Service Manual en

SWE100, SWE120, SWE120S

Valid from serial number: 715612-

Order number: 220813-040

Issued: 2006-11-17 ITS

© BT Europe AB
Document revisions:

Issue date Order Changes

number
2005-03-22 220813-040 Completely new issue.
2006-03-13 220813-040 Updated chapters: M4, P2, P3, P4, 5000, 7000, 8340 (new)
2006-11-17 220813-040 Updated chapters: Maintenance (replaces P1, P2 and P3), 2550,
5000
Removed sections: 8340 (included in 5000), TruckCom (replaced
by a separate manual).

This manual covers following truck models:

T-code Model Serial number

700 SWE100 715612-
700 SWE120 715612-
701 SWE120S 715612-

© BT Europe AB Service Manual SWE100, SWE120, SWE120S

 Table of contents
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

1- Table of contents
2- Technical data ..................................................................................... 2-1
2.1 General tightening torques............................................................. 2-4
2.1.1 Galvanised, non-oiled bolts ............................................. 2-4
2.1.2 Untreated, oiled bolts ....................................................... 2-4

3- Maintenance ........................................................................................ 3-1

3.1 Safety regulations with maintenance work ..................................... 3-1
3.2 Cleaning and washing.................................................................... 3-2
3.2.1 External cleaning ............................................................. 3-3
3.2.2 Cleaning the motor compartment .................................... 3-3
3.2.3 Electrical components ..................................................... 3-3
3.3 Safe lifting ...................................................................................... 3-4
3.4 Maintenance Schedule .................................................................. 3-5
3.5 Lubrication schedule .................................................................... 3-10
3.6 Oil and grease specification ......................................................... 3-11

4- Tools ..................................................................................................... 4-1

4.1 Super Seal connectors................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.2.1 AMP Connectors, 040 series ........................................... 4-3
4.3 Molex connectors........................................................................... 4-3
4.4 Grease guns .................................................................................. 4-4
4.5 Other tools ..................................................................................... 4-5

5- Support arm chassis – 0350 ............................................................... 5-1

5.1 General .......................................................................................... 5-1
5.2 Main components........................................................................... 5-2
5.3 Maintenance .................................................................................. 5-2
5.4 Adjustment of the support arm width.............................................. 5-3
5.5 Exchange of support arms ............................................................. 5-4

6- Electric drive motor – 1760 ................................................................. 6-1

6.1 Component parts ........................................................................... 6-1
6.1.1 Dismantling of motor from truck ....................................... 6-2
6.1.2 Assembling ...................................................................... 6-2
6.2 Service/Repairs.............................................................................. 6-3
6.2.1 Dismantling of motor ........................................................ 6-3
6.2.2 Assembling of motor ........................................................ 6-4
6.2.3 Cleaning .......................................................................... 6-4
6.3 Technical data................................................................................ 6-5

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 1- 1

 Table of contents
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

7- Drive unit/gear – 2550 ......................................................................... 7-1

7.1 General .......................................................................................... 7-1
7.2 Included components..................................................................... 7-2
7.3 Disassembly of the drive unit from the truck................................... 7-4
7.4 Assembly of the drive unit in the truck............................................ 7-4
7.5 Oil inspection or changing oil ......................................................... 7-5
7.5.1 Oil inspection/replenishment ........................................... 7-5
7.5.2 Changing oil ..................................................................... 7-5
7.6 Replacing the gasket ring............................................................... 7-5
7.6.1 Disassembly .................................................................... 7-5
7.6.2 Assembly ......................................................................... 7-6
7.7 Leakage from top cover ................................................................. 7-6

8- Electro magnetic brake – 3370 ........................................................... 8-1

8.1 Main components........................................................................... 8-1
8.1.1 Serial number 570989- .................................................... 8-1
8.2 Maintenance .................................................................................. 8-2
8.2.1 Exchange of brake disc ................................................... 8-2

9- Steering – 4000 .................................................................................... 9-1

9.1 Component parts, tiller arm............................................................ 9-1
9.2 Adjustments ................................................................................... 9-2
9.2.1 Adjusting of brake microswitch ........................................ 9-2
9.3 Tiller arm handle ............................................................................ 9-3
9.3.1 Dismantling/Assembling .................................................. 9-5
Changing of signal button/switch (9, 10) ......................... 9-5
Changing of lift/lowering button (13) ................................ 9-6
Changing of pushbutton (16) ........................................... 9-6

1- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Table of contents
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10- Electrical System – 5000 ................................................................. 10-1

10.1 General ........................................................................................ 10-1
10.1.1 Software/hardware order numbers ............................... 10-1
10.1.2 Nomenclature ................................................................ 10-2
10.2 Electrical equipment overview...................................................... 10-3
10.2.1 Electric component overview ......................................... 10-5
10.3 Electrical wiring diagram .............................................................. 10-7
10.3.1 Symbol list ..................................................................... 10-7
10.3.2 Overview ........................................................................ 10-8
10.3.3 Detailed wiring diagram ................................................. 10-9
10.4 Functional description ................................................................ 10-15
10.4.1 Theory of operation ..................................................... 10-15
10.4.2 Spider expansion unit (SEU) ....................................... 10-20
10.4.3 Hour meter and battery condition ................................ 10-21
10.4.4 TLS - Truck log system (optional) ................................ 10-22
General ........................................................................ 10-22
Registration ................................................................. 10-22
Logging in/out SD16 .................................................... 10-22
Logging in/out S16 ....................................................... 10-22
Collision sensor ........................................................... 10-23
Settings ........................................................................ 10-23
10.4.5 ID unit (optional) .......................................................... 10-23
10.4.6 Built-in battery charger (optional) ................................ 10-24
Technical data ............................................................. 10-24
Charging ...................................................................... 10-25
Troubleshooting and service ....................................... 10-26
Adjusting the charger ................................................... 10-26
10.5 Parameters & adjustments......................................................... 10-28
10.5.1 General ........................................................................ 10-28
10.5.2 Displaying parameters - without the CAN service key . 10-28
10.5.3 Adjusting operator parameters -
without the CAN service key ........................................ 10-29
10.5.4 Displaying & changing parameters -
CAN service key connected ........................................ 10-29
Changing a parameter ................................................. 10-30
10.5.5 List of operator parameters ......................................... 10-31
10.5.6 Description of operator parameters ............................. 10-32
# 1 - Travel speed, Turtle button ................................. 10-32
# 2 - Maximum travel speed ........................................ 10-32
# 3 - Acceleration ......................................................... 10-32
# 4 - Neutral speed reduction ...................................... 10-32
# 5 - Logout ................................................................. 10-32
10.5.7 List of Service parameters ........................................... 10-33

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 1- 3

 Table of contents
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.5.8 Description of Service parameter ................................ 10-34

# 10 - PIN code ............................................................ 10-34
To enter a new PIN-code: ............................................ 10-34
To remove an existing PIN-code: ................................ 10-35
# 14 - Creep speed ...................................................... 10-35
#15 - Non-configurable options ................................... 10-35
Setting Non-configurable options ................................ 10-35
#16 - Configurable option #1 ....................................... 10-36
#17 - Configurable option #2 ....................................... 10-36
#18 - Configurable option #3 ....................................... 10-36
#19 - Configurable option #4 ....................................... 10-36
# 20 - Hour meter selection ......................................... 10-37
# 21 - Battery size ........................................................ 10-38
Instructions for verifying parameter setting .................. 10-39
Instructions for verifying parameter setting .................. 10-40
# 22 - Brake switch ...................................................... 10-40
# 25 - Service interval .................................................. 10-40
# 28 - Button selection ................................................. 10-40
# 39 - Login method and driver parameter access ...... 10-41
Expanded keypad - General ........................................ 10-41
Expanded keypad - Programming ............................... 10-42
10.5.9 Configurable “Option” parameters ............................... 10-44
General ........................................................................ 10-44
Parameter #16 to #19 configurable options ................. 10-45
Setting Configurable options ....................................... 10-45
10.6 Diagnostic and troubleshooting.................................................. 10-58
10.6.1 General ........................................................................ 10-58
10.6.2 Fault code history ........................................................ 10-59
10.6.3 List of fault codes ......................................................... 10-60
10.6.4 Transistor regulator troubleshooting and error codes .. 10-73
General ........................................................................ 10-73
Transistor regulator errors ........................................... 10-74
Resetting errors ........................................................... 10-75
Safety .......................................................................... 10-75
10.6.5 Built-in Test Function ................................................... 10-76
Digital inputs/outputs test mode .................................. 10-77
Transistor regulator inputs ........................................... 10-77
Transistor regulator outputs ......................................... 10-77
Digital input of logic card [A2] ...................................... 10-78
Extra functions ............................................................. 10-78
10.6.6 Display test mode ........................................................ 10-79
10.7 Technical specifications –
Curtis 1243 10-80

1- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Table of contents
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

11- Hydraulic system – 6000 ................................................................. 11-1

11.1 General ........................................................................................ 11-1
11.2 Hydraulic diagram and components............................................. 11-1
11.2.1 Main components .......................................................... 11-2
11.2.2 Description ..................................................................... 11-2
Lift .................................................................................. 11-2
Lowering ........................................................................ 11-2
Operating pressure ........................................................ 11-2
Relief valve .................................................................... 11-2
Pressure switch ............................................................. 11-3
11.3 PowerTrak cylinder ...................................................................... 11-3
11.3.1 Included components .................................................... 11-3
11.3.2 Disassembling the PowerTrak
cylinder and spring guides ............................................. 11-4

12- Lifting Mast – 7000 .......................................................................... 12-1

12.1 Grease the beam flanges and beam ribs ..................................... 12-1
12.2 Main lift chain system................................................................... 12-2
12.2.1 General .......................................................................... 12-2
12.2.2 Checking the chain setting ............................................ 12-2
12.2.3 Chain inspection ............................................................ 12-2
12.2.4 Noise ............................................................................. 12-2
12.2.5 Surface rust ................................................................... 12-2
12.2.6 Rusty links ..................................................................... 12-2
12.2.7 Stiff links ........................................................................ 12-2
12.2.8 Bolt rotation ................................................................... 12-3
12.2.9 Loose bolts .................................................................... 12-3
12.2.10 Outline wear .................................................................. 12-4
12.2.11 Stretching ...................................................................... 12-5
12.2.12 Damage ......................................................................... 12-5
12.2.13 Damaged discs .............................................................. 12-6
12.2.14 Damaged bolts .............................................................. 12-6
12.2.15 Dirty chain ...................................................................... 12-6
12.3 Cleaning....................................................................................... 12-6
12.4 Lubrication ................................................................................... 12-7

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 1- 5

 Table of contents
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

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1- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Technical data
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

2- Technical data

Model SWE100 SWE120 SWE120S

Drive motor
Type TSL140S-DS20 TSL140S-DS30 TSL140S-DS30
Output, kW 1.0 1.2 1.2
Duty cycle S2, 60 min S2, 60 min S2, 60 min
Minimum carbon brush length, mm 13 13 13
Nominal commutator diameter, mm 50 50 50
Minimum commutator diameter, mm 47 47 47
Resistance, shunt field winding, 0.55 0.55 0.55
Ω at 25 C°
Resistance armature winding, 0.0156 0.0156 0.0156
Ω at 24 °C
Insulation resistance between the >=1 Mohm >=1 Mohm >=1 Mohm
windings and motor casing
Weight, kg 14 14 14
Broms
Type BFK457-08 BFK457-08 BFK457-08
Braking force, Nm 12 12 12
Output, W 25 25 25
Resistance coil, Ω 23 23 23
Nominal play in actuated position, mm 0.2-0.4 0.2-0.4 0.2-0.4
Minimum thickness brake disc, mm 5.5 5.5 5.5
Thickness of a new brake disc, mm 7.0 7.0 7.0
Transmission/drive gear
Type 2-stage angle 2-stage angle 2-stage angle
transmission transmission transmission
Gear ratio 19,14:1 19,14:1 19,14:1
Oil volume, litre 1.0 1.0 1.0
Oil type Hypoid oil Hypoid oil Hypoid olja
at normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W SAE 75W

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 2- 1

 Technical data
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Model SWE100 SWE120 SWE120S

Wheels
Drive wheel, mm Dia 215x70 Dia 215x70 Dia 215x70
Axle pressure without load, kg 340 345 690
Axle pressure at rated load, kg 340 345 735
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm 65 Nm
Support arm wheel, mm Dia 80x95 Dia 80x95 Dia 100x75
Axle pressure without load, kg 2x 230 (240) 2x 270 (240) 2x 355(240)
Axle pressure at rated load, kg 2x 1100 (240) 2x 1350 (240) 2x 1510(240)
Support castors, mm Dia 125x40 Dia 125x40
Axle pressure without load 2x 235 (240) 2x 350 (240)
Axle pressure at rated load, kg 2x 365 (240) 2x 470 (240)
Hydraulic system
Output, kW 2.2 2.2 2.2
Duty cycle,% 5 5 5
Minimum carbon brush length, mm 12 12 12
Minimum commutator thickness/diam- 4.75 4.75 4.75
eter, mm
Pressure at rated load, bar 193 193 193
Overflow pressure, bar 210 210 210
Pump flow, litre/minute 5.0 5.0 5.0
Tank volume, litre 4.5 4.5 4.5
Oil type: Hydraulic oil Hydraulic oil Hydraulic oil
at normal temperature ISO-HM32 ISO-HM32 ISO-HM32
at temperature < -15oC ISO-VG32 ISO-VG32 ISO-VG32
Fuses
Drive motor circuits, A 125 125 125
Pump motor circuits, A 125 125 125
Control circuits, A 7,5 7,5 7.5
Battery compartment, Batteries
Dimensions LxWxH, mm, 180 Ah 196x643x452 196x643x452 196x643x452
240 Ah 196x643x572 196x643x572 196x643x572
320 Ah 244x643x572 244x643x572
Capacity, Ah 180-240 180-320 180-320
Weigh, kg 150-200 150-250 150-250

2- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Technical data
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Model SWE100 SWE120 SWE120S

Driving speed
Without load, 0-750 kg, km/h 6.0 6.0 6.0
With rated load, km/h 5.3 5.3 5.3
Lift/lowering speed
Lift without load, m/s 0.19 0.19 0.19
Lift with rated load, m/s 0.10 0.10 0.10
Lowering without load, m/s 0.15 0.15 0.15
Lowering with rated load, m/s 0.19 0,19 0,19
Power consumption
Driving without load, A 23 23 23
Driving with rated load, A 30 34 34
Lift without load, A 54 54
Lift with rated load, A 148 148
Incline climbing ability
With rated load 8% 10 % 8%
Measurement, L2
Medium 741 728 805
Long 780 857
Turning radius WA 1482 1479 1519
Weight
Truck without battery, Medium 570 727 765

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 2- 3

 Technical data
General tightening torques
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

2.1 General tightening torques

Millimetre thread M3 to M24.
The following applies under ideal conditions, e.g. steel against steel.

