear C2500
9.1.1. Drive unit/gear C2550
9.1.1.1. Overview
9.1.1.2. Description
9.1.1.3. Check the drive gears attachment
9.1.1.4. Checking for leaks in the drive gear
9.1.1.5. Checking for noise in the drive gear
9.1.1.6. Replacing the drive gear
9.1.1.7. Replacing the wheel hub seal
9.1.1.8. Drive gear oil change
9.1.1.9. Replacing the drive gear steering bearing
9.1.1.10. Stud replacement
10. Brake/wheel/track system C3000
10.1. Travel brake system C3100
10.1.1. Description
10.1.1.1. Brake types
10.2. Parking brake details C3300
10.2.1. Electrical parking brake, magnet brake C3370
10.2.1.1. Overview
10.2.1.2. Description
10.2.1.3. Cleaning the parking brake
10.2.1.4. Adjusting the parking brake gap
10.2.1.5. Adjusting the parking brake gap
10.2.1.6. Tighten the parking brake mounting bolts
10.2.1.7. Emergency release of the parking brake
10.2.1.8. Checking the parking brake
10.2.1.9. Replacing the brake hub
10.2.1.10. Replacing the friction disc
10.2.1.11. Replacing the parking brake
10.3. Wheels C3500
10.3.1. Drive wheel C3530
10.3.1.1. Overview
10.3.1.2. Description
10.3.1.3. Measuring the drive wheel tread
10.3.1.4. Replacing the drive wheel
10.3.2. Support arm wheels/castor wheels C3540
10.3.2.1. Overview
10.3.2.2. Description
10.3.2.3. Cleaning castor wheels
10.3.2.4. Measuring the castor wheel tread
10.3.2.5. Measuring the castor wheel tread
10.3.2.6. Measuring the castor wheel tread
10.3.2.7. Measuring the castor wheel tread
10.3.2.8. Checking the castor wheels
10.3.2.9. Replacing the castor wheel
10.3.2.10. Replacing the castor wheel assembly
10.3.3. Fork wheels/support arm wheels C3550
10.3.3.1. Overview
10.3.3.2. Description
10.3.3.3. Cleaning the fork wheels
10.3.3.4. Measuring the fork wheel tread
10.3.3.5. Checking the fork wheel mounting
10.3.3.6. Checking the fork wheel bushings
10.3.3.7. Replacing a single wheel
10.3.3.8. Replacing bogie wheels
10.3.3.9. Replacing a bogie link
11. Steering system C4000
11.1. Mechanical steering system C4100
11.1.1. Steering arm/wheel/lever C4110
11.1.1.1. Overview tiller arm
11.1.1.2. Operating panel
11.1.1.3. Tiller arm handle
11.1.1.4. Tiller arm
11.1.1.5. Steering yoke
11.1.1.6. Tiller arm wiring harness
11.2. Electric steering system C4300
11.2.1. Steering angle sensor C4350
11.2.1.1. Replacing the steering angle sensor mech.
12. Electrical system C5000
12.1. Description
12.1.1. General
12.1.2. Truck firmware applications
12.2. Software update
12.3. Programming tools
12.3.1. TruckCom
12.3.1.1. Connect the CAN interface to the truck
12.3.2. Software
12.3.2.1. Software update
12.4. General electric equipment C5100
12.4.1. Battery C5110
12.4.1.1. Cleaning the battery
12.4.1.2. Checking the connections
12.4.1.3. Checking the battery cables
12.4.1.4. Checking the battery
12.4.1.5. Checking cell and terminal protectors
12.4.1.6. Checking the level of the electrolyte
12.4.1.7. Checking the electrolyte density
12.4.1.8. Checking the battery parameters
12.4.1.9. Checking the battery voltage
12.4.1.10. Resetting/restarting the battery
12.4.1.11. Charging the battery
12.4.1.12. Replacing a battery using a lifting device
12.4.1.13. Replacing a battery using a battery changing table
12.4.2. General alarm signals (audible/visual) C5160
12.4.2.1. Horn
12.4.3. Battery charger (built-in) C5170
12.4.3.1. Checking the battery charger cables
12.4.3.2. Checking the battery charger parameters
12.4.4. Battery cut out switch, main contactor C5190
12.4.4.1. Main contactor
12.5. Instrument panel, display C5200
12.5.1. Menu
12.5.1.1. Menus
12.5.1.2. Menu navigation
12.5.1.3. Menu list
12.5.1.4. Menu information
12.5.1.5. Show hour meter values
12.5.1.6. Show error codes
12.5.1.7. Show part numbers for software/hardware
12.5.1.8. Built-in test ICH
12.5.1.9. Show collisions
12.5.1.10. Show/change parameters
12.5.1.11. Emergency driving mode
12.5.1.12. Calibration
12.5.1.13. Show/change PIN code
