BT SWE100 120 120L 120S 140 140L 200D Repair Manual – PDF DOWNLOAD
DESCRIPTION:
BT SWE100 120 120L 120S 140 140L 200D Repair Manual – PDF DOWNLOAD
Valid from serial number: 6061850-
Order number: 258946-040
General introduction
2.1 How to use the manual
The service manual is divided into chapters containing the following information:
•Functions and parameters – This chapter contains a basic description of the main functions of the truck and the control system parameters
•Installation and initial operation – This chapter describes the work that needs to be done before the truck is used for the first time
•Maintenance – This chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out
•Troubleshooting – This chapter describes the error codes that appear in the display when the truck completely or partly stops working. The chapter also describes reasons why errors occur and suggested remedies.
•Step by step – This chapter describes the various parts of the truck, for example the hydraulic system, including what the parts look like and the service activities that need to be carried out. The various descriptions are organised according to BT’s C-code system.
•Appendices – The appendices contain:
-instructions for disposal
-information about electrical components and wiring diagrams
-hydraulics diagrams
-list of required tools
-information about general tightening torques
-oil and grease specifications
-technical data.
TABLE OF CONTENTS:
BT SWE100 120 120L 120S 140 140L 200D Repair Manual – PDF DOWNLOAD
1 – Contents 3
2 – General introduction 9
2 1 How to use the manual 9
2 2 Warning symbols 10
2 3 Pictogram 10
2 3 1 Screws/nuts 10
3 – General safety rules 11
3 1 Safety while working 11
3 2 Electrical system 12
3 3 Safe lifting 13
4 – Installation 15
4 1 General 15
4 2 Battery installation 15
4 2 1 Battery installation safety 15
4 2 2 Install battery 16
4 3 Programming PIN codes 17
4 3 1 Standards for PIN codes 18
4 4 Setting the parameters 19
4 4 1 Adjusting the parameters for collision sensor (option) 20
Collision sensor parameters 105, 106 och 111 20
Programming PIN for resetting the truck 21
4 4 2 Adjusting the parameters for the battery and battery charger 21
4 4 3 Parameter 107 – battery size 23
Free ventilated batteries 23
Verifying the parameter adjustment for free ventilated batteries (Lead/acid batteries) 24
Verifying the parameter adjustment for valve controlled batteries (Hawker/Exide) 24
4 5 Function and safety check 25
5 – Maintenance 27
5 1 General 27
5 2 Service intervals 27
5 3 Maintenance schedule 28
6 – Functions and parameters 37
6 1 General 37
6 2 Function description 37
Symbols on key pads and display 38
6 3 Principle functions 39
6 4 Timer 44
6 5 Parameters 45
6 5 1 General 45
6 5 2 Show parameters 45
6 5 3 Enter the parameters 46
6 5 4 Operator parameters 47
Factory installed driver parameters 48
6 5 5 Service parameters 49
6 5 6 Factory parameters 52
7 – Troubleshooting 55
7 1 General 55
Software compatibility 55
Emergency travel mode 55
7 2 Troubleshooting methods 56
7 2 1 Troubleshooting general introduction 56
7 2 2 Completed troubleshooting 57
7 3 Error code history 58
7 4 Error code system 59
7 5 Error codes 60
7 6 Troubleshooting diagram 76
7 6 1 The truck cannot be driven 77
7 6 2 The truck can only be driven at reduced speed 78
7 6 3 The truck can be driven but behaves abnormally 79
7 6 4 The truck can be driven but lacks certain functions 79
Software compatibility 79
Matrix for hardware compatibility 80
7 6 5 Faulty hydraulic functions 81
7 7 Built-in test function 84
7 8 Status of digital inputs/outputs 85
7 8 1 Test function “9” – Transistor regulator 85
7 8 2 Test function “10” – Logic card 88
7 8 3 Test function “12” – Expansion unit SEU (optional) 89
7 9 Testing display function 90
8 – Chassis 0000 91
8 1 Support arm 0350 91
8 1 1 Support arm lift, lateral adjustment 91
8 1 2 Adjusting the kneeling movement 92
8 2 Motor fixing points 0450 93
8 2 1 Replacing springs (not applicable for SWE120S) 93