2.1.1 Galvanised, non-oiled bolts

Tightening torques (Nm)
Strength class:
8,8 10,9 12,9
M3 1,1 1,6 2,0
M4 2,8 3,8 4,7
M5 5,5 7,7 9,3
M6 9,5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075

2.1.2 Untreated, oiled bolts

Tightening torques (Nm)
Strength class:
8,8 10,9 12,9
M3 1,2 1,7 2,1
M4 2,9 4,0 4,9
M5 5,7 8,1 9,7
M6 9,8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120

NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will achieve the correct torque value for
galvanised bolts. Do not tighten more than the values set out in the ta-
ble, as the bolts may otherwise be destroyed.

2- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Safety regulations with maintenance work
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

3- Maintenance
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with BT’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
Day time: 08.00-17.00 (20 hr./week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use BT approved spare parts when service and repair work are
carried out.

3.1 Safety regulations with

maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 1

 Maintenance
Cleaning and washing
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal
• Disconnect the battery when welding on the truck
NOTE!
The battery can be damaged.
When welding using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

3.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery con-
nector.

3- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Cleaning and washing
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

3.2.1 External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.

3.2.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure
washing unit.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water

3.2.3 Electrical components

• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
Risk of short-circuiting.
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 3

 Maintenance
Safe lifting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

3.3 Safe lifting

All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis these can be used to obtain a well balanced lift
• Ensure that the surface under the jack is clean and free from oil and
grease
• Ensure that your hands and the jack’s lever are free from oil and
grease
• Use the lever that belongs to the jack. A lever that is too short re-
quires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded
• Support the truck:
- as close as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

3- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Maintenance Schedule
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

3.4 Maintenance Schedule

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to appli- 5 20 500 1000 3000
cation
Interval in days/weeks/months - may 1d 1w 6m 12m 36m
vary due to application
0000. Chassis
0000.1 Check all links and locking pins I
0000.2 Check wear on cover/battery locking I
0000.3 Check of cracking and damage I
0000.4 Check the drive housing’s mounting on the T
chassis
0000.5 Check finger guard I
0000.6 Check signs and stickers I
0350 Support arm
0350.1 Tightening torque inspection of the cap bolts T
(Tightening torque 120 Nm)
0380. Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
1700. Drive motor
1700.1 Check clearance in connections I/T1 I/T
1700.2 Check the carbon brushes in the drive motor M
1700.3 Clean the drive motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 5

 Maintenance
Maintenance Schedule
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to appli- 5 20 500 1000 3000
cation
Interval in days/weeks/months - may 1d 1w 6m 12m 36m
vary due to application
2550 Drive gear
2550.1 Check for leakage I3 I
2550.2 Check the oil level. Measured using the I
screwed in dipstick
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steer- I
ing bearing
2550.5 Change the oil in the drive gear L4 L
3100. Brake
3100.1 Clean and check functionality C
3100.2 Check the brake disc M
3100.3 Check the clearance in disengaged position M
0,2-0,5 mm
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tight- I/T
ening torque on bolts
(New wheel: Drive tread thickness = 30mm)
(Tightening torque = 65Nm)
3500.3 Check that the castor wheel turns and rotates I
freely
3500.4 Check for wear on the castor wheel I
(New wheel:Drive tread thickness = 10mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I

3- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Maintenance Schedule
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to appli- 5 20 500 1000 3000
cation
Interval in days/weeks/months - may 1d 1w 6m 12m 36m
vary due to application
5000 Electrical functions
5000.1 Check the function of the brake microswitch I I
5000.2 Check the function of the collision safety I
switch
5000.3 Check the function of the horn I I
5000.4 Check for wear to cables in the tiller arm I
5000.5 Check the function of the driver’s control I I
5000.6 Check the error code log and operating times I I
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the M
cell plates
5110.2 Check connections to battery, truck and I
charger
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/ C/T
T1
5400.2 Re-tighten cable connections T1
5400.3 Check the contactor points on K10 and K30 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
5700 Electronic circuit board
5700.1 Check connectors and cables TI
5700.2 Check all segments on display I

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 7

 Maintenance
Maintenance Schedule
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to appli- 5 20 500 1000 3000
cation
Interval in days/weeks/months - may 1d 1w 6m 12m 36m
vary due to application
6000 Hydraulic system
6000.1 Check hoses and connections for leakage I
6000.2 Check hoses for wear and damage I
6000.3 Check the oil tank for cracks, leakage and I
damaged mountings
6000.4 Check that the oil level is correct I I
6100.5 Change the oil and clean the filter L5 L
6600. Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
7100 Lifting Mast
7100.1 Check for damage and crack formation I
7100.2 Retighten tha mast mounting bolts T
(Tightening torque = 197Nm)
7100.3 Check the play of the inner section rollers I X
7100.4 Check the lateral play of the inner section I X
7100.5 Check for wear on the lifting chains and chain I X
rollers
7100.6 Check the adjustment of the lifting chains I X

1 = The connections are re-tightened for the first time after 500 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after 500 h/1 month to 45
Nm.
3 = Check for leakage in conjunction with the first oil change.
4 = The oil is changed for the first time after 500 h/1 month, and then
every 3000 h/36 months
5 = The oil is changed and the filter cleaned for the first time after
500 h/1 month, and then every 1000 h/12 months
When points with higher hour intervals are carried out the points with
lower hour intervals should also be carried out unless otherwise speci-
fied above.

3- 8 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Maintenance Schedule
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

7100

6600 4110

0380
5000
5700

0000

5110 3100

6000
5400

2550
3500 1700

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 9

 Maintenance
Lubrication schedule
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

3.5 Lubrication schedule

Pos no Service point Interval/Running hours Lubricant

500h 1000h 3000h
1 Wheel bearings L A
2 Mast beam L F
2 Inside surfaces of S I
beam ribs
2 Inside surfaces of S A
beam flanges
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering Bearings L G
6 Drive gear C O C

L = Lubrication C = Check O = Oil change

6 5

3- 10 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Maintenance
Oil and grease specification
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

3.6 Oil and grease specification

Table 1: Oil and grease specification

Lubricant Specification Application area
> - 15°C < - 15°C
A Grease S213366 S213366 Bearings and bushings
Q8 Rubens WB Q8 Rubens WB
A Grease 223690 223690 Inside surfaces of beam
Q8 Rembrandt EP2 Q8 Rembrandt EP2 flanges
B Hydraulic oil ISO-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease See table below See table below Chains
F Grease 055-70111 055-74320 Mast
G Grease Staburags Staburags Steering bearings
NBU 8EP NBU 8EP
I Fett Gleitmo 805 Gleitmo 805 Inside surfaces of beam
ribs

Ambient temperature Viscosity Recommended products ( Similar products

class from other manufacturers may be used)
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
Anticorit LBO 160 TT, Fuchs DEA
< + 5°C
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
Anticorit LBO 160, Fuchs DEA
< +45°C
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
<+ 80°C

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 3- 11

 Maintenance
Oil and grease specification
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

This page is intentionally left blank

3- 12 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Tools
Super Seal connectors
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

4- Tools

4.1 Super Seal connectors

3
3

Figure Number Application

159232 Tools for fitting pins/sleeves

159229 Tools for loosening locks (1)

159230 Tool for fitting secondary locks

1-2 poles (2)

159231 Tool for fitting secondary locks

3-6 poles (2)

159228 Tools for removing pins/sleeves (3)

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 4- 1

 Tools
AMP connectors
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

4.2 AMP connectors

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)

Figure Number Application

151080 (PT) Tools for removing pins/sleeves

213296 (JPT) Tools for removing pins/sleeves

213298 (MPT) Tools for removing pins/sleeves

1=163787 Tools for fitting sleeves

2=163788

1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2

1
2

4- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Tools
Molex connectors
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

4.2.1 AMP Connectors, 040 series

Figure Number Application

213130 Pin removal tool

213129 Tools for fitting pins

4.3 Molex connectors

16
9
8
1
Figure Number Application
156937 Tools for fitting pins/sleeves

156936 Tools for fitting sleeves/pins

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 4- 3

 Tools
Grease guns
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

4.4 Grease guns

Figur Nummer Användning

24981 A tool with a pointed nozzle used to
apply grease. Length 170 mm.

755132 Single-hand grease gun with straight

discharge pipe and nozzle.

755142 Two-hand grease gun with angled dis-

fif

charge pipe and nozzle.

755152 Two-hand grease gun with hose and

nozzle.

755146 Grease hose 450 mm.

Grease hose 750 mm.
Grease hose 1500 mm.

202154PM Pointed nozzle for grease guns used

to apply grease in recessed nipples.
Fits grease guns with hose and dis-
charge pipe. Length 125 mm.
755140 Nozzle for neck nipples. Fits grease
guns with hose and discharge pipe.

4- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Tools
Other tools
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

4.5 Other tools

Figure Number Application
156263 Service instrument (CAN)

1=163793 Service instrument for pro-

2=163792 gramme changes

08-13022 Driving gear puller

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 4- 5

 Tools
Other tools
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

This page is intentionally left blank

4- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Support arm chassis – 0350
General
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

5- Support arm chassis – 0350

5.1 General
NOTE! Only for SWE120S.
The truck consist of one unit built up in such a manner that the support
arm chassis and the separate mounting points for the mast and lift cyl-
inders are bolted to the drive unit.
The support arms of the straddle chassis are adjustable in width from
900 mm to 1300 mm to suit different pallet sizes. Normally the support
arms are only adjusted prior to a truck being delivered to a customer.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 5- 1

 Support arm chassis – 0350
Main components
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

5.2 Main components

5

6
3

7
2

10

9
1

Pos no Description
1 Support arm wheel axle
2 Wheel axle locking circlip
3 Support arm wheel
4 Support arm
5 Mounting bracket to drive unit chassis
6 Support arm safety catch
7 Support arm clamp
8 Support arm locking bolt
9 Lift cylinder mounting bracket
10 Mast mounting bracket

5.3 Maintenance
The fastening of the support arms needs to be checked at the regular
500 hours preventive maintenance service. The torque setting of the
support arm clamp bolts (pos no. 7 in chapter “Main components”) must
be checked with a torque wrench set at 120 Nm.

5- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Support arm chassis – 0350
Adjustment of the support arm width
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

5.4 Adjustment of the support arm

width

3
2
1

To adjust the measurement A between the support arms proceed as

follows:
• Jack up the side of the truck.
Warning!
The truck can tip over.
Do not jack up both support arms at the same time. the truck is a three
wheeler.
Jack up one side at the time and support it while working.
• Loosen the bolt at the front of the cross beam.
• Loosen the clamp bolts,2.
• Pull out (or push in) the support arm. To get the measurement A,
measure B = A/2 - 305 mm. Make sure that the measurement B is
equal on both sides.
If the support arm is pulled out too much the safety catch, 3, will drop
into the hole in the arm to stop it from falling out.
• Tighten bolt 1 and lock it with the locking nut.
• Tighten the four clamp bolts, 2, with a torque wrench. Torque value:
120 Nm.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 5- 3

 Support arm chassis – 0350
Exchange of support arms
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

5.5 Exchange of support arms

When changing a support arm the job is more extensive than adjusting
the arm width.
• Lift out the battery.
• Remove the battery box from the chassis. Two bolts at the bottom of
the box.

• Remove the safety catch from the support arm clamp.

• Jack up the side of the truck where the support arm is to be changed.
• Loosen the bolt at the front of the cross beam, 1.
2 • Loosen the clamp bolts, 2.
1 • Pull out the support arm.
• Fit the new support arm and adjust the arm width according to “Ad-
justment of the support arm width”.
• Lower the truck to the floor.
• After tightened the clamp bolts, fit the safety catch.

• Remount the battery box.

• Fit the battery.

5- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electric drive motor – 1760
Component parts
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

6- Electric drive motor – 1760

6.1 Component parts

16

21
20
14 19
18
13 17

15 10

12
11 8

7
6
5
4
3
1
2

Pos Description Note

1 Screw M6x25
2 Bearing shield
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Key
11 Plug
12 Stator
13 Cable

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 6- 1

 Electric drive motor – 1760
Component parts
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Pos Description Note

14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring

6.1.1 Dismantling of motor from truck

• Switch off the truck and pull out the battery plug.
• Remove the covers for the motor compartment.
• Release the cables for the motor and tiller arm.
• Unscrew the four nuts for the attachment of the motor to the drive
gear.
• Loosen the cables for the key switch and emergency switch. Pull out
all the cables from the cover’s cable duct.
• Loosen the cover over the motor compartment and the tiller arm’s
mounting from the motor. Remove the cover over the motor com-
partment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the sealing sur-
faces to the drive gear and place the motor on a clean surface.
• Protect the drive gear from impurities by covering over its opening in
an appropriate manner, e.g. with a piece of plastic.
The requisite service and repair of the motor can now be carried out.

6.1.2 Assembling
• Assembling is carried out in the reverse order.
• Carefully lift down the motor in the drive gear to avoid damaging the
seals and gear wheels.
• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm.
• Fit and adjust the brakes as per the instructions. Screw tight the cov-
er and tiller arm, and connect the cables that were previously re-
moved. Check that the polarity is correct.
• The function of the brakes should be checked before the truck is
moved.

6- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electric drive motor – 1760
Service/Repairs
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

6.2 Service/Repairs

6.2.1 Dismantling of motor

16

21
20
14 19
18
13 17

15 10

12
11 8

7
6
5
4
3
1
2

• Release the brake disc’s companion flange by first removing the

locking ring together with the washer in the end of the rotor shaft.
The companion flange can now be lifted off. It may be necessary to
unclamp it with an appropriate tool.
• Remove the four plugs that cover the carbon brushes, move the
springs on the carbon brushes to one side and pull out the carbon
brushes.
• Dismantle the commutator end’s bearing shield (2) together with the
carbon brush bridge (5) and carbon brushes (8) by unscrewing the
eight screws (1). Now put down the motor with a firm resting point
against the edge of the bearing shield, and carefully tap on the rotor
shaft’s end with a rubber mallet.
• Dismantle the drive end’s bearing shield (15) together with the rotor
(9). Make sure not to damage the motor windings when the rotor is
removed from the motor housing.
• After dismantling the motor’s bearing shields and removing the rotor
from the motor housing, the gear wheel in the rotor’s drive end is re-
moved. This is done by unscrewing the nuts on the gear wheel and
then pulling the gear wheel off with a puller. Note that the gear wheel
is locked with Loctite to the rotor shaft.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 6- 3

 Electric drive motor – 1760
Service/Repairs
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

• Now release the inner locking ring together with the underlying
washer. Pull out the rotor shaft from the bearing (18).
• Release the outer locking ring together with its washer, and remove
the bearing from the bearing shield.
• Remove the bearing shield’s seal (17) and carefully clean the bear-
ing shield.
• Fit a new seal in the bearing shield.

6.2.2 Assembling of motor

Assemble the motor in the reverse order.
• Carefully check that the rotor can move freely in the direction of rota-
tion and that the carbon brushes are flush with the commutator.
• Check the motor’s insulation resistance (between respective wind-
ing and the motor housing). For a new motor this should lie between
2 - 3 Mohm. When a used motor has been exposed to impurities an
insulation resistance down to approx. 1 Mohm is acceptable.
• Fit a new O-ring in the drive shaft end’s bearing shield and a new
seal on the collar of the bearing shield.

6.2.3 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum cleaner with an appropriate nozzle can be used to clean the
motor if the motor windings and inner compartment are dry Com-
pressed air can be used in combination with a vacuum cleaner. In which
case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings have a
coating. The cloth can also be moistened with a grease-dissolving,
organic and volatile detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.

6- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electric drive motor – 1760
Technical data
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

6.3 Technical data

Type of machine SWE100/120,

SWE120S
Type TSL140S-DS30
Output (kW) 1,2
Intermittence S2 60 min.
Minimum length of carbon brush (mm) 13
Minimum commutator diameter (mm) 47
Resistance, shunt field winding Ω at 25 C° 0,55
Resistance, armature winding,Ω at 24C° 0,0156
Insulation resistance between windings and >= 1Mohm
motor housing
Weight (kg) 14

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 6- 5

 Electric drive motor – 1760
Technical data
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

This page is intentionally left blank

6- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Drive unit/gear – 2550
General
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

7- Drive unit/gear – 2550

7.1 General
These service instructions cover descriptions of service performed at
the customer site. Complete reconditioning of the driving gear must be
performed in the workshop by trained technicians.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 7- 1

 Drive unit/gear – 2550
Included components
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

7.2 Included components

2
3

5
16
15
14
13

9
8

7
6

12
11
10

7- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Drive unit/gear – 2550
Included components
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Pos. Designation Note

1 Bleeder valve
2 Cover
3 Dip stick
4 Seal
5 Screw Upper cover and gear housing
Tightening torque 26.6 Nm
Secure with Loctite 242.
6 Nut Tightening torque 300 Nm
Lock with centre punch
7 Washer
8 Conical roller
bearing
9 Shims
10 Bolt Lower cover and gear housing
Tightening torque 25 Nm
Secure with Loctite 242.
11 Cover
12 Seal
13 Conical roller
bearing
14 Shims
15 Sealing
16 Drive shaft
Nuts (assembly of Tightening torque 26.6 Nm
motor - gear hous-
ing)
Wheel nuts Tightening torque 65 Nm

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 7- 3

 Drive unit/gear – 2550
Disassembly of the drive unit from the truck
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

7.3 Disassembly of the drive unit from

the truck
1. Jack up the truck until the wheel clears the floor. Support the truck
with trestles in a safe manner.
2. Disassemble the drive wheel.
3. Drain all oil from the driving gear.
4. Disconnect the motor cables.
5. Disconnect the cables to the brake.
6. Loosen and remove the drive motor bolts and lift away the drive
motor.
7. Secure the drive unit from below.
8. Loosen and remove the nuts securing the drive unit to the chassis.
9. Lower the drive unit enabling removal from under the truck.
10. Place the drive unit on a workbench or similar.

7.4 Assembly of the drive unit in the

truck
1. Lift the gear unit into place in the chassis.
2. Fit a new O-ring on the drive motor bearing cage.
3. Assemble the drive motor and gear case.
Proceed with caution to prevent damage to the O-ring.
4. Tighten the nuts to the torque indicated in the table.
Prior to assembly, apply grease on the nuts.
5. Connect the motor cables.
6. Connect the cable to the brake unit.
7. Fill the driving gear with oil.
8. Assemble the drive wheel.
Tighten the wheel nuts diagonally to the torque indicated in the ta-
ble.
9. Lower the truck to the ground and assemble the motor cover.

7- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Drive unit/gear – 2550
Oil inspection or changing oil
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

7.5 Oil inspection or changing oil

7.5.1 Oil inspection/replenishment

Inspect the oil level in the gear case according to the maintenance
chart.
1. Check the oil level in the gear case by removing the oil filling plug
on the upper part of the gear housing.
2. Fill up with oil according to the indication on the dip stick.

7.5.2 Changing oil

Change the gear case oil in accordance with the maintenance chart.
1. Drain the old oil by removing the lower cover.
Use a new seal and apply Loctite when refitting the cover.
2. Fill with oil according to the oil filling instructions.

7.6 Replacing the gasket ring

It is easiest to replace the drive shaft gasket ring when the drive unit
has been disassembled from the truck.
If oil leaks from the drive shaft, follow the instructions below.

7.6.1 Disassembly
1. Disassemble the drive unit from the truck.
2. Remove the lower cover.
3. Loosen the nut. Remove the nut and washer.
4. Press out the drive shaft.
5. Pull of the bearing from the drive shaft is a bearing remover.
6. Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing remover, then measure the to-
tal thickness of the spacing washers and replace them prior to as-
sembly.
7. Remove the gasket ring from the drive shaft.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 7- 5

 Drive unit/gear – 2550
Leakage from top cover
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

7.6.2 Assembly
Following replacement of the gasket ring, follow the instructions below.
1. Position the outer bearing of the drive shaft in the gear housing.
2. Press the new gasket ring into the gear housing.
When pressing the gasket ring into place, exercise care to make
sure it is correctly positioned.
3. Press the drive shaft into the gear.
Check to make sure the drive shaft splines interconnect with the
drive wheel splines.
4. Screw on the nut and tighten to the torque indicated in the table.
Be sure to always to use a new nut. Prior to assembly, apply
grease on the nut.
5. Before fitting the lower cover, assemble a new seal and apply Loc-
tite.
6. Replace the cover and tighten the bolts to the torque indicated in
the table.
Make sure the seal is not damaged. Prior to assembly, apply
grease on the bolts.
7. Fill with oil.
8. Assemble the drive wheel and tighten the wheel nuts diagonally to
the torque indicated in the table.
Prior to assembly, apply grease on threads.
9. Install the drive unit in the truck.

7.7 Leakage from top cover

Follow the instructions below in case of leakage from the gear case top
cover.
1. Disassemble the gear case from the truck.
2. Loosen all bolts securing the top cover to the gear housing and re-
move the cover.
3. Carefully clean the sealing surfaces of the cover and gear housing.
4. Apply Loctite on the sealing surfaces.
5. Insert the bolts in the cover and tighten the bolts to the torque indi-
cated in the table.
Prior to assembly, apply grease on the bolts.
6. Fill with oil.
7. Assemble the gear case and drive motor. Install the drive unit in the
truck.

7- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electro magnetic brake – 3370
Main components
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

8- Electro magnetic brake – 3370

8.1 Main components

8.1.1 Serial number 570989-

1 9
2
8
3

4
7

5 6

Pos No Description
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Pressure springs
6 Flange
7 Mounting bolts
8 Brake disc
9 Hub

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 8- 1

 Electro magnetic brake – 3370
Maintenance
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

8.2 Maintenance
Basically the brake is maintenance free in normal work environments.
However it is recommended according to the preventive maintenance
schedule to check the brake disc for wear.

8.2.1 Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 5,5 mm.
• Disconnect the electrical wires of the brake.
• Undo and remove the three fastening bolts.
• Loosen the brake disc from the hub and check for wear and tear. Re-
place the brake disc if the surface is unevenly worn.
• Reassemble the brake.
• Reconnect the electrical wiring.

8- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Steering – 4000
Component parts, tiller arm
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

9- Steering – 4000

9.1 Component parts, tiller arm

1

8
9

10 11

12
14 13

16
15
18 17

19

20

21
22
23

Pos Description Note

1 Screw 4
2 Washer
3 Handle
4 Screw 4
5 Washer 2

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 9- 1

 Steering – 4000
Adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Pos Description Note

6 Cable holder
7 Nut
8 Gas damper
9 Bracket
10 Stop screw
11 Screw 4
12 Ball joint
13 Screw
14 Distance
15 Bush 2
16 Damper 2
17 Axle
18 Cam
19 Distance
20 Screw
21 Distance
22 Distance
23 Switch S 10

9.2 Adjustments

9.2.1 Adjusting of brake microswitch

Switch (23) is always adjusted to its lowest position.
• Unscrew the screws (13, 20) that hold the switch and the distance.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the cam (18) in the arm’s top
and bottom position.

9- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Steering – 4000
Tiller arm handle
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

9.3 Tiller arm handle

28
29
27 26
24 14
25 14
23 22
17
21 18

20 16
19 15
14
30 14

31 13
12
10 11
32 9
8

35 33
34

5 6 7
4

1 2
3

Pos Description Note

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic circuit board
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring
16 Pushbutton Not used

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 9- 3

 Steering – 4000
Tiller arm handle
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Pos Description Note

17 Arm
18 Holder
19 Spring
20 Control switch
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control switch
30 Button for safe reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45 - 2xM5x60

9- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Steering – 4000
Tiller arm handle
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

9.3.1 Dismantling/Assembling
• Dismantle cover (2), (keyboard option).
• Remove the screws (35), hold top cover firm (7).
• Disconnect the cable connected to the electronic circuit board (4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), and place a finger between the
lower cover (33) and button (30) to hold the button (30) in place.
Assembling is carried out in the reverse order.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure to take the necessary precautions before working with the
electronics.

Changing of signal button/switch (9, 10)

• Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic circuit

board (4).
• Press out the switch from its mounting.
Assembling is carried out in the reverse order.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 9- 5

 Steering – 4000
Tiller arm handle
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Changing of lift/lowering button (13)

• Remove the button by placing a screwdriver in the hole (A) as per
the diagram below.

A A

• Unscrew the holder (18) so that the arm (12) comes loose.
Assembling is carried out in the reverse order.

Changing of pushbutton (16)

• Press the button by hand sideways.
• Place a screwdriver as per the diagram and carefully pry the button
loose.

• Unscrew the button’s holder and arm.

Assembling is carried out in the reverse order.

9- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
General
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10- Electrical System – 5000

10.1 General
The electrical system of the truck is based on the PowerDrive platform.
• The main power source is a 24 V DC traction battery.
• The travel drive motor is a separate excitation type (SEM) . The trav-
el drive motor is operated by an enclosed transistor regulator relying
on pulse width modulation (PWM) technology. The transistor regula-
tor also controls the input and output signals for truck travel and lift-
ing operations.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• All electric units communicate via a CAN bus with an IC card in the
steering unit handle. This card contains a processor and software
that controls and monitors truck functions. A set of parameters used
to adjust truck functions and characteristics is stored in the card. The
card also monitors error conditions that may occur.

10.1.1 Software/hardware order numbers

• Press and hold the horn button [S18], enter a valid PIN-code and

then press on the keypad [A17].

• Keep [S18] depressed until = the part number is

displayed.
By scrolling with [L1] you can get the following information:

• Software part number

• Hardware part number

• Hardware serial number

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 1

 Electrical System – 5000
General
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.1.2 Nomenclature
Items shown in square brackets [ ] refer to electric component designa-
tions as stated in the electrical wiring diagrams. See “10.2.1 Electric
component overview” on page 5.
{high} refers to a voltage level that is approximately the same as the
supply voltage level.
{low} refers to a voltage level of approximately 0 Volt.

10- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Electrical equipment overview
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.2 Electrical equipment overview

A2:S22 A2:S21 A2:S1-9 A2:S10-18 A2

1
10

18

A2:S17 A2:S20 A2:S19

A6

S113 S116
S112 S115
S111 S114

S18:1 S18:2
A2:S20
A2:S19
L1
A2:S22
A2:S21
A2:S17

A17

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 3

 Electrical System – 5000
Electrical equipment overview
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

S10
S21 S17

X41
F50
F51
K10

F1

A1
Y1

F3
M1

R1

K30 H1
M3

P2

Y34

Y52
P1
Y41

S42

10- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Electrical equipment overview
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.2.1 Electric component overview

The following table shows a summary of the major electric components
of this truck.