12.5.1.14. PIN codes
12.5.2. Hour counter, tachograph C5290
12.5.2.1. Checking error log and operating hours
12.6. Control system travel function C5300
12.6.1. Direction selector/speed regulator
12.6.2. Pressure equalization
12.6.3. Weighing system
12.6.4. Display
12.6.5. Symbols on keypad and display
12.6.6. Option buttons
12.6.7. Signal buttons
12.6.8. Lifting and lowering control
12.6.9. Hour meter
12.6.10. Battery indicator
12.6.11. Safety reversing
12.6.12. Travel function wiring/fuse C5390
12.6.12.1. Description
12.7. Power system travel function C5400
12.7.1. Overview
12.7.2. Transistor panel C5460
12.7.2.1. Description
12.7.2.2. Checking the contactors
12.7.2.3. Checking the cable connections
12.7.2.4. Checking the electric panel mounting
12.7.2.5. Cleaning the electric panel heatsink
12.7.2.6. Replacing the motor control panel
12.8. Control system, working function C5500
12.8.1. Work function harnesses/fuse C5590
12.8.1.1. Checking the wiring harnesses
12.9. Protective sensors, position sensors C5800
12.9.1. Description
12.9.1.1. Inductive sensors
12.9.1.2. Pressure sensor
12.9.1.3. Pulse transducer
12.9.2. Safety probes/sensors C5830
12.9.2.1. Emergency switch off
12.10. Calibrations
12.10.1. Steering angle calibration
12.10.2. Hydraulic valve calibration
12.10.2.1. Proportional valve calibration
12.10.2.2. Tilt angle calibration
12.10.3. Pressure sensor calibration
12.10.3.1. Weight measuring calibration
12.10.3.2. Overload calibration
13. Hydraulics/Pneumatics C6000
13.1. Overview
13.2. Description
13.2.1. Hydraulic hygiene
13.2.1.1. Washing
13.2.1.2. Packaging
13.2.1.3. Handling
13.2.1.4. Storage
13.2.1.5. Work procedures
13.2.1.6. General rules
13.2.1.7. Measures
13.2.2. Design
13.3. Quick change connectors
13.3.1. Overview quick change connectors
13.3.2. Removing quick change connectors (female)
13.3.3. Installing quick change connector (female)
13.3.4. Removing a quick change connector (male)
13.3.5. Installing a quick change connector (male)
13.4. Hydraulic unit C6100
13.4.1. Hydraulic unit
13.4.2. Description
13.4.2.1. Pressure limiting valve
13.4.3. Hydraulic oil tank C6110
13.4.3.1. Tank
13.4.3.2. Description
13.4.3.3. Cleaning the tank
13.4.3.4. Checking the tank
13.4.3.5. Oil change
13.4.3.6. Replacing the tank
13.4.4. Filter, filter housing C6130
13.4.4.1. Cleaning the suction filter
13.4.4.2. Oil filter replacement
13.4.4.3. Replacing the suction filter
13.4.5. Hydraulic pump C6140
13.4.5.1. Hydraulic pump
13.4.5.2. Description
13.4.6. Pressure/flow control valve C6170
13.4.6.1. Description
13.4.6.2. Replacing the flow control valve
13.4.6.3. Replacing the pressure limiting valve
13.4.7. Replacing the hydraulic unit
13.4.7.1. Removing the hydraulic unit
13.4.7.2. Fitting the hydraulic unit
13.4.8. Replacing the valve coil
13.4.8.1. Removing the valve coil
13.4.8.2. Fitting the valve coil
13.4.9. Replacing the pressure sensor
13.4.9.1. Removing the pressure sensor
13.4.9.2. Fitting the pressure sensor
13.5. Hydraulic system, fitted on the mast C6300
13.5.1. Mast hydraulic conduits C6320
13.5.1.1. Checks for leaks from hydraulic conduits and connections, hydraulic unit
13.5.1.2. Checks for leaks from hydraulic conduits and connections, mast
13.6. Hydraulic cylinder C6600
13.6.1. Main lift cylinders C6610
13.6.1.1. Checking for leaks in the lift cylinder
13.6.1.2. Replacing the main lift cylinders
13.6.2. Support arm/initial lift cylinder C6630
13.6.2.1. Replacing the main initial lift cylinder
13.6.3. PowerTrak cylinder C6680
13.6.3.1. Replacing the PowerTrak cylinder
14. Work function – lifting masts C7000
14.1. Description
14.1.1. Ordering a replacement mast
14.2. Chain system, general
14.2.1. General
14.2.2. Adjusting the chain
14.2.3. Lubrication
14.2.4. Checking the chains
14.2.4.1. Noise
14.2.4.2. Surface rust
14.2.4.3. Rusty links
14.2.4.4. Stiff links

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