Repair manual en

SWE100, 120, 120L, 120S, 140, 140L, 200D

Applies from serial number: 6061850-

Order number: 258946-120

Issued: 2012-08-30 TP

© BT Industries AB

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Document revisions:

Publishin Order Amendments

g date: number
2008-08-25 258946-XXX Completely new issue.
2008-11-24 258946-XXX Updated with SWE120S
2009-04-17 258946-XXX Updated
2009-10-05 258946-XXX Chapter 4.4 New table and adjustment to text in chapter
Chapter 5.3 Action added to "Maintenance schedule for masts"
Chapter 6 Text and value changes
Chapter 7 Text and value changes
Chapter 8.1 section "8.1.2 Adjusting the kneeling movement" added
Chapter 9.3 "Tightening torques drive motor" added
Chapter 15 New descriptions concerning repairs of tiller arm
Chapter 17 New text concerning clean hydraulics
Chapter 17 "Tightening torques hydraulic unit" added
Chapter 23 Updated with new tool
Table "21.4 Overflow pressure mast" added
Various minor corrections throughout entire document
2012-08-30 258946-XXX Chapter 5 Maintenance
- 5.3 - Maintenance schedule updated 3180 brakes
Chapter 6 Function and Parameters
- 6.5.5 - Service parameters 204-206 added
- 6.5.6 - Factory parameters 1024 added
Chapter 8 Chassis
- 8.2.1 - Replacement springs updated
Chapter 11 Brakes
- 11.1 - Components updated
- 11.3, 11.4 - Mounting dust shields new sections
Chapter 14 Tiller arm
- 14.5 - Electrical control system updated
Chapter 18 Lifting mast
- 18.5 - Replacement of the mast updated
- 18.6 - Adjustment mast new section
Chapter 25 Electrical components and wiring diagrams
- 25.2.3 - Wiring diagram updated

This manual contains information on the following trucks:

T-Code Model: Serial number

841 SWE100
841 SWE120
842 SWE120L
841 SWE140
842 SWE140L
842 SWE200D
843 SWE120S

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D

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 Contents
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

1 – Contents
2 – General introduction .......................................................................... 2-1
2.1 How to use this manual .................................................................. 2-1
2.2 Warning symbols ............................................................................ 2-2
2.3 Pictograms ..................................................................................... 2-2
2.3.1 Screws/Nuts ..................................................................... 2-2

3 – General safety rules ........................................................................... 3-1

3.1 Safety while working....................................................................... 3-1
3.2 Electrical system............................................................................. 3-2
3.3 Safe lifting....................................................................................... 3-3

4 – Installation .......................................................................................... 4-1

4.1 General........................................................................................... 4-1
4.2 Battery installation .......................................................................... 4-1
4.2.1 Battery installation safety ................................................. 4-1
4.2.2 Install battery .................................................................... 4-2
4.3 Programming PIN codes ................................................................ 4-3
4.3.1 Standards for PIN codes .................................................. 4-4
4.4 Setting the parameters ................................................................... 4-5
4.4.1 Adjusting the parameters for collision sensor (option) ..... 4-6
Collision sensor parameters 105, 106 och 111 ................ 4-6
Programming PIN for resetting the truck .......................... 4-7
4.4.2 Adjusting the parameters for the battery and
battery charger 4-7
4.4.3 Parameter 107 - battery size ............................................ 4-9
Free ventilated batteries ................................................... 4-9
Verifying the parameter adjustment for free ventilated
batteries (Lead/acid batteries) ........................................ 4-10
Verifying the parameter adjustment for valve controlled
batteries (Hawker/Exide) ................................................ 4-10
4.5 Function and safety check ............................................................ 4-11

5 – Maintenance ....................................................................................... 5-1

5.1 General........................................................................................... 5-1
5.2 Service intervals ............................................................................. 5-1
5.3 Maintenance schedule.................................................................... 5-1

6 – Functions and parameters ................................................................ 6-1