Symbol Description Function Comments

A1 Transistor regulator
A2 Electronic card
A6 Display Display of truck functions
A17 Keypad Login with PIN code Option
F1 Fuse Drive motor circuits 125 A
F3 Fuse Pump motor circuits 125 A
F50 Fuse Working circuit A5 7.5 A
F51 Fuse Working circuit A1 7.5 A
F52 Fuse Optional equipment Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor
K30 Contactor Pump motor
L1 Hall sensor Speed control and travel direction
selector (butterfly)
M1 Motor Drive motor
M3 Motor Pump motor
P2 Pressure switch Pressure switch fork lift 120 bar
R1 PTC resistance Power supply 15 Ohm
A2:S1-18 Hall sensor Speed control
S10 Inductive switch Mechanical activation of the brake Brake handle
S17 Switch Key
A2:S17 Hall sensor Emergency reversing
S18 Switch Button for horn
A2:S19 Hall sensor Fork lift (Standard)
A2:S20 Hall sensor Fork lowering (Standard)
S21 Switch Emergency switch
S111 Switch Optional button Option
S112 Switch Optional button Option
S113 Switch Optional button Option
S114 Switch Optional button Option
S115 Switch Optional button Option
S116 Switch Optional button Option

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 5

 Electrical System – 5000
Electrical equipment overview
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Symbol Description Function Comments

Y1 Electromechanical brake Mechanical brake
Y41 Solenoid valve Fork lowering
X1 Coupling Battery
X41 Connection point CAN communication (External)

10- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Electrical wiring diagram
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.3 Electrical wiring diagram

10.3.1 Symbol list

Table 2: Symbol list

Symbol Description Symbol Description
Truck battery Horn

Fuse Emergency stop switch NC

Resistor (PTC)a Switch, weight pressure oper-

ated

DC motor b(SEM type)c Sensor, inductive NO

A1 A2
M

E1 S E2

DC motor Sensor, inductive NC

Contactor Variable resistor (potentiometer)

Brake coil (normally applied) Pressure switch NO

Coil for hydraulic magnetic valve Multi-pin connector

Analogue pressure sensor NO = Normally Open

P NC = Normally closed

a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)

b. DC = Direct Current
c. SEM = Separately Excited Motor

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 7

 Electrical System – 5000
Electrical wiring diagram
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.3.2 Overview
2 1
3 F1 R1
M1
24 (+) POWER 24VDC 6 A2 A1 X1
M
40 (16) SUPPLY 24VDC ARMATURE (M)
(-) POWER 0VDC 4 S
G1

+
E2 E1
FIELD (S2)

-
5 X1
FIELD (S1)
CHARGER
40
64 K10 S170
MAIN CONTACTOR (4)
P2 F51
49
(15) FORK LOAD
A1 21
S21
p
F3

S10 M3
57 A1 A2
(12) TILLER ARM M

45
PUMP CONTACTOR (6)
K30
H1

39
SIGNAL HORN (7)
Y1
31
BRAKE RELEASE (5)
Y41
38 24
LOWER VALVE (9)

CAN HIGH/LOW
(1/8)
24

X41 F50 1
20
40 120 CHARGER
119 RED
BLACK (+) OUT. POS.
(-) OUT. NEG. A30
X9 S17 (X3:3/7) CAN HIGH/LOW
22
ONLY 40 (X3:2) +24VDC A2:S17
KEYBOARD (X3:6) 0VDC Hall F

(X2:1/2) TURTLE A2:S19 EXT. EQUIP.

Hall
(X1:1) HORN 2
S113 (X4:1) HORN 1 A2:S20
S18:2 A2 Hall
S18:1
(X4:2) A2:S1-S9 A2:S10-S18
Hall Hall
(X1:2)
(X2:1/3)
KEYBOARD DISPLAY
(X11) (X12) (X1)
A17 A6

10- 8 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 220813-040
Order number

© BT Europe AB
TRANSISTOR REGULATOR
A1

X1 G1 X1
1 + - 40
Sh. 6 - INP. POWER SUPPLY 0V DC

R1 F1
Date

2 3
+ INP. POVER SUPPLY +24V DC
130A PUMP MOTOR DRIVE MOTOR
PTC 15~E
F50 F3 M3 M1
2006-11-17

20 2 1 9 1 2 10 A1 A2 A1 A2 6
Sh. 3 M M M OUT. ARMATURE
7,5A 130A

F51 S
21 E1 E2 4
Sh. 2 S2 OUT. FIELD
7,5A

F EXTERNAL EQUIPMENT
5
S1 OUT. FIELD
715612-

Service Manual
X10 Y1 X10
24 1 2 31
Sh. 2 5 OUT. BRAKE RELEASE

S10
X10 X10
Bn Bl 57
Valid from serial number

12 INP. TILLER ARM IN DRIVE POS.

Bu

X10
40
Sh. 3
K10
A1 A2 64
4 OUT. MAIN CONTACTOR

K30
A1 A2 45

SWE100, SWE120, SWE120S

6 OUT. PUMP CONTACTOR
10.3.3 Detailed wiring diagram
T-code
700, 701

Y41
1 2 38
9 OUT. LOWER VALVE

39
7 OUT. SIGNAL HORN

H1

- +
1/6 PROD C
Electrical wiring diagram
Electrical System – 5000

218892

10- 9
 Electrical System – 5000
Electrical wiring diagram
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

INP. SUPPLY +24V DC

TRANSISTOR REGULATOR

2/6 PROD C
INP. FORK LOAD

218892
CAN HIGH

CAN LOW
16

15
A1

8
120
119
24

49
P2

p
EMERGENCY SWITCH OFF

2
S21
1

120
119
21

24
Sh. 1

Sh. 3

Sh. 3
Sh. 1 6

10- 10 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 220813-040
Order number

© BT Europe AB
Date
2006-11-17

ONLY KEY BOARD ELECTRONIC CARD TILLER ARM

A2
KEY
S17 X5 X5
20 22
Sh. 1 X3 2 INP. +24V DC
715612-

Service Manual
X5 X5
119 119
Sh. 2 X3 3 CAN HIGH

X5 X5
120 120
Sh. 2 X3 7 CAN LOW

X5 X5
40 40
Sh. 1 6 X3 6 INP. 0V DC
Valid from serial number

A2:S17
BELLY BUTTOM
X9
20 1
X41 A2:S1-S9 A2:S10-S18
1 20 40 2 SPEED REF. VALUE

SWE100, SWE120, SWE120S

40 119 3
A2:S19
T-code
700, 701

3 119 120 4 FORK LIFT

4 120 CAN CONNECTION A2:S20

FORK LOWER
CAN, SERVICE CONNECTOR

3/6 PROD C
Electrical wiring diagram
Electrical System – 5000

218892

10- 11
10- 12
DISPLAY ELECTRONIC CARD TILLER ARM
T-code
A6 A2 700, 701

X1 1 X12 1 +5V DC

X1 2 X12 2 SI

X1 3 X12 3 SCK
Electrical wiring diagram

8 8 8 8
X1 4 X12 4 ENABLE
Electrical System – 5000

715612-

X1 5 X12 5 LCLK

Service Manual
X1 6 X12 6 0V DC

S18:1
1 2
X4 1 INP. HORN 1
Valid from serial number

X4 2 OUT. 0V DC HORN 1

S18:2
1 2
X1 1 INP. HORN 2
Date

X1 2 OUT. 0V DC HORN 2
2006-11-17

S113

SWE100, SWE120, SWE120S

1 2
X2:1/2 TURTLE

X2:1/3 TURTLE
220813-040
Order number

4/6 PROD C
218892

© BT Europe AB
 Electrical System – 5000
Electrical wiring diagram
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

5/6 PROD C
218892
ELECTRONIC CARD TILLER ARM

LED_GREEN

LED_RED
2580

369#

0V DC
147-

123

456

789

-0#

X11 10
X11 1

X11 2

X11 3

X11 4

X11 5

X11 6

X11 7

X11 8

X11 9
A2

3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 13

10- 14
T-code
700, 701
OPTION
ONBOARD CHARGER
Electrical wiring diagram

START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
S170 K10
Electrical System – 5000

715612-

24 23 A1 A2 64
Sh. 2 4 OUT. MAIN CONTACTOR

Service Manual
ONBOARD CHARGER, PLUG. A/B
ONBOARD CHARGER
A30
Valid from serial number

1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE

40 (BLACK) (BLACK)
Sh. 3 - OUT. NEGATIVE CHARGER VOLTAGE

PLUG. A
Date

MAINS, VAC

PLUG. B
2006-11-17

MAINS, VAC

SWE100, SWE120, SWE120S

MAINS, EARTH
220813-040
Order number

6/6 PROD C
218892

© BT Europe AB
 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.4 Functional description

means constantly on means flashing

10.4.1 Theory of operation

This section gives basic electrical descriptions of the truck’s main func-
tions in tabular form. It describes, in simple terms, what happens when
performing any of the truck’s main operations.
• Event - The main stages in performing any of the truck’s main func-
tions are referred to as “Events”. Each event is numbered.
• Prior events - Indicates the event number which must have taken
place immediately before in order for current event function correct-
ly.
• Action(s) - A required action from the operator for the event to occur.
• Influencing elements - Conditions which must be fulfilled in order for
the event to occur. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions - Describes key occurrences which can be
checked to confirm operation.
Note that “resulting conditions” show what is expected when no error
conditions are present. Items shown in square brackets [ ] refer to elec-
trical component designations as stated in the electrical wiring dia-
grams.
Unless otherwise stated, {high} ≈ 24 V and {low} ≈ 0 V.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 15

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 3: Theory of operation

Event: 1. Battery connected
Action(s) Connect the traction battery [X1, G1].
Influencing Main power fuses ok [F1, F3] .
elements Operating circuit fuses ok [F50, F51].
PTC resistor ok [R1]
Resulting Curtis status LED blinks once every 5 seconds [A1].
conditions
Event: 2. Switch on
Prior event(s) 1
Action(s) Turn on the key [S17].
Key
Action(s)
Keypad (Option) Enter valid PIN-code and press [A17].
Influencing Emergency switch-off not activated [S21] [A1:INP.SUPPLY+24VDC] {high}.
elements Tiller in drive position sensor not activated [S10] [A1:INP.TILLER ARM IN
DRIVE POS] {low}.
Resulting
conditions Power lamp lights. Main display shows hour meter reading

and for 4 seconds followed by battery condition as a

percentage of full charge and [A6].

Mechanical brake remains on [Y1, A1:OUT.BRAKE A] {high}.
Event: 3. Tiller unit lowered for driving
Prior event(s) 2
Action(s) Lower tiller unit handle.
Influencing Tiller in drive position sensor [S10].
elements
Resulting Tiller in drive position sensor activates [S10] [A1:INP.TILLER ARM IN
conditions DRIVE POS] {low}.
Main contactor output goes {low} [A1:OUT.MAIN CONTACTOR].
Main contactor closes [K10].

10- 16 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 3: Theory of operation

Event: 4. Traction, forks first
Prior event(s) 3
Action(s) Move butterfly [L1] in forks direction.
Influencing Butterfly Hall sensors [A2:S10-18].
elements #1, #2 & #3 settings affect traction performance.
Resulting [A1:OUT.BRAKE A] goes {low}.
conditions Brake coil [Y1] energises, mechanical brake releases.
Current fed to traction motor field winding (S2 +ve and S1 -ve).
Pulsed current fed to traction motor armature proportional to butterfly
deflection.
Event: 5. Traction, drive wheel first
Prior event(s) 3
Action(s) Move butterfly [L1] in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S1-9].
elements #1, #2 & #3 settings affect traction performance.
Resulting [A1:OUT.BRAKE A] goes {low}.
conditions Brake coil [Y1] energises, mechanical brake releases.
Current fed to traction motor field winding (S2 -ve and S1 +ve).
Pulsed current fed to traction motor armature proportional to butterfly
deflection.
Event: 6. Neutral braking
Prior event(s) 4 or 5
Action(s) Let butterfly [L1] return to neutral position.
Influencing #4 setting.
elements
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy, thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery [G1]
helping to recharge it. The mechanical brake [Y1] activates when the truck
comes to a complete stand still. [A1:OUT.BRAKE A] goes {high}.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 17

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 3: Theory of operation

Event: 7. Reverse braking
Prior event(s) 4 or 5
Action(s) Move butterfly [L1] so as to reverse the direction of travel
Influencing
elements
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery help-
ing to recharge it [G1]. The braking effect increases the more the butterfly
is deflected
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck
comes to a complete stand still
Event: 8. Mechanical brake operation
Prior event(s) 4 or 5
Action(s) Move tiller unit handle to upper or lower position.
Influencing Tiller in drive position sensor [S10].
elements
Resulting Tiller in drive position sensor [S10] de-activates, [A1:INP.TILLER ARM IN
conditions DRIVE POS] {low}.
The mechanical brake [Y1] activates, [A1:OUT.BRAKE A] {high}.
Event: 9. Emergency reverse function
Prior event(s) 5
Action(s) Whilst travelling in drive wheel direction, the emergency reverse button
[A2:S17] becomes depressed.
Influencing Emergency reverse [A2:S17].
elements
Resulting Hall switch [A2:S17] is directly activated. The [A2] card interprets this signal
conditions as a command to the transistor regulator [A1] to drive the traction motor at
a reduced speed in the forks direction as long as [A2:S17] is depressed.
The normal drive command signal received from [L1] is blocked until [L1] is
released and returns to neutral position.

10- 18 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 3: Theory of operation

Event: 10. Forks lifting
Prior event(s) 2
Action(s) Press the lift forks button [A2:S19].
Influencing Main contactor [K10].
elements Fuse [F3].
Fork lift button [A2:S19].
Battery status ok (battery discharge indicator > 0 or battery charge > 20 %).
Resulting [A1:OUT.PUMP CONTACTOR] goes {low}.
conditions Pump contactor [K30] activates, pump motor [M3] starts.
Event: 11. Forks lowering
Prior event(s) 2 or 10
Action(s) Press the lower forks button [A2:S20].
Influencing Main contactor [K10].
elements Forks lower button [A2:S20].
Resulting [A1:OUT.LOWER VALVE] goes {low}, lowering hydraulic valve [Y41] acti-
conditions vates.
Event: 12. Click-2-creep (option)
Prior event(s) 2
Action(s) “Double-operate” [L1] to activate function.
Operate [L1] with tiller arm in upright position to drive truck at creep speed
(2.5 km/h).
Influencing Main contactor [K10].
elements Setting of parameter #15:0.