8 3 Removing the platform 95
9 – Electrical drive motor 1700 97
9 1 Components 97
9 2 Disassemble engine and truck 98
9 3 Tightening torque Drive motor 100
9 4 Fitting the tempreature sensor 100
9 5 Cleaning 101
10 – Drive gear 2550 103
10 1 General 103
10 2 Components 103
10 3 Removing the gear from the truck (not applicable for SWE120S) 104
10 4 Removing the gear from the truck (not applicable for SWE120S) 106
11 – Brake 3180 107
11 1 Components 107
11 2 Release of brakes 108
12 – Drive wheel 3530 109
12 1 Changing drive wheel 109
13 – Castor wheel 3540 111
13 1 Components 111
13 2 Changing castor wheel 112
14 – Support arm wheel 3550 113
15 – Tiller arm 4000 115
15 1 Components in tiller arm 115
15 2 Removing tiller arm 116
15 3 Changing gas spring 116
15 4 Changing the safety sensor 117
15 4 1 Dismantling 117
15 4 2 Assembly 117
15 5 Components in tiller arm handle 118
15 5 1 Removing the tiller arm handle 119
15 5 2 Replacing the logic card 119
15 5 3 Changing signal button/switch 120
15 5 4 Changing raising/lowering button 121
15 5 5 Changing push button 121
15 5 6 Changing the position of the controls – support arm lift/fork lift 122
15 5 7 Changing a switch for safety reversing 123
16 – Electrical components 125
16 1 Changing wiring harness 125
16 1 1 Changing the transistor regulator’s wiring harness 126
16 2 Replacing the transistor regulator 127
17 – Hydraulic system 6000 129
17 1 General 129
17 2 Hygiene when working on hydraulics 130
17 2 1 Washing 130
17 2 2 Packaging 130
17 2 3 Handling 130
17 2 4 Storage 131
17 2 5 Carrying out work 131
17 3 Hydraulic unit 6100 132
17 3 1 Emptying the hydraulic tank 133
17 3 2 Hydraulic system, bleeding 133
Cylinders with bleeding valve 133
Cylinders without bleeding valve 133
17 4 Hydraulic connections 6230 134
17 4 1 Quick change connector 134
Assembling the quick change connector 134
Dismantling the quick change connector 135
17 5 Hydraulic calibration 136
17 6 Adjustment of the pressure limit valve 137
17 7 Disassembling the hydraulic unit 139
17 8 Hydraulic unit tightening torques 141
18 – Lift mast – 7000 143
18 1 Main mast 7100 143
18 1 1 Components 143
18 1 2 Maintenance 144
Mounting 144
Lubrication 144
18 2 Fork carriage 7420 145
18 2 1 Maintenance 145
18 3 Main lift chain system 7120 146
18 3 1 Checking the chain setting 146
18 3 2 Inspecting the chain 146
Noise 146
Surface rust 146
Rusty links 146
Stiff links 146
Bolt rotation 147
Loose bolts 147
Plate wear 147
Elongation 148
Damage 149
Damaged plates 149
Damaged bolts 149
Dirty chain 149
18 3 3 Cleaning 149
18 3 4 Lubrication 150
18 4 Changing the fork-lift trolley 151
18 5 Changing the stand 153
19 – Accessories 157
19 1 Spider expansion unit 157
19 2 TLS – Truck log system 158
19 3 ID unit 158
19 4 Toyota Wireless Information System T W I S 158
19 5 Built-in battery charger 159
19 5 1 Technical data 159
19 5 2 Battery charging 160
Main charge 160
Uneven charging 160
Charging complete 160
20 – Appendices 161
20 1 General 161
21 – Technical data 163
21 1 SWE100, SWE120, SWE140 163
21 2 SWE120L, SWE140L, SWE200D 166
21 3 SWE120S 169
21 4 Overflow pressure for the mast 172
22 – General tightening torque 173
22 1 General 173
22 2 Galvanised non-oiled bolts 173
22 3 Untreated, oiled bolts 173
23 – Tools 175
23 1 MQS contacts 175
23 2 AMP contacts 177
23 2 1 AMP contacts Multilock series 040 178
23 3 Molex contacts 178
23 4 Grease guns 179
23 5 Other tools 180
24 – Oil and grease specification 181
25 – Electrical components and wiring diagram 183
25 1 Electrical components 183
25 2 Wiring diagram 187
25 2 1 Index of symbols 187
25 2 2 Overview diagram 188
25 2 3 Wiring diagram 189
26 – Hydraulics chart 201
27 – Instructions for disposal 203
27 1 General 203
27 2 Marking of plastics 203
27 2 1 General marking of products and packaging 203
27 2 2 Marking to BT Standard 204
Abbreviations 204
Example of marking 204
27 3 Pressure vessels 205
27 3 1 Gas damper 205
27 4 Sorting categories 206
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V