6.1 General........................................................................................... 6-1
6.2 Function description ....................................................................... 6-1
Symbols on keypad and display ....................................... 6-2
6.3 Operating principle ......................................................................... 6-3
6.4 Hour meter...................................................................................... 6-8
6.5 Parameters..................................................................................... 6-9
6.5.1 General ............................................................................ 6-9
6.5.2 Show parameters ............................................................. 6-9
6.5.3 Setting the parameters ................................................... 6-10
6.5.4 Operator parameters ...................................................... 6-11
Factory pre-set operator parameters ............................. 6-12
6.5.5 Service parameters ........................................................ 6-13

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Contents
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

6.5.6 Factory parameters ....................................................... 6-17

* Matrix for hardware/software compatibility .................. 6-19

7 – Troubleshooting ................................................................................ 7-1

7.1 General .......................................................................................... 7-1
Software compatibility ...................................................... 7-1
7.1 Emergency travel mode ................................................................. 7-1
7.2 Troubleshooting methods .............................................................. 7-2
7.2.1 General initial troubleshooting ......................................... 7-2
7.2.2 Concluding troubleshooting ............................................. 7-3
7.3 Error code history........................................................................... 7-4
7.4 Error code system .......................................................................... 7-5
7.5 Error codes .................................................................................... 7-6
7.6 Troubleshooting chart .................................................................. 7-23
7.6.1 The truck cannot be driven. ........................................... 7-24
7.6.2 Truck only travels at reduced speed .............................. 7-25
7.6.3 The truck can be driven but behaves abnormally .......... 7-26
7.6.4 The truck travels, but some functions do not work. ....... 7-27
Software compatibility .................................................... 7-27
Hardware compatibility matrix ....................................... 7-27
7.6.5 Defective hydraulic functions ......................................... 7-28
7.7 Built-in test function...................................................................... 7-31
7.8 Digital input/output status............................................................. 7-32
7.8.1 Test function “9” – Transistor regulator ......................... 7-32
7.8.2 Test function “10” – Logic card ...................................... 7-35
7.8.3 Test function “12” – Expansion unit SEU (option). ........ 7-36
7.9 Test function for the display ......................................................... 7-37

8 – Chassis 0000 ...................................................................................... 8-1

8.1 Support arm 0350 .......................................................................... 8-1
8.1.1 Support arm lift, lateral adjustment ................................. 8-1
8.1.2 Adjusting the kneeling action ........................................... 8-2
8.2 Motor mounts 0450 ........................................................................ 8-3
8.2.1 Replacing springs (not applicable for SWE120S) ............ 8-3
8.3 Disassembling the platform............................................................ 8-5

9 – Electric drive motor 1700 .................................................................. 9-1

9.1 Components .................................................................................. 9-1
9.2 Disassemble the motor from the truck............................................ 9-2
9.3 Tightening torques – Drive motor ................................................... 9-5
9.4 Installing the temperature sensor................................................... 9-5
9.5 Cleaning......................................................................................... 9-6

10 – Drive gear 2550 .............................................................................. 10-1

10.1 General ........................................................................................ 10-1
10.2 Components ................................................................................ 10-1
10.3 Removing the gear from the truck (not applicable for SWE120S) 10-2
10.4 Removing the gear from the truck (not applicable for SWE120S) 10-4

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 Contents
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

11 – Brakes 3180 .................................................................................... 11-1

11.1 Components ................................................................................. 11-1
11.2 Releasing the brake...................................................................... 11-2
11.3 Installing the dust shield ............................................................... 11-3
11.4 Installing the dust shield ............................................................... 11-5

12 – Drive wheel 3530 ............................................................................ 12-1

12.1 Replacing the drive wheel............................................................. 12-1

13 – Castor wheels 3540 ........................................................................ 13-1

13.1 Components ................................................................................. 13-1
13.2 Replacing the castor wheel........................................................... 13-2

14 – Support arm wheel 3550 ................................................................ 14-1

15 – Tiller arm 4000 ................................................................................ 15-1