Resulting [A1:OUT.BRAKE A] goes {low}.

conditions Brake coil [Y1] energises, mechanical brake releases.
Current fed to traction motor field winding (S2 +ve and S1 -ve).
Pulsed current fed to traction motor armature proportional to butterfly
deflection. “SLO” displayed (flashing).
Event: 13. Turtle (option)
Prior event(s) 3
Action(s) Press [S113] to activate function.
Move butterfly [L1] in either direction.
Influencing Option button 1 [S113].
elements Setting of parameter #1 & #15:1.

Resulting [A1:OUT.BRAKE A] goes {low}.

conditions Brake coil [Y1] energises, mechanical brake releases.
Current fed to traction motor field winding (S2 +ve and S1 -ve).
Pulsed current fed to traction motor armature proportional to butterfly
deflection. Maximum speed limited by parameter #1. “SLO” displayed (con-
stantly on).

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 19

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.4.2 Spider expansion unit (SEU)

The Spider expansion unit, referred to as the SEU, allows the main con-
trol card to handle a greater number of inputs and outputs. The SEU
allows up to 8 extra digital inputs and 4 digital outputs which can be
addressed and controlled via the CAN bus. The SEU contains firmware
but this is only for internal configuration. No truck control logic is
present in the SEU. This means a faulty SEU can be exchanged with-
out affecting the truck’s functions in any way.
There are 3 cases covering the usage of SEU:
a) The SEU can be fitted if the truck is modified according to a customer
special request. In this case, correct operation of the modification is
acheived by adjustment of service parameters 16 to 19.
b) The SEU is fitted as standard in certain truck models, to allow control
of standard features. Such trucks do not require that service parame-
ters 16 to 19 be activated. (Parameters 16 to 19 shall be set to “0”.)
c) Trucks fitted with an SEU as standard can also have additional mod-
ifications using “configurable options”. These additional modifications
are controlled by the setting of service parameters 16 to 19.
Refer to section Parameter #16 to #19 configurable options on page 45
for more detailed information.
.

A2
Electronic
card

TLS
A36 Extra / Customised
A5 SEU function(s)
Steer servo
CAN bus

A3
Pump
controller

X41
CAN service
connector
A1
Traction
controller
Fig. 1 Connection architecture for SEU
Fig. 1 shows how the SEU is used to allow a greater number of func-
tions to be controlled via the CAN bus. The SEU has one 42-pin mul-
tipin connector which handles all inputs, outputs, CAN and supply sig-
nals.
10- 20 Service Manual SWE100, SWE120, SWE120S © BT Europe AB
 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.4.3 Hour meter and battery condition

At switch on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 2.
The display will then change to show the battery’s remaining capacity
Fig. 2 expressed as a percentage of full charge and the battery symbol lights.
Fig. 3.
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See “ # 20 - Hour meter selection” on
page 37). However, any of these time values can be temporarily dis-
played on the hour meter. To choose which value to display carry out
the following procedure:
Fig. 3
• Ensure the battery is connected.

• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid

PIN-code and then press on the keypad.

• Hold [S18] depressed until “H” is displayed, then release [S18]. Fig. 4

Hourmeter symbol lights.

Fig. 4
The different hourmeter modes are displayed by repeatedly operating
speed control [L1]. The actual time value will be displayed momentar-
ily after the mode is selected.

Table 4: Hour meter modes

Description Display
Key time:
Total time truck has been switched on

Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
Drive motor time:
Total time drive motor has been in operation

Pump motor time:

Total time pump motor has been in operation.

Remaining time to next service

(Parameter #25 controls the initial value) See “ # 25 - Service interval” on
page 40 for more information.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 21

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.4.4 TLS - Truck log system (optional)

General
The truck log system, which is CAN based, is either an integrated sys-
tem (SD16) or a freestanding supplementary system (S16). A collision
sensor can also be connected.
The TLS communicates wirelessly with a base station (RG3) once the
truck is within range. The base station then receives information on
what the truck has done since they last communicated with one anoth-
er.

Built-in system PC

A2 RG3
Electronic card
Add-on system
CAN bus

TLS SD16
TLS S16
CAN bus

Shock sensor
Shock sensor

A1
Traction controller I/O-unit

Registration
To register the truck with the base station, follow the instructions below:
• Position the truck close to the base station.
• Press and hold the green button for approx. 5-10 seconds until
three LEDs on the base station start flashing at the same time.
The base station can now communicate with the truck whenever it is
within range.

Logging in/out SD16

Logging in and out is performed as usual via the keyboard on the han-
dle (or by using an ID unit). The difference is that communication pass-
es through the TLS, which makes all the decisions.

Logging in/out S16

Logging in and out is performed using the keyboard on the TLS.

10- 22 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Collision sensor
If there is a collision sensor installed on the CAN bus, it registers when
the truck bumps into something. If the impact exceeds a certain level, it
is classified as a collision and the truck comes to a halt. It can be reset
by entering the PIN code for “resetting the collision sensor” (see table
below).

Settings
Additional equipment (software and wiring) from Davis Derby is
required to change the TLS settings.

Table 5: Settings TLS

Function Description Default setting
PIN code PIN code for different driver pro- 00001 (profile 1)
files. 00002 (profile 2)
00003 (profile 3)
11111 (resetting the collision sensor)
Logoff time Time in minutes (1-254) that the 255 (not switched off)
truck is inactive before it is
switched off.
Impact level Determines how sensitive the 5 % (sideways)
truck is to an impact. 5 % (forwards/backwards)
Department Only applies when ID unit is 14
installed.
Type of truck Only applies when ID unit is 16
installed.

10.4.5 ID unit (optional)

See the separate manual that is included with the software.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 23

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.4.6 Built-in battery charger (optional)

Technical data

Designation SMCI 300

Dimensions 250x115x67 mm
Weight 1,6 kg
Ambient temperature -25° C to +40° C
Line voltage 90-255 V AC, 45-400 Hz
NOTE: The charging current is
reduced in case of a line voltage
below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max. output power 800 W
Efficiency > 86%
Battery types Freely ventilated lead batteries with
water filling, Valve-regulated (VR)
lead batteries
Protection class IP 20
Other Temperature regulated cooling fan
Protected against incorrect polari-
sation.
In order for chargers on trucks with
machine numbers from 936513- to
switch on, the battery voltage must
be between 19.8 and 34.7 V.

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 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Charging
WARNING!
Please note that when charging valve-regulated batteries (Evolution
type), the SMCI300 has been designed to charge batteries that are
used in normal room temperature, i.e. +15°C to +30°C. For other tem-
peratures, the charger must be loaded with different firmware, availa-
ble from the charger dealer.
Machine number 723984-936512
The charger is designed for batteries with a capacity from approx. 100
Ah to 320 Ah.
Charging starts automatically when the charger is connected. During
charging, the status indicator lights in orange. When charging has been
completed, the status indicator switches to a green light.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.
Machine number 936513-
The charger is designed for freely ventilated batteries with a capacity
from approx. 100 Ah to 350 Ah as well as for valve-regulated batteries
with capacities of 134 Ah, 174 Ah and 201 Ah.
When connecting the charger, first the battery type is indicated. For
valve-regulated batteries, the indicator lights green for three seconds,
while for freely ventilated batteries it lights orange for three seconds.
After this, the charger setting is indicated through a number of blinks
corresponding to the selected setting (see “ Adjusting the charger” on
page 26).
Once the setting has been indicated, charging starts. During charging,
the status indicator lights in orange. When charging has been complet-
ed, the status indicator switches to a green light.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 25

 Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Troubleshooting and service

First check whether the charger indicates an error. A red blinking indi-
cator means that the charger has not detected any connected battery
or that a battery has not been set with the selection switch. Check the
switch position, cables, terminals and other battery connections. Meas-
ure the battery voltage.
If the charger still does not operate, contact the supplier for service.

Adjusting the charger

The battery size and battery type can be selected with the switch locat-
ed on the ventilation panel (C). Set the switch using a flat screwdriver.
Machine number 723984-936512

Freely ventilated batteries

Switch Battery size Output I2 current Max. current, trickle
current charging
0 No charging (red LED lit) - - -
1 100-119 Ah 22 A 5,5 A 0,6 A
2 120-144 Ah 26 A 6,6 A 0,7 A
3 145-174 Ah 30 A 8,0 A 0,8 A
4 175-209 Ah 30 A 9,6 A 1,0 A
5 210-249 Ah 30 A 11,5 A 1,2 A
6 250-299 Ah 30 A 13,7 A 1,4 A
7 300-350 Ah 30 A 16,2 A 1,6 A

Valve-regulated batteries
Switch Battery size Output I2 current Max. current, trickle
current charging
8 No charging - - -
9 300-350 Ah 30 A 3,8 A 1,6 A
A 250-299 Ah 30 A 3,4 A 1,4 A
B 210-249 Ah 30 A 2,8 A 1,2 A
C 175-209 Ah 28 A 2,4 A 1,0 A
D 145-174 Ah 22 AA 1,9 A 0,8 A
E 120-144 Ah 18 A 1,5 A 0,6 A
F 100-119 Ah 15 A 1,3 A 0,6 A

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 Electrical System – 5000
Functional description
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Machine number 936513-

Freely ventilated batteries

Switch Battery voltage Battery type Battery Indication Max. charg-
position size ing current =
I1
0 No charging - - Continuous -
red
1 24 V Freely venti- 100-119 Ah 1 blink, 22 A
lated Orange
2 24 V Freely venti- 120-144 Ah 2 blinks, 26 A
lated Orange
3 24 V Freely venti- 145-174 Ah 3 blinks, 30 A
lated Orange
4 24 V Freely venti- 175-209 Ah 4 blinks, 30 A
lated Orange
5 24 V Freely venti- 210-249 Ah 5 blinks, 30 A
lated Orange
6 24 V Freely venti- 250-299 Ah 6 blinks, 30 A
lated Orange
7 24 V Freely venti- 300-350 Ah 7 blinks, 30 A
lated Orange
8 No charging - - Continuous -
red

Valve-regulated batteries (Evolution type)

Switch Battery voltage Battery type Battery Indication Max. charg-
position size ing current =
I1
9 24 V Valve-regulated 134 Ah 1 blink, 23 A
green
A 24 V Valve-regulated 174 Ah 2 blinks, 30 A
green
B 24 V Valve-regulated 201 Ah 3 blinks, 30 A
green
C No charging - - Continuous -
red
D No charging - - Continuous -
red
E No charging - - Continuous -
red
F No charging - - Continuous -
red

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 27

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.5 Parameters & adjustments

10.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Operator parameters and Service parameters.
• Operator parameters (1 to 9) - These parameters are used to tailor
the driving characteristics of a truck for a specific operator or opera-
tion. A maximum of 10 operator parameter sets, so called operator
profiles, can be stored in a truck. Operator parameters can be ad-
justed directly without the requirement for a suitable CAN service
key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as operator parameters. Service
parameters can ONLY be adjusted when a suitable CAN service key
is plugged into the truck.2

10.5.2 Displaying parameters - without the

CAN service key
Proceed as follows to display parameters when a CAN service key is
not connected:
• Ensure the battery is connected.

• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid

PIN code and then press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
5

Parameters symbol lights.

Fig. 5
The different parameters are now displayed by repeatedly operating
speed control [L1]. Operator parameters can be both viewed and
changed.1

1.Operator parameters can only be set without a CAN key if parame-

ter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Login
method and driver parameter access on page 41.
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.5.3 Adjusting operator parameters -

without the CAN service key
NOTE!
Operator parameters can only be set without a CAN key if parameter
#39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Login meth-
od and driver parameter access on page 41.
To change the value of a particular operator parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Operator parameters
active . Any changes made will only be in effect when that particular
“operator” is logged in.
• Select the required parameter.
• Press horn button [S18].

Parameter symbol flashes. .

• Set parameter value by repeatedly operating speed control [L1] up

or down
• Press horn button [S18] once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing on the keypad.

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.

10.5.4 Displaying & changing parameters -

CAN service key connected
• Ensure the battery is connected.
• Connect a suitable CAN-service key to [X41].

• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second and then

press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
6

Fig. 6
Parameters symbol lights.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 29

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

When pressing the speed control [L1] forwards repeatedly, the first
operator profile will be displayed. Continue to press [L1] in the forward
direction and the next operator profile will be displayed (operator no. 2),
etc. until the last operator (operator no. 10). See Fig. 7
Once the 10 operator profile have been displayed, the truck service
parameters will be displayed as [L1] is repeatedly pressed in the for-
ward direction.
Operator parameter no.
Profile no. Changing a parameter
Fig. 7 • Select the required parameter.
• Press horn button [S18].

Parameter symbol flashes. .

• Set the parameter value by repeatedly operating speed control [L1]

up or down
• Press horn button [S18] once to confirm the new setting.

Parameters symbol lights. (stops flashing).

• Switch off the truck by pressing on the keypad.

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
The truck’s service parameters can be displayed first by operating
speed control [L1] in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
For detailed descriptions and effects of these parameters see the sec-
tion List of Service parameters on page 33.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.

1.Certain parameters numbers displayed are not active in this truck

model.

10- 30 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.5.5 List of operator parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying parameters - without the CAN service key on page 28
and Changing a parameter on page 30.

Parameter Description Unit Min. Max. Step Std. Description

01 Speed, Turtle % 40 100 5 60 Speed, Turtle button
button 40: slow speed
100: maximum speed.
02 Max. speed % 40 100 5 100 Max. speed
40: slow speed
100: maximum speed
03 Acceleration % 10 100 5 70 10: slow acceleration
100: maximum acceler-
ation
04 Braking in neu- % 5 100 5 50 Specifies motor braking
tral mode once the lever is put
into neutral.
5: weak braking power
100: maximum break-
ing power
05 Logout min- 0 20 1 20 The time it takes for the
utes truck to switch off when
the keypad is used. The
time counts down from
the moment the last
power-consuming unit
is used. Value = 0 gives
4 hours.
In steps of 1

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 31

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.5.6 Description of operator parameters

# 1 - Travel speed, Turtle button
The travel speed when the Turtle button is used can be adjusted.

# 2 - Maximum travel speed

The maximum travel speed can be adjusted.

# 3 - Acceleration
The lower value of the parameter the longer time it takes to accelerate
the truck to top speed.

# 4 - Neutral speed reduction

Defines motor brake force when lever [L1] goes to neutral position.The
lower value of parameter the longer time to reduce speed.

# 5 - Logout
The time until the truck will be switched off when a key pad is used.
Time is counted from when the latest power consumer is used.
Value = 0 gives 4 hours.

10- 32 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.5.7 List of Service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying & changing parameters - CAN service key connected
on page 29 and Changing a parameter on page 30.
The CAN service key must be connected to the external CAN connec-
tor [X41] before adjusting any Service parameters.

Param- Description Unit Min Max Step Std Description

eter . . .
10 PIN-code 0 9999 1 1 Facility for specifying up to 10
PIN codes (10 different drivers).
14 Creep speed -10 10 1 -5 The amount of power the moni-
tor should emit when you reach
the first speed sensor can be
specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
15 Non-config- See “ #15 - Non-configurable options” on page 35,
urable option
0 to 9
16 Configurable See “10.5.9 Configurable “Option” parameters” on page 44,
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
option
21 Battery size 1 20 1 5 Selection of battery size.
22 Brake switch 0 1 1 1 0: Mechanical switch
1: Inductive sensor
25 Service inter- hour 0 2000 50 0 Option for setting service timer
val
28 Lift button 0 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 33

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.5.8 Description of Service parameter

# 10 - PIN code
NOTE!
The functionality of parameter #10 is ignored if the value of parameter
#39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the ex-
tended keypad. For detailed information, see the section Expanded
keypad - General on page 41.
This parameter stores the active PIN-codes for the truck. The truck can
store a maximum of ten operator profiles. The operator profile is acti-
vated when the operator logs in with the assigned PIN code. Logging in
with a specific PIN code when the truck is started will activate the oper-
ator profile to which this PIN code has been assigned. This allows up to
ten operators to individually adjust the characteristics of the truck.
On delivery the truck has one default PIN-code stored which is “1“.

To enter a new PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this op-
erator.
• Repeat the step above until parameter#10 for the next operator is
displayed, the display will either show PIN-code for that operator OR
“0”(zero).
• Repeat the step above until the PIN-code displayed is “0”(zero).
• Press horn button [S18].

Parameter symbol flashes. .

• Operate [L1] to set the desired value of the new PIN-code.1

• Press horn button [S18].

Parameters symbol lights (stops flashing).

The new PIN-code has now been entered.

1.Operating [L1] lightly will step the value in increments of 1.

Operating [L1] fully will step the value in increments of 100
Valid values are 1 to 9999

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

To remove an existing PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this op-
erator.
• Repeat the step above until the PIN-code to be removed is dis-
played.
• Press horn button [S18].

Parameter symbol flashes. .

• Operate [L1] to set the PIN-code value to “0”(zero).

• Press horn button [S18].

Parameters symbol lights (stops flashing).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
2. Switch on on page 16.
Parameter #10 cannot be displayed without the CAN service key.

# 14 - Creep speed
Defines the speed you will get when you reach the first speed sensor.

#15 - Non-configurable options

See Service Manual.
Up to 16 so called sub-parameters are stored and accessed via param-
eter #15. These options are either switched ON or switched OFF and
require no other adjustments. They are therefore called non-configura-
ble options. The number of available options is dependant on the truck
type. Consult table #15 - Non-configurable options on page 35 for avail-
able options.

Setting Non-configurable options

• Ensure the truck is in the parameter mode.

The parameters symbol lights.

• Select parameter #15 using [L1].

The first sub-parameter will be displayed
Continued operation of the speed control [L1] will display the next sub-
parameter. Note also that only relevant sub-parameters will be dis-
played.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 35

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

After 1 second the value of the sub-parameter will be displayed.

• Press horn button [S18].

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control
[L1] up or down. See Table 9: for details.
• Press horn button [S18] once to confirm the new setting.

The parameters symbol lights. (stops flashing).

• Switch off the truck by pressing on the keypad.

The non-configurable option will now be activated.
• Ensure the option operates correctly before returning the truck for
normal use.
P

Table 6: Parameter #15 Non-configurable

options
Option name Value NOTE!
Sub-parameter No.

Default setting
Function OFF
Function ON

0 Click-2-creep 1 0 0
1 Turtle 1 0 0

#16 - Configurable option #1

See “10.5.9 Configurable “Option” parameters” on page 44.

#17 - Configurable option #2

See “10.5.9 Configurable “Option” parameters” on page 44.

#18 - Configurable option #3

See “10.5.9 Configurable “Option” parameters” on page 44.

#19 - Configurable option #4

See “10.5.9 Configurable “Option” parameters” on page 44.

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

# 20 - Hour meter selection

This parameter determines which hour meter mode to display during
normal use.

Table 7: Hour meter parameter selection

Value Description Display
1 Key time:
Total time truck has been switched on

2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation

4 Pump motor time:

Total time pump motor has been in operation

5 Remaining time to next service

(Parameter #25 controls the initial value)
See # 25 - Service interval on page 40

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 37

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

# 21 - Battery size
You must specify the type of battery the truck is equipped with.
In order to set the meter for the battery’s level of discharge, the follow-
ing should be taken into account:
• Acid concentration when the battery is fully charged, to check the
grade of the battery. Must be between 1.27-1.29.
• When the lifting capacity is disconnected (the battery is 80 % dis-
charged), the value must be close to, but not below, 1.14.
The acid concentration can vary depending on the battery make.
Recommendation on parameter setting for freely ventilated batteries

Parameter 21 Battery size SWE100, SWE120,

SWE120S
1
2
Less dis-
charge 3
4
5 260Ah - 320Ah
Standard value
6 190Ah - 250Ah
7 120Ah - 180Ah
8
9
10
11
12
13
14
Greater dis- 15
charge
16
17
18
19
20

WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Remove the battery from the truck and allow to rest for at least two
hours. NB! No charging or discharging during this period.
• Measure the acid weight of the battery at room temperature. If the
acid weight is less than 1.15 g/cm3, the parameter value must be
reduced. If the value significantly exceeds 1.15 g/cm3, the risk of
damage to the battery is reduced. At the same time, the operating
time of the truck is reduced. If a longer operating time is required, the
parameter value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.
Recommendation on parameter setting for valve-controlled bat-
teries (VRLA)

Parameter 21 Battery size SWE100, SWE120, SWE120S

1
2 260Ah - 320Ah
Less discharge
3 190Ah - 250Ah
4 120Ah - 180Ah
5
6
7
8
9
10
11
12
13
14
15
Greater dis- 16
charge 17
18
19
20
WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 39

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Disconnect the battery from the truck and allow the battery to rest for
at least two hours. NB! No charging or discharging during this peri-
od.
• Measure the battery voltage at room temperature. If the voltage is
less than Uend, see the table below, the parameter value must be re-
duced. If the value significantly exceeds Uend, the risk of damage to
the battery is reduced. At the same time, the operating time of the
truck is reduced. If a longer operating time is required, the parameter
value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.

Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V

# 22 - Brake switch
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1

# 25 - Service interval
Using this parameter you can specify a limit for when the next service is
to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for
a service, warning 29 (C29) is shown in the display.

# 28 - Button selection
Using this parameter you can select which button is to be used for lift/
lower.
0 = No lift/lower button activated
1 = Bottom lift/lower button activated (default)
2 = Top lift/lower button activated
3 = Both lift/lower buttons are activated

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

# 39 - Login method and driver parameter access

This parameter determines which function is to be used for login and
whether the operator can adjust the driver parameter settings.
• Value 1 – Key switch fitted – Driver parameters accessible (without
CAN service key).
• Value 2 – Key switch fitted – Driver parameters NOT accessible
(without CAN service key).
• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters acces-
sible (without CAN service key) NB! this is the original setting.
• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT
accessible (without CAN service key).
• Value 5 – Expanded keypad (100 PIN code)- Driver parameters ac-
cessible (without CAN service key)
• Value 6 – Expanded keypad (100 PIN code)- Driver parameters
NOT accessible (without CAN service key)
• Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parame-
ters accessible (without CAN service key)
• Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parame-
ters NOT accessible (without CAN service key)
• Value 9 – ID unit – Driver parameters accessible without CAN serv-
ice key.
• Value 10 – ID unit – Driver parameters NOT accessible without CAN
service key.
• Value 11 – ID unit + TLS – Driver parameters accessible without
CAN service key.
• Value 12 – ID unit + TLS – Driver parameters NOT accessible with-
out CAN service key.

Expanded keypad - General

The truck can contain a maximum of 10 individual driver profiles. The
expanded keypad function thus allows you to assign a maximum of 10
PIN codes for each of the driver profiles. This allows you to manage a
maximum of 100 unique PIN codes.
If the expanded keypad function is activated, the standard manage-
ment of PIN codes normally accessible via parameter #10 is set aside.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 41

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Expanded keypad - Programming

A number of PIN codes can be made accessible by activating the so-
called block. Block no. 0 is activated as standard. This means that 3 dif-
ferent driver profiles are available from the start. Activation of other
blocks means that all PIN codes for the block are accessible (See Table
9:). If all 10 blocks are activated, there will be 10 PIN codes available for
the driver profile.
The truck program stores a standard list of PIN codes as per Table 9:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.
To start programming the expanded keypad:
• Connect an appropriate CAN service key to [X41]

• Enter code 341671 and press on the keypad.

• Select the programming command from Table 8:

Table 8: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deacti-
Press “1” + vated. Original PIN
codes reset as per
Table 9:
PIN codes in the block can be B= Block no. 0 - 9
Press “2” + B + used
PIN codes in the block cannot B= Block no. 0 - 9
Press “3” + B + be used
Programming a new PIN code B= Block no. 0 - 9
Press “4” + B + F + NNNN + F= Driver profile no.
0-9
NNNN = PIN code

• Switch off the truck by pressing on the keypad.

The expanded keypad programming is now complete
Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN
codes to be valid.
Carry out a practical test by logging in using some of the new PIN codes. It
is important to establish that the correct driver profile has been activated
when a certain PIN code has been entered, especially if a specific driver
profile has been set for a specific application/goods handling.
Table 9: shows the PIN codes available as standard in the program. These
can be activated for use or changed according to the driver’s wishes.
One or more of these blocks can be activated.

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

A driver profile is activated, on normal login, by all PIN codes whose block
no. is activated.
The truck program does not approve login using the PIN code “0000”.
Service personnel should keep notes on activated blocks, changed PIN
codes and specially-set driver profiles.
NOTE!
Resetting the expanded keypad does NOT affect the driver profile set-
tings.

Table 9: Standard PIN code assignment with the expanded keypad

Driver 0 1 2 3 4 5 6 7 8 9
profile
no.
Block 0 0000 0001 0002 0003 0000 0000 0000 0000 0000 0000
Block 1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574
Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023
Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215
Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025
Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715
Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527
Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6067
Block 8 2876 4731 1022 5377 3257 7334 9009 7881 8843 7436
Block 9 3242 3162 5878 2828 1910 6907 2136 5730 2957 7691

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 43

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.5.9 Configurable “Option” parameters

WARNING!
The information in this section is not intended as a programming ref-
erence and is included solely to allow the reader to gain a thorough
understanding of parameter setting/checking.
Do not attempt to make any adjustments to these parameters unless
you have sufficient knowledge of the truck’s options/modified func-
tions. This manual only covers the truck’s standard equipment. Spe-
cially modified trucks may require that you have access to special
service information. Improper adjustment of the option service pa-
rameters may compromise safe operation and/or result in a malfunc-
tion.

General
Parameters #16 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parame-
ters configure and control the behavior of the Spider expansion unit
(SEU) which must be fitted in the truck. See “10.4.2 Spider expansion
unit (SEU)” on page 20. This method of implementation allows the
standard software program to be used without the need for a special-
ised software. Normally, these parameters are configured by the manu-
facturer when the truck is modified or customized. It is advisable to up-
load the parameter settings from trucks which are modified. In the event
the main control card[A2] is changed, the original parameter settings
can then be transferred to the new card thus ensuring the special option
functions correctly.
Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed “base options” to be activated and con-
figured to suit a specific special option or customisation. See table
below.

Table 10: Summary of base options

Base Function Refer to..
option no.
1 Pressing an option button controls a digital o/p table 11 on page 47
2 Activating a digital input will reduce maximum drive speed table 12 on page 48
3 Specific truck movement(s) activates a digital o/p table 13 on page 49
4 Activating a digital input causes main contactor to close table 14 on page 52
5 Activating digital inputs will operate lift /lower table 15 on page 53
6 Lift height can be restricted by activating a digital input + abil- table 16 on page 55
ity to override by pressing an option button
11 Automatic control of fork lifting/lowering. table 17 on page 56

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Parameter #16 to #19 configurable options

• Each parameter can be designated to hold a particular base option.
• Each designated option has up to 4 arguments associated with it.
• Each argument holds a value which configures that option.

Parameter no. (range 16-19)

Argument: #0 holds option designator (displayed for 2 s only)
Argument value (range 0 - 63)
0= no base option is activated for this parameter
1 to 6 = Base option no. See See separate tables)
16 - 0 - 1

OPTION ASSIGNATION

Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1

OPTION CONFIGURATION

Fig. 8 Configurable option layout

Setting Configurable options

To activate a configurable option the base option must first be assigned
to one of the parameters #16 to #19. This is achieved by setting argu-
ment #0 to the base option number. Once it is assigned, the option’s
arguments must be configured. This is achieved by setting a value for
arguments #1, #2, #3 and #4.
• Ensure the truck is in parameter mode.

Parameters symbol lights.

• Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed

After 1 second the argument’s value will be displayed. A value of “0”

indicates no option is assigned to this parameter, in which case contin-
ued operation of the speed control [L1] will display the next parameter.
• Press horn button [S18].

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 45

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Parameter symbol flashes. .

• Set argument #0 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 10:
• Press horn button [S18] once to confirm the new setting.

Parameters symbol lights (stops flashing).

• Select argument #1 by operating speed control [L1].

After 1 second the value of argument #1 will be displayed.
• Press horn button [S18].

Parameter symbol flashes..

• Set argument #1 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 10:
• Press horn button [S18] once to confirm the new setting.

Parameters symbol lights (stops flashing).

Adjust arguments #2, #3 and #4 using the same method as above.

• Switch off the truck by pressing on the keypad.

The special option shall now be activated.
• Ensure the special option operates correctly before returning the
truck for normal use.

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 11: Base option 1 - Option button controls SEU output

Argument #0 Option designator
Initial display Values Meaning
1 Sets relevant parameter to handle base option 1

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital output
Initial display Values Meaning Pin no.
0 Activate SEU digital o/p 1 (1,6A) 16
1 Activate SEU digital o/p 2 (1,6A) 30
(value shown after 2s delay) 2 Activate SEU digital o/p 3 (1,6A) 1
3 Activate SEU digital o/p 4 (1,6A) 2
Argument #3 Selection of option button
Initial display Values Meaning
1 Activated by option button 1
2 Activated by option button 2
(value shown after 2s delay) 3 Activated by option button 3
4 Activated by option button 4
5 Activated by option button 5
6 Activated by option button 6
Argument #4 Type of switching
Initial display Values Meaning
0 Activated when button is depressed
1 Option is toggled when button is pressed
(value shown after 2s delay)

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 47

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 12: Base option 2 - Reduced drive speed by SEU i/p

Argument #0 Option designator
Initial display Values Meaning
2 Sets relevant option parameter to handle base option
2
(value shown after 2s delay)
Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1[A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital input
Initial display Values Meaning Pin no.
0 Activate SEU digital i/p 1 (1mA) 5
1 Activate SEU digital i/p 2 (1mA) 19
(value shown after 2s delay) 2 Activate SEU digital i/p 3 (1mA) 33
3 Activate SEU digital i/p 4 (1mA) 6
4 Activate SEU digital i/p 5 (7mA) 20
5 Activate SEU digital i/p 6 (7mA) 34
6 Activate SEU digital i/p 7 (7mA) 7
7 Activate SEU digital i/p 8 (7mA) 21
Argument #3 Speed limitation as a percentage of max. speed
Initial display Values Meaning
0-12 Max. speed adjustable from 40-100%
formula: =40+5*Arg.3
e.g. 40+5*4=60%
(value shown after 2s delay)
Argument #4 Speed range
Initial display Values Meaning
0 Affects only high speed range
1 Affects only low speed range
(value shown after 2s delay) 2 Affects both speed ranges

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 13: Base option 3 - Truck movement activates SEU O/P

Argument #0 Option designator
Initial display Values Meaning
3 Sets relevant option parameter to handle base
option 3

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital output
Initial display Values Meaning Pin no.
0 Activate SEU digital o/p 1 (1,6A) 16
1 Activate SEU digital o/p 2 (1,6A) 30
(value shown after 2s delay) 2 Activate SEU digital o/p 3 (1,6A) 1
3 Activate SEU digital o/p 4 (1,6A) 2
...table continued on next page

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 49

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 13: Base option 3 - Truck movement activates SEU O/P

...continued from previous page
Argument #3 Selection of activating movement
Initial display Values Drive Drive Lift Lower Any
forward back- forks forks other
ward movement
1 X
(value shown after 2s delay)
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16 X
17 X X
18 X X
19 X X X
20 X X
21 X X X
22 X X X
23 X X X X
24 X X
25 X X X
26 X X X
27 X X X X
28 X X X
29 X X X X
30 X X X X
31 X X X X X
...table continued on next page

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 13: Base option 3 - Truck movement activates SEU O/P

...continued from previous page
Argument #4 Output switching mode
Initial display Values Meaning
0 Output continuously on
1 Output switches at 1Hz
(value shown after 2s delay) 2 Output switches at 2Hz

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 51

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 14: Base option 4 - Activate main contactor by SEU i/p

Argument #0 Option designator
Initial display Values Meaning
4 Sets relevant option parameter to handle base option 4

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital input
Initial display Values Meaning Pin no.
0 Activated by SEU digital i/p 1 (1mA) 5
1 Activated by SEU digital i/p 2 (1mA) 19
(value shown after 2s delay) 2 Activated by SEU digital i/p 3 (1mA) 33
3 Activated by SEU digital i/p 4 (1mA) 6
4 Activated by SEU digital i/p 5 (7mA) 20
5 Activated by SEU digital i/p 6 (7mA) 34
6 Activated by SEU digital i/p 7 (7mA) 7
7 Activated by SEU digital i/p 8 (7mA) 21
Argument #3 Hold time in minutes
Initial display Values Meaning
0-30 Contactor is held on from 0 to 30 minutes after digital
i/p is activated
(value shown after 2s delay)
Argument #4 Not used

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 15: Base option 5 - Activate lift/lower by SEU i/p

Argument #0 Option designator
Initial display Values Meaning
5 Sets relevant option parameter to handle base
option 5.

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital inputs
Initial display Values Meaning Pin no.
0 Lift - SEU digital i/p 1 5
Lower - SEU digital i/p 2 19
Lower inhibit - SEU digital i/p 3 33
(value shown after 2s delay)
1 Lift - SEU digital i/p 2 19
Lower - SEU digital i/p 3 33
Lower inhibit - SEU digital i/p 4 6
2 Lift - SEU digital i/p 3 33
Lower - SEU digital i/p 4 6
Lower inhibit - SEU digital i/p 5 20
3 Lift - SEU digital i/p 4 6
Lower - SEU digital i/p 5 20
Lower inhibit - SEU digital i/p 6 34
4 Lift - SEU digital i/p 5 20
Lower - SEU digital i/p 6 34
Lower inhibit - SEU digital i/p 7 7
5 Lift - SEU digital i/p 6 34
Lower - SEU digital i/p 7 7
Lower inhibit - SEU digital i/p 8 21
...table continued on next page

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 53

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 15: Base option 5 - Activate lift/lower by SEU i/p

...continued from previous page
Argument #3 Enable/disable lower inhibit
Initial display Values Meaning
0 Lower inhibit disabled
1 Lower inhibit enabled
(value shown after 2s delay)
Argument #4 Selection of fork / support arm
Initial display Values Meaning
0 Selects fork lift/lower
1 Selects support arm lift/lower
(value shown after 2s delay)

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 16: Base option 6 - Lift height restriction by SEU i/p &
override
Argument #0 Option designator
Initial display Values Meaning
6 Sets relevant option parameter to handle base option 6

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of SEU digital input for restriction switch
Initial display Values Meaning Pin no.
0 Activate SEU digital i/p 1 (1mA) 5
1 Activate SEU digital i/p 2 (1mA) 19
(value shown after 2s delay) 2 Activate SEU digital i/p 3 (1mA) 33
3 Activate SEU digital i/p 4 (1mA) 6
4 Activate SEU digital i/p 5 (7mA) 20
5 Activate SEU digital i/p 6 (7mA) 34
6 Activate SEU digital i/p 7 (7mA) 7
7 Activate SEU digital i/p 8 (7mA) 21
Argument #3 Selection of option button to override
Initial display Values Meaning
1 Activated by option button 1
2 Activated by option button 2
(value shown after 2s delay) 3 Activated by option button 3
4 Activated by option button 4
5 Activated by option button 5
6 Activated by option button 6
Argument #4 Not used

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 55

 Electrical System – 5000
Parameters & adjustments
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Table 17: Base option 11 - Automatic lift/lower function

Argument #0 Option designator
Initial display Values Meaning
11 Sets relevant option parameter to handle base option 11

(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
Initial display Values Meaning
0 option is handled by SEU unit 1 [A36]
1 option is handled by SEU unit 2 (second SEU unit)
(value shown after 2s delay)
Argument #2 Selection of option buttons
Initial display Values Meaning
0 No option buttons used
1 Option button 1 & 2 used (left side of handle)
(value shown after 2s delay) 2 Option button 2 & 3 used (left side of handle)
3 Option button 3 & 4 used (one on each side of handle)
4 Option button 4 & 5 used (right side of handle)
5 Option button 5 & 6 used (right side of handle)
6 Option button 1, 6, 2 & 5 used (Duplicate switches on
both sides of handle)
7 Option button 2, 5, 3 & 4 used (Duplicate switches on
both sides of handle)
...table continued on next page

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 Electrical System – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Table 17: Base option 11 - Automatic lift/lower function

...continued from previous page
Argument #3 Selection of input & output signals
Initial display Values Meaning Pin no.
0 Photocell -SEU digital i/p 1 (1 mA) 5
Lower limit -SEU digital i/p 2 (1 mA) 19
upper limit -SEU digital i/p 3 (1 mA) 33
(value shown after 2 s delay) External lift button -SEU digital i/p 4 (1 mA) 6
External lower button -SEU digital i/p 5 (7 mA) 20
Auto lamp o/p - SEU digital o/p 1 (1,6 A) 16
1 Photocell -SEU digital i/p 2 (1 mA) 19
Lower limit -SEU digital i/p 3 (1 mA) 33
upper limit -SEU digital i/p 4 (1 mA) 6
External lift button -SEU digital i/p 5 (1 mA) 20
External lower button -SEU digital i/p 6 (7 mA) 34
Auto lamp o/p - SEU digital o/p 2 (1,6 A) 30
2 Photocell -SEU digital i/p 3 (1 mA) 33
Lower limit -SEU digital i/p 4 (1 mA) 6
upper limit -SEU digital i/p 5 (1 mA) 20
External lift button -SEU digital i/p 6 (1 mA) 34
External lower button -SEU digital i/p 7 (7 mA) 7
Auto lamp o/p - SEU digital o/p 3 (1,6 A) 2
3 Photocell -SEU digital i/p 4 (1 mA) 6
Lower limit -SEU digital i/p 5 (1 mA) 20
upper limit -SEU digital i/p 6 (1 mA) 34
External lift button -SEU digital i/p 7 (1 mA) 7
External lower button -SEU digital i/p 8 (7 mA) 21
Auto lamp o/p - SEU digital o/p 4 (1,6 A) 3
Argument #4 Activation of external lift & lower buttons
Initial display Values Meaning
0 Disabled
1 Enabled
(value shown after 2 s delay)

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 57

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.6 Diagnostic and troubleshooting

10.6.1 General

means constantly on means flashing.

The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 9.
Fig. 9
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C1 to C49 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely, i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.

10- 58 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.6.2 Fault code history

Up to 50 of the most recently occurred fault codes will be stored in a log
along with the hour meter reading when the fault occurred. When the
fault code log is displayed, it shows the fault codes in chronological
order with the newest code first.
Carry out the following to display the fault code log:
• Ensure the battery is connected.

• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid

PIN-code and then press on the keypad.

• Hold [S18] depressed until “E” is displayed, then release [S18]. Fig.
10

Fig. 10 Fault symbol lights.

The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control [L1].

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 59

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.6.3 List of fault codes

NOTE!
The text “Restart the truck!” in the following tables always means
switching the truck off completely by removing the battery connector
[X1], reconnecting and then switching the truck on again.

Code C3
Description TLS: Shock sensors registered values outside
the limits
Possible error A shock sensor has reported values that exceed
cause the truck’s tolerance values.
Driving may be too hard
Check that the shock sensor’s limit values are
correctly set.
Check that the shock sensor is correctly posi-
tioned./The brake engages and stops the truck.
The TLS reset command activates the truck

Code C4
Description TLS: Use of the truck has been blocked
Possible error Truck use can be “blocked” by a TLS command. /
cause The truck cannot be used until a new TLS com-
mand cancels the blocking of the truck

10- 60 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code C19
Description Parameter caution. Displayed for 5 seconds.
Possible error The parameters have probably been changed.
cause When changing/updating the program the param-
eters have automatically been changed to default
values (only applies to old program versions).
In later program versions the parameters are only
changed if they are outside the values permitted
by the new program.
Action 1. This means that the special parameters must
be reset manually.

Code C20
Description Speed control caution.
Possible error Problem with the speed control sensors.
cause The toggle switch may have been activated when
starting or there may be a fault on one of the sen-
sors on the electronic card. (tiller arm head)
Action 1. Restart with the speed control in neutral posi-
tion.
2. Replace the electronic card.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 61

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code C28
Description Emergency switch caution
Possible error The emergency switch has been activated.
cause No current to the travel regulator, input. A1/16.
Action 1. Check fuse F51.
2. Check the emergency switch.
3. Check the cables from the battery and the bat-
tery contacts.
4. If PTC resistor R1 is very hot, remove the bat-
tery contact and allow the resistor to cool.
Restart.

Code C29
Description Service warning
Possible error Time for service.
cause The service counter has not been reset since the
last service.

10- 62 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code C41
Description Warning of low battery voltage
Possible error Battery voltage < 17 volt.
cause The battery parameters are not correctly set.
Time to charge up the battery.
Action 1. Check parameter 21, battery size and type.
2. Check the battery contact and the pole con-
nections on the battery
3. Check the key switch, S17, poor contact
causes unpermitted voltage drop.
The electrical system measures the voltage inside
the travel regulator.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 63

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code C42
Description Warning of high battery voltage
Possible error Battery voltage > 33 volt.
cause Energy return feed to battery during motor braking
with a fully-charged battery.
Action 1. The fault disappears after a few lifts, once the
battery has been run down slightly.
2. Check the cabling, the battery contact and the
contact points on main contactor K10.

Code C43
Description The travel regulator shuts off due to excess or
subnormal temperature.
Possible error Too intensive operation or ambient temperature
cause too cold.
Error in the travel regulator.
Temperature levels below -25oC or above +85oC
reduce running speed.
Action 1. Check that the M12 fan is functioning.
2. Check that the travel regulator is installed with
good contact with the chassis.

10- 64 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code C90 (Option)

Description Extra I/0 (0) CAN communication error
Possible error Data from extra I/0 box /(0) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.

Code C91 (Option)

Description Extra I/0 (1) CAN communication error
Possible error Data from extra I/0 box /(1) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.

Code C92 (Option)

Description Configuration error Extra I/0 (0)
Possible error Incorrect setting of options in the extra I/0 box (0)
cause Check the outputs’ allocation on the I/0 expansion
box (0)

Code C93 (Option)

Description Configuration error Extra I/0 (1)
Possible error Incorrect setting of options in the extra I/0 box (1)
cause Check the outputs’ allocation on the I/0 expansion
box (1)

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 65

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code E101
Description Travel regulator does not correspond with the type
of truck
Possible error Incorrect travel regulator or electronic card has
cause been installed. The truck has a built-in control
function that checks to ensure the wrong combina-
tion of travel regulator and electronic card has not
been installed.
Action Check travel regulator and electronic card.

Code E104
Description Switch-transistor to brake is short-circuited
Possible error Error in the travel regulator, output. A1/3.
cause Incorrect value on parameter 22
Action Check cabling and contacts. Measure Ohms on
the magnet coil (Y1) for the brake. Value 13-15
ohm.
Check parameter 22

10- 66 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code E106
Description Digital outputs short-circuited or exceeding field
current limit.
Possible error Problem regulating the field current.
cause Internal monitoring error.
Action 1. Check the output for main contactor K10 (A1/
4), check cabling and contacts and measure
ohms for the coil. Value 25-30 ohm. Check the
output for the brake coil K10 (A1/3), check ca-
bling and contacts and measure ohms for the
coil. Value 13-15 ohm.
2. Check the output for horn (A1/7), check ca-
bling and contacts.
3. Check the drive motor’s shunt winding and ca-
bling and contacts. Unfortunately it is not pos-
sible to measure ohms for the field winding us-
ing a standard universal instrument, since the
winding has a value as low as 0.3 ohm.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 67

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code E107
Description Contactor K10 does not close.
Possible error Problem with main contactor points or coil.
cause Contactor’s operating cabling off/not connected.
Interruption in the travel regulator’s output, A1/4.
Action 1. Check if the contactor is activated.
2. If the contactor is working, check the contact
points and accompanying cabling.
3. If the contactor is not working, check the coil
and accompanying cabling. Measure Ohms
for the coil. Value 25-30 ohm.
4. Check the travel regulator’s output, A1/4.

10- 68 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code E108
Description Contactor K10 does not open.
Possible error Main contactor points welded.
cause Short circuit in the travel regulator’s output A1/4.
Action 1. Check that the contactor’s contact points are
not welded together.
2. Check that the R1 resistor is not short-
circuited.
3. If the contact points are OK, but the contactor
engaged, check cable 64 and the travel regu-
lator’s output A1/4.

Code E110
Description System error.
Possible error Temporary error/error in the travel regulator.
cause
Action 1. Restart the machine.
2. Replace travel regulator.

Code E140
Description Error in control total.
Possible error Fault on the internal micro-monitoring (tiller arm
cause head), incorrect software or circuit board.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 69

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
Action 1. Restart the machine.
2. Download the program again.
3. Replace the electronic card
w

Code E150
Description Fault in the data communication.
Possible error Break on the CAN cable.
cause
Action 1. Check the 119 and 120 cables and their con-
tacts.
2. Replace travel regulator.

Code E151
Description Tx error in data communication.
Possible error Travel regulator not responding.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.

Code E157
Description Bus shut off.
Possible error CAN bus problem.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.
3. Replace the electronic card

10- 70 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Code E159
Description Transgression error.
Possible error CAN bus problem.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.
3. Replace the electronic card

Code E160
Description Error in safety reversing function
Possible error Error in important sensor part.
cause
Action 1. Replace the electronic card

Code E200
Description Open field.
Possible error Shunt field’s circuit open.
cause
Action 1. Check the field winding connections E1 and
E2. Unfortunately it is not possible to measure
ohms for the field winding using a standard
universal instrument, since the winding has a
value as low as 0.3 ohm.
2. Check cables 4 and 5 and outputs S1 and S2
3. Replace travel regulator

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 71

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Code E201
Description M minus error.
Possible error Problem with switch transistor in the armature cir-
cause cuit inside the travel regulator.
Action 1. Check cable and connections between A1/M
on the travel regulator and connection A2 on
drive motor.
2. Replace travel regulator.

Code E202
Description Fault on sensor in travel regulator
Possible error Fault on armature current sensor in travel regula-
cause tor
Action Replace travel regulator

Code E214
Description CAN timeout in power amplifier.
Possible error The motor monitor is reporting an unexpected
cause data loss from the electronic card in the tiller arm
head.
Action 1. Check cables 119 and 120 between electronic
card and travel regulator.
2. Replace electronic card
3. Replace travel regulator.

10- 72 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.6.4 Transistor regulator troubleshooting

and error codes

B+ M-
STATUS
MODEL VOLTAGE
SERIAL CURRENT

A1
M A2

General
Curtis 1243 is a regulator [A1] for controlling shunt motors. Varying the
voltage applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
S1 S2
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 73

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Transistor regulator errors

The table below depicts the error codes that may be shown by the STA-
TUS LED or read using the hand-held terminal.

STATUS
MODEL VOLTAGE
SERIAL CURRENT

Table 18: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator.
LED on - Defective regulator Defective regulator.
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head.
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in arma-
B- ture circuit inside motor controller.
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding specified from outputs.
or shorted field Problem to regulate field current.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shunt field open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor regu-
lator
4. Operation under extreme condi-
tions.

10- 74 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Resetting errors
To reset an error turn [S17] to off and then on again.

Error Reset when

OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLTAGE When battery voltage exceeds 16 V

Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Risk of short-circuiting.
Remove all watches, jewellery and always use insulated tools only.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 75

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.6.5 Built-in Test Function

The truck’s control system provides a number of useful built-in test
functions

• Connect CAN-key in [X41] and press [A17].

• Battery status is shown.

• Press Horn [S18] repeatedly to choose Built-in Test mode.

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!

Table 19: Built-in test modes

Mode Flashing symbol Displayed data
1 Speed reference value sent to Curtis.

2 Digital inputs/outputs can be tested. See Table

20:, Table 21: & Table 22:for more information.

3 Battery voltage (V)

4 Armature current (A)

5 Field current (A)

6 PWM Armature in %

7 Status Curtis

10- 76 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.

Transistor regulator inputs

Table 20: Transistor regulator inputs check

Segment Function
Pressure switch [P2], input A1:INP.FORK LOAD

Mechanical brake [S10], input A1:INP.TILLER

ARM IN DRIVE POSITION

Watchdog [Y1], A1:OUT.BRAKE RELEASE

(Senses whether Y1 is drawing current correctly
- should normally show the inverse of output sig-
nal)

Transistor regulator outputs

Table 21: Transistor regulator outputs

check
Segment Function
Fork lowering [Y41], output A1:OUT.LOWER
VALVE

Main contactor [K10], output A1:OUT.MAIN

CONTACTOR

Horn [H1], output A1:OUT.SIGNAL HORN

Mechanical brake [Y1], output A1:OUT.BRAKE

A

Pump contactor [K30], output A1:OUT.PUMP

CONTACTOR

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 77

 Electrical System – 5000
Diagnostic and troubleshooting
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

Digital input of logic card [A2]

Table 22: Digital input of logic card [A2]

check
Segment Function
Cabin up [A2:S19]

Cabin down [A2:S20]

Initial forks [A2:S21]

Initial forks [A2:S22]

Horn [A2:S18]

Extra functions

Table 23: Extra functions check

Segment Function
Extra function 6

Extra function 5

Extra function 4

Extra function 3

Extra function 2

Extra function 1

10- 78 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Electrical System – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

10.6.6 Display test mode

The digital display itself can be tested to verify all the segments of the
display function correctly.
To select Display test mode carry out the following procedure:
• Ensure the battery is connected.

Fig. 11 • Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid

PIN-code and then press on the keypad.

• Hold [S18] depressed until “d” is displayed, then release [S18]. Fig.
11
All number segments on the display and symbol lamps should flash
Fig. 12 sequentially. Fig. 12

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 10- 79

 Electrical System – 5000
Technical specifications – Curtis 1243
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

10.7 Technical specifications –

Curtis 1243

Value Unit Explanation

Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 150 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 20 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C

* During specific test conditions.

10- 80 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Hydraulic system – 6000
General
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

11- Hydraulic system – 6000

11.1 General
To avoid functional problems with the lowering valve, such as uninten-
tional lowering of forks, the valve must be cleaned and the function
checked before replacing the valve.

11.2 Hydraulic diagram and

components
n

C
2
B
A

D E

P F
F

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 11- 1

 Hydraulic system – 6000
Hydraulic diagram and components
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

11.2.1 Main components

Pos No Description Remark
1 Lift Cylinders Fork lift
2 Hydraulic Unit A = Non return valve
B = Lowering valve, manual
C = Lowering valve, el
D = Overflow valve
E = Flow control valve
F = Filter
M = Pump motor
P = Pump
3 Pressure switch Load >750 kg
Speed = 5,3 km/h

11.2.2 Description
Lift
When the pump motor starts, the oil flows through the non return valve
to the lift cylinders.

Lowering
When the lowering valve is actuated by the lowering lever on the chas-
sis, or the lowering button on the tiller arm, the valve opens to allow the
oil in the pressure lines to return to the oil tank. The lowering speed can
be regulated by the movement of the lowering lever on the chassis.
Lowering using the button on the tiller arm gives a constant lower
speed.

Operating pressure
The operating pressures at rated load are:
• SWE100: 150 bar.
• SWE120: 180 bar.
• SWE120S: 190 bar.

Relief valve
The relief valve opens at the following pressures:
• SWE100: 170 bar.
• SWE120: 200 bar.
• SWE120S: 210 bar.

11- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Hydraulic system – 6000
PowerTrak cylinder
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

Pressure switch
The pressure switch is used to regulate the speed and is influenced by
the load. It only has an off/on operation.
Load > 750 kg. Speed = 5,3 km/h
Load < 750 kg. Speed = 6,0 km/h

11.3 PowerTrak cylinder

11.3.1 Included components

3

2
4

Pos. Designation Notes

1 PowerTrak spring
2 PowerTrak cylinder
3 Spring guide 2 pcs.
4 Drive unit

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 11- 3

 Hydraulic system – 6000
PowerTrak cylinder
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

11.3.2 Disassembling the PowerTrak cylinder

and spring guides
Make sure the truck is unloaded and the forks have been lowered to the
1 ground.
2
3 1. Switch off the truck and disconnect the battery connector.
2. Remove the upper covers and the top cap.
3. Loosen the hydraulic hose (1).
4. Carefully loosen the screws (2) of the cap (3), which secures the
4 spring guides, in order to relieve the spring force.
5. Then completely unscrew the screws and remove the cap.
6. Lift out the PowerTrak cylinder (4).
5 7. Lift out the spring guides (5)
Reassemble in reverse.

49

The measure from washer to screw head must be 49 mm.

WARNING!
Risk of injury.
Risk of injury when working on the PowerTrak system. Because the
spring guides hold a considerable latent force, proceed with extreme
care.
Carefully follow the instructions.

11- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Lifting Mast – 7000
Grease the beam flanges and beam ribs
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

12- Lifting Mast – 7000

12.1 Grease the beam flanges and beam

ribs
Grease the inside surfaces of the beam flanges with Q8 Rembrandt
EP2 (see the lubrication chart).
Grease the inside surfaces of the beam ribs with Gleitmo 805 (see the
lubrication chart).

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 12- 1

 Lifting Mast – 7000
Main lift chain system
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

12.2 Main lift chain system

12.2.1 General
Applies to all machines with a mast.
NOTE!
On machines with T-code 407 RR B7-B8/15, 408 RR B7C-B8C/15, 413
RR E7-E8/15 and 414 RR E7C-E8C the chains should be replaced eve-
ry 2.5 years.

12.2.2 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out in
the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and 7800
as applicable.

12.2.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.

12.2.4 Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.

12.2.5 Surface rust

Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced

12.2.6 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.
The chain should be replaced.

12.2.7 Stiff links

If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.

12- 2 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Lifting Mast – 7000
Main lift chain system
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

The chain should be replaced.

12.2.8 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
.

The chain should be replaced.

12.2.9 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.

The chain should be replaced.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 12- 3

 Lifting Mast – 7000
Main lift chain system
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

12.2.10 Outline wear

H2 H3

P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.

Maximal permitted outline wear is 5% of the height H2. If a lift chain

reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

12- 4 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Lifting Mast – 7000
Main lift chain system
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

12.2.11 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain.
Measurement is suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.

Type of Nominal Minimum Pitch P Nominal chain Maximum permitted

chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295

Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is more
than 2%.

12.2.12 Damage

The chain should be replaced if damaged in any way.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 12- 5

 Lifting Mast – 7000
Cleaning
T-code Valid from serial number Date Order number
700, 701 715612- 2006-11-17 220813-040

12.2.13 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.

The chain should be replaced.

12.2.14 Damaged bolts

It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.

The chain should be replaced.

12.2.15 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.

12.3 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.

12- 6 Service Manual SWE100, SWE120, SWE120S © BT Europe AB

 Lifting Mast – 7000
Lubrication
Order number Date Valid from serial number T-code
220813-040 2006-11-17 715612- 700, 701

12.4 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubri-
cation
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
Lubrication
< + 5°C
Anticorit LBO 160 TT, Fuchs DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

© BT Europe AB Service Manual SWE100, SWE120, SWE120S 12- 7

 © BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com