15.1 Tiller arm components .................................................................. 15-1
15.2 Disassembling the tiller arm.......................................................... 15-2
15.3 Replacing the gas strut ................................................................. 15-2
15.4 Replacing the safety sensor ......................................................... 15-3
15.4.1 Dismantling .................................................................... 15-3
15.4.2 Installation ...................................................................... 15-3
15.5 Electrical steering system – 4000 ................................................. 15-4
15.5.1 Tiller arm handle C4110 ................................................. 15-4
15.5.2 Components of the tiller arm handle (new model) ......... 15-4
15.5.3 Components of the tiller arm handle (old model) ........... 15-6
15.5.4 Disassembly/assembly of tiller arm handle .................... 15-8
15.5.5 Replacing the horn button/switch ................................. 15-11
15.5.6 Replacement of lift/lower button ................................... 15-11
15.5.7 Replacing the button .................................................... 15-12
15.5.8 Changing the position of the controls -
support arm lift / fork lift ................................................ 15-13
15.5.9 Replacing the safety reversal switch ............................ 15-14

16 – Electrical components ................................................................... 16-1

16.1 Replacing the wiring harness........................................................ 16-1
16.1.1 Replacing the transistor regulator cables ....................... 16-2
16.2 Replacing the transistor regulator................................................. 16-3

17 – Hydraulic system 6000 .................................................................. 17-1

17.1 General......................................................................................... 17-1
17.2 Hygiene when working on hydraulics ........................................... 17-2
17.2.1 Washing ......................................................................... 17-2
17.2.2 Packaging ...................................................................... 17-2
17.2.3 Handling ......................................................................... 17-2
17.2.4 Storage ........................................................................... 17-3
17.2.5 Carrying out work ........................................................... 17-3
17.3 Hydraulic unit 6100....................................................................... 17-4
17.3.1 Emptying the hydraulic tank ........................................... 17-5
17.3.2 Hydraulic system, bleeding ............................................ 17-5
Cylinders with bleeding valve ......................................... 17-5
Cylinders without bleeding valve .................................... 17-5
17.4 Hydraulic connections 6230 ......................................................... 17-6

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Contents
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

17.4.1 Quick change connector ................................................ 17-6

Assembling the quick change connector ....................... 17-6
Dismantling the quick change connector ....................... 17-7
17.5 Hydraulic calibration..................................................................... 17-8
17.6 Adjustment of the pressure limit valve.......................................... 17-9
17.7 Disassembling the hydraulic unit................................................ 17-11
17.8 Hydraulic unit tightening torques................................................ 17-13

18 – Lift mast – 7000 .............................................................................. 18-1

18.1 Main mast 7100 ........................................................................... 18-1
18.1.1 Components .................................................................. 18-1
18.1.2 Maintenance .................................................................. 18-2
Fixing point .................................................................... 18-2
Lubrication ..................................................................... 18-2
18.2 Fork carriage 7420 ....................................................................... 18-3
18.2.1 Maintenance .................................................................. 18-3
....................................................................................... 18-3
18.3 Main lift chain system 7120 .......................................................... 18-4
18.3.1 Checking the chain setting ............................................ 18-4
18.3.2 Chain inspection ............................................................ 18-4
Noise ............................................................................. 18-4
Surface rust ................................................................... 18-4
Rusty links ..................................................................... 18-4
Stiff links ........................................................................ 18-4
Bolt rotation ................................................................... 18-5
Loose bolts .................................................................... 18-5
Outline wear .................................................................. 18-5
Stretching ...................................................................... 18-6
Damage ......................................................................... 18-7
Damaged discs .............................................................. 18-7
Damaged bolts .............................................................. 18-7
Dirty chain ...................................................................... 18-7
18.3.3 Cleaning ........................................................................ 18-7
18.3.4 Lubrication ..................................................................... 18-8
18.4 Replacing the fork carriage .......................................................... 18-9
18.5 Replacement of the mast ........................................................... 18-11
18.6 Adjusting the mast ..................................................................... 18-15

19 – Accessories ................................................................................... 19-1

19.1 Spider expansion unit .................................................................. 19-1
19.2 TLS - Truck log system ................................................................ 19-2
19.3 ID unit........................................................................................... 19-2
19.4 Toyota Wireless Information System (T.W.I.S.) ........................... 19-2
19.5 Built-in battery charger ................................................................. 19-3
19.5.1 Technical data ............................................................... 19-3
19.5.2 Charging the battery ...................................................... 19-4
Main charging ................................................................ 19-4
Equalising charging ....................................................... 19-4
Charging completed ...................................................... 19-4

20 – Appendices .................................................................................... 20-1

20.1 General ........................................................................................ 20-1

21 – Technical data ............................................................................... 21-1

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 Contents
Order no.. Date Valid from serial no. T code
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21.1 SWE100, SWE120, SWE140 ....................................................... 21-1

21.2 SWE120L, SWE140L, SWE200D ................................................ 21-4
21.3 SWE120S..................................................................................... 21-7
21.4 Overflow pressure for the mast................................................... 21-10

22 – General tightening torque ............................................................. 22-1

22.1 General......................................................................................... 22-1
22.2 Galvanised non-oiled bolts ........................................................... 22-1
22.3 Untreated, oiled bolts.................................................................... 22-1

23 – Tools ............................................................................................... 23-1

23.1 MQS connectors........................................................................... 23-1
23.2 AMP connectors ........................................................................... 23-3
23.2.1 AMP connectors, Multilock series 040 ........................... 23-4
23.3 Molex connectors ......................................................................... 23-4
23.4 Grease guns ................................................................................. 23-5
23.5 Other tools .................................................................................... 23-6

24 – Oil and grease specification ......................................................... 24-1

25 – Electrical components and wiring diagrams ............................... 25-1

25.1 Electrical components .................................................................. 25-1
25.2 Wiring diagram ............................................................................. 25-5
25.2.1 List of symbols ............................................................... 25-5
25.2.2 General wiring diagram .................................................. 25-6
25.2.3 Wiring diagram ............................................................... 25-7

26 – Hydraulics chart ............................................................................. 26-1

27 – Instructions for disposal ............................................................... 27-1

27.1 General......................................................................................... 27-1
27.2 Marking of plastics........................................................................ 27-1
27.2.1 General marking of products and packaging ................. 27-1
27.2.2 Markings according to Standard .................................... 27-2
Abbreviations ................................................................. 27-2
Marking examples .......................................................... 27-2
27.3 Pressure vessels .......................................................................... 27-3
27.3.1 Gas struts ....................................................................... 27-3
27.4 Sorting categories......................................................................... 27-4

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Contents
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 General introduction
How to use this manual
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

2 – General introduction

2.1 How to use this manual

This service manual is divided into chapters to provide the following
information:
• Function and Parameters – This chapter provides basic descriptions
of the truck's main functions together with the controller system
parameters
• Installation and Commissioning – This chapter describes the work
that is necessary for commissioning of the truck
• Maintenance – This chapter contains a general periodic
maintenance schedule and a detailed description of the
maintenance to be carried out
• Troubleshooting – The troubleshooting chapter describes the error
codes that are displayed when the truck is partially or completely out
of service. It also describes the cause of the problem and suggests
remedies.
• Service Actions– This chapter describes the different parts of the
truck, e.g. the hydraulic system, descriptions of components and the
service actions that need to be carried out. These descriptions are
divided according to the C code system of the truck manufacturer.
• Appendices - The appendices include:
- Instructions for disposal
- Information about electrical components and wiring diagrams
- Hydraulics diagram
- List of required tools
- Information about general tightening torques
- Specifications for oil and grease
- Technical data

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General introduction
Warning symbols
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

2.2 Warning symbols

The following warning symbols are used throughout the service
manual:
DANGER!
DANGER! means there is a risk of accident potentially leading to
death or serious injury and material loss or damage. This is always
indicated by the warning symbol.
WARNING!
WARNING! means that there is a risk of damage to components that
are sensitive to electrostatic discharge.
Heed applicable ESD safety precautions.
Note:
Note: means there is a risk of material loss or damage if the
instructions are not followed. It is also used to call for attention to
various points.

2.3 Pictograms

2.3.1 Screws/Nuts
Wherever possible, pictograms have been used to describe certain
work operations.
Pictograms are primarily used for operations that require loosening or
tightening of screws:

×n
s mm
The pictograms contain information about the screw head type and
have arrows that show if the screw should be loosened or tightened.
The text below the pictograms provide additional information, such as:
‘s’: spanner size, ‘n’: number of screws and, where required, ‘T’: the
recommended tightening torque.

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 General safety rules
Safety while working
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

3 – General safety rules

Only persons trained in servicing and repairing this type of truck are
qualified to carry out servicing and repair work.

3.1 Safety while working

To ensure that you work safely and to prevent accidents while working
on a truck, remember the following:
• keep the area where servicing activities are performed clean. Oil or
water will make the floor slippery.
• use the correct working position. Service activities often involve
kneeling or bending forward. Try sitting on a toolbox, for example, to
relieve the strain on your knees and back.
• loose articles and jewellery may become trapped in the moving parts
of the truck. Never wear loose articles or jewellery while working on
the truck.
• use well maintained tools that are intended for the work being
carried out.
• store and transport old oil according to applicable local regulations.
• do not flush solvents or similar that have been used for cleaning
down drains that are not intended for this purpose. Follow the local
disposal regulations.
• heated paint gives off harmful gases. Therefore remove the paint at
least 100 mm around the welding/grinding area using sanding
equipment or paint remover when welding or grinding a painted
area.

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General safety rules
Electrical system
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

3.2 Electrical system

When working on the electrical system of the truck, remember the
following:
• a short circuit may occur if metal objects come into contact with live
electrical connections. This can result in burns. Remove watches,
rings and other metal jewellery before starting work.
• always use insulated tools while working on the electrical system.
• always switch off the truck's power supply before opening the hoods
to the drive assembly and the electrical system.
• disconnect the battery when using electric welding equipment. The
welding current can enter and damage the battery.
• always remove the battery plug when carrying out maintenance on
the truck, unless the instructions in this repair manual state
otherwise.
• blow electric motors clean using compressed air.
• clean electrical panels, PCBs, contactors, contacts, magnetic
valves, etc., with a moist cloth and a cleaning agent.
Note!
Risk of short circuit that may damage electrical components.
Do not break the warranty seal on the PCBs.

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 General safety rules
Safe lifting
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

3.3 Safe lifting

All lifting must be carried out on a flat, nonslip and stable surface. Avoid
freshly laid tarmac or tarmac at high daytime temperatures.
• When lifting the drive wheel, chock the other wheels so that the truck
stands still.
• Select the lifting points so that the lift is as easy as possible (one
corner at a time). If the truck has marked lifting points on the lower
part of the chassis, these should be used for a well-balanced lift.
• Ensure the area where you place the jack is clean and free of oil and
grease.
• Ensure there is no grease or oil on your hands or the jack lever.
• Use the lever supplied with the jack. If the lever is too short, it will
require more effort than is necessary. If the lever is too long there is
a risk that the jack will be overloaded.
• Place supports:
- as close to the raised part of the chassis as possible to reduce the
falling height if the truck tips over
- so that the truck cannot roll.
• Never place a support under the jack to increase the lifting height.
• Never work under a lifted truck without appropriate supports.
DANGER!
Risk of crushing – a poorly chocked truck may fall.
Never work under a truck that is not blocked with supports or secured
by a lifting device.

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General safety rules
Safe lifting
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

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 Installation
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4 – Installation

4.1 General
The chapter describes the work that has to be done before the truck is
put into operation.

4.2 Battery installation

4.2.1 Battery installation safety
Remember the following safety regulations before you begin working
with the battery:
• Gel batteries are only intended for use at room temperature with a
temperature interval of +15 to +30, otherwise there is a great risk
that the battery will be damaged and its lifetime reduced.
• Always use protective equipment to protect the eyes, face and skin
when you are inspecting, handling or filling batteries.
DANGER!
Battery acid causes burns. If your skin or clothing comes into contact
with battery acid, rinse the area immediately with cold water. If your
face or eyes come into contact with battery acid, rinse the area with
cold water and seek immediate medical attention.
• Ensure that there is a shower and an eye bath nearby in case an
accident occurs.
• A battery emits explosive gases. Never use naked flames or
anything else that could cause sparks close to a battery.
• Do not put tools or other metal objects on the battery. This can lead
to a short circuit or explosion.

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Installation
Battery installation
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

4.2.2 Install battery

The battery that is to be installed in the truck must be of the right size. A
battery that is too small in terms of size and weight can seriously affect
the truck's braking ability and stability when lifting. See the truck's data
plate for correct information about the battery.
1. Lift the battery into place using an approved lifting device and a
suitable battery yoke or lifting straps.
DANGER!
The battery may fall when the lifting device is loosened if it has not
been secured with an axle stand or other similar suspension gear of
the right height. Check the height of your suspension gear before
loosening the lifting yoke.
2. Check the electrolyte level in the battery. This should normally be
10-15 mm above the cell plates.
3. Connect the battery cables/battery sleeve.
DANGER!
Always check that you have the right polarity when connecting the
battery cables. Compare the markings on the cables with the
markings on the battery terminals. A wrongly connected battery may
cause a short circuit.
4. Close the battery lid.
5. Put the battery connector back.
6. Check or enter the parameters for the battery and battery charger.
See the section Adjusting battery and battery charger parameters
in this chapter.
7. Function test the truck before using it.

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 Installation
Programming PIN codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4.3 Programming PIN codes

The majority of PIN codes can be made available by activating the so-
called block. Block 0 (zero) is activated as standard, which means that
3 driver profiles can be used from the start. Activating the second block
makes all PIN codes for that block accessible. If all 10 blocks are
activated, 10 PIN codes become available for the driver profile.
The truck programme stores a standard set PIN code according to the
table "Standard assignment of PIN codes". These PIN codes may be
changed to a chosen value, but PIN codes that exist for other driver
profiles should be avoided.
There are two alternative methods for programming PIN codes. The
first and simplest is to use TruckCom where it clearly shows what to do.
See the separate manual for using TruckCom.
The other alternative is to use the truck's keypad.
Carry out the following to start the programming:
1. Connect the CAN service key to socket [X41].
2. State code 341671 and press the ON button.
3. Choose the programming code from the table below:

Function Programming Remark

Return to factory settings. Press 1 + ON button Block 1-9 is
deactivated. The
original PIN codes
are reset according
to the table for
standard
assignment of PIN
codes.
PIN codes in the block can be Press 2 + b + ON button B = Block 0-9
used.
PIN codes in the block cannot Press 3 + b + ON button B = Block 0-9
be used.
Programming new PIN codes Press 4 + b + P + NNNN + ON button B = Block 0-9
Note! P = Driver profile 1-
The block that applies must be activated 10
first (see function 2 above in the table). NNNN = PIN code
Note!
You may only state
one number per
driver profile. Driver
profile 10 must
therefore be stated
as 0 (zero).

4. Turn off the truck by pressing the OFF button.

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Installation
Programming PIN codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Programming the PIN codes is now finished. Verify that the

programming is correct by logging in with some of the new PIN
codes.
Note!
It is important to establish that the correct driver profile is activated
when a certain PIN code is stated. This especially applies when a
driver profile is set up for a specific application.

4.3.1 Standards for PIN codes

The table below shows the PIN codes that are found as standard in the
programme. The PIN codes can be activated or changed according to
the driver's wishes. A driver profile is activated with the normal log in of
all PIN codes, whose block number is activated.
The truck programme does not permit a login using the PIN code 0000.
Note!
It is recommended that service personnel keep notes about activated
blocks, changed PIN codes and specially adjusted driver profiles.

Standard assignment for PIN codes

Drive 1 2 3 4 5 6 7 8 9 10
r Note!
profil Stated
as 0
e
no.
Block 0 0001 0002 0003 0000 0000 0000 0000 0000 0000 0000
Block 1 7901 1437 3731 1049 9439 7265 1322 2869 1574 5421
Block 2 4854 2907 9175 5799 1490 3031 7392 5622 5023 1787
Block 3 3174 1026 3815 6703 1179 5152 7514 5668 3215 4659
Block 4 7110 5477 3846 9491 5918 8222 6923 8139 7025 9197
Block 5 6276 9879 9658 1690 4042 5201 9807 4332 9715 2549
Block 6 4142 8620 3754 8432 8788 7430 1948 2595 8527 7474
Block 7 1482 7135 2395 7365 7092 4611 2831 4185 6067 1930
Block 8 4731 1022 5377 3257 7334 9009 7881 8843 7436 2876
Block 9 3162 5878 2828 1910 6907 2136 5730 2957 7691 3242

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 Installation
Setting the parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4.4 Setting the parameters

The parameters that are handled in this chapter are only the
parameters that need to be adjusted when putting the truck into
operation and that require more detailed description. For more
information about parameters, see the chapter Functions and
parameters.
Check that parameters are adjusted to desire values with regards to
• maximum speed, driver parameter - see chapter Functions and
parameters
• acceleration, driver parameter - see chapter Functions and
parameters
• internal braking, driver parameter - see chapter Functions and
parameters
• Collision sensor (option)
• battery
• battery charger (option)
Note!
When you check or adjust parameters, remember to write down, in a
truck report for example, the truck's specific parameter values.
Separate information about the truck specific parameters are good to
have e.g. in case of truck breakdown, since the information cannot be
received in another way.

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Installation
Setting the parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

4.4.1 Adjusting the parameters for collision

sensor (option)
This parameters for collision sensitivity must be adjusted on truck
installation.
If a collision sensor is installed on the CAN bus, this registers when the
truck knocks against something. If a knock exceeds a certain level,
indicated by parameters 105 and 106, this is calculated as a collision
and the truck's speed is reduced to creep speed, a signal sounds and
error code 8.001 is shown on the display.
Information about the collision is stored in the truck's internal memory.
The last ten registered collisions can be read directly on the display and
the driver's identity can also be read via the PIN code. Other
information is received via TruckCom where the collision levels and
times can also be seen.

Collision sensor parameters 105, 106 och 111

See the table below for information about the values that can be stated:

Service parameters
Parameter Name/unit Min/ Incr Std Description
Max eme
nt
105 Collision 0/100 1 0 States the degree
sensor of sensitivity for
X level what should be
interpreted as a
collision for a
shock to the side.
106 Collision 0/100 1 0 States the degree
sensor of sensitivity for
Y level what should be
interpreted as a
collision for a
shock to the front
or back.
111 Resetting 0/1 1 0 0 = Special
following a pincode required
collision for resetting after a
collision.
1 = The truck can
be reset using all
activated pincodes.

Note!
If you set the parameter value for the collision sensor at 0 (zero) this
means that the collision sensor and the log function are turned off.

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 Installation
Setting the parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Programming PIN for resetting the truck

When the truck has stopped after a collision, the truck must be reset by
entering a special PIN code. This PIN code must be programmed by a
service technician at installation.
The PIN that is activated is found in driver profile 1 and special block
10. The PIN code has a standard value 0000, which must be changed
to a chosen PIN code by a service technician.
Note!
The PIN code must not contain the same number combination as any
of the preprogrammed PIN codes.

4.4.2 Adjusting the parameters for the battery

and battery charger
The following parameters must be adjusted or checked on battery
installation.
Note!
Even if the battery comes with the truck from the factory, the
parameters must be adjusted or checked.
Note!
Ensure that service parameter 109 is set to the value of the battery
fitted, and that the correct battery capacity has been set in parameter
110.
Note!
Only 134 Ah, 174 Ah and 201 Ah battery sizes may be used when
using a Hawker Evolution battery.

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Installation
Setting the parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Parameter Name/unit Min/ Incr Std Description

Max eme
nt
107 service Battery 1/20 1 9 9 = Large battery
parameter adjustment, Ah 13 = Medium battery
17 = Small battery
For more information, see text following
the table. See section“4.4.3 Parameter
107 - battery size”.
109 service Battery 0/3 1 0 State battery type
parameter charger, 0 = No charge. Standard type. Error
battery type code is displayed if this parameter is
set at 0 when there is a battery charger
and factory parameter 1101 is set at 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Sizes
134 Ah, 174 Ah, 201 Ah
3 = Exide GEL battery
110 service Built-in battery 0/300 1 0 State battery capacity.
parameter charger, (100/ (100) 0 (100) = No charge. Standard type.
battery 300) Error code is displayed if this
capacity, Ah parameter is set at 0 (100) when there
is a battery charger and factory
parameter 1101 is set at 1.
The values in brackets () apply if the
truck has software version -006 or later.
1101 factory Built-in battery 0/1 1 0 0 = No battery charger
parameter charger 1= Battery charger present

Note!
If factory parameter 1101 has been set to 0 (zero), service parameters
109 and 110 should also be set to 0 (zero). If the truck has software
version -006 or later, and if the factory parameter 1101 has the value 0
(zero), service parameter 109 must have the value 0 (zero) and 110
must have the value 100 (one hundred). The values of service
parameters 109 and 110 only need to be changed if the truck is
equipped with a built-in charger and the value of factory parameter
1101 has been set to 1.

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 Installation
Setting the parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4.4.3 Parameter 107 - battery size

You must state which type of battery the truck is equipped with. To
adjust the meter for battery charge level, consideration must be given
to the following:
• Acid concentration when the battery is fully charged, in order to
check the battery's quality. The value should lie between 1.27-1.29.
Note that the acid concentration can vary depending on the make of
battery.
• When the lifting capability is disconnected (the battery is discharged
to 80 %) the value should be close to 1.14 but no lower.
Free ventilated batteries
See the table below for the recommended parameter settings.
Parameter 107 Battery size Battery size Battery size
Lead/acid battery Hawker Evolution Exide
1
Lower 2
discharge 3
4
5
6 271-280 Ah 271-290 Ah
7 251-270 Ah 251-270 Ah
8 231-250 Ah 231-250 Ah
9 286-320 Ah 211-230 Ah 211-230 Ah
10 251-285 Ah 191-210 Ah 191-210 Ah
11 221-250 Ah 171-190 Ah 171-190 Ah
12 206-220 Ah 151-170 Ah 151-170 Ah
13 191-205 Ah 131-150 Ah 131-150 Ah
14 176-190 Ah 120-130 Ah 110-130 Ah
15 161-175 Ah
16 146-160 Ah
17 131-145 Ah
Deeper dis-
charge 18 115-130 Ah
19
20
DANGER!
The battery's service life will be reduced if the value of parameter 107
is set to a value that is too high. The standard adjustment of
parameter 107 is set for normal handling of the truck. Other
applications may require a different adjustment of parameter 107.
Check that the parameter adjustment is right using the instructions
below.

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 Installation
Setting the parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Verifying the parameter adjustment for free

ventilated batteries (Lead/acid batteries)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator
shows a discharged battery (0% on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two hours.
Note!
Do not charge or discharge during this time.
4. Measure the acid weight of the battery at room temperature.

If the acid weight is under 1.15 g/cm3, the parameter must be

reduced. A value substantially above 1.15 g/cm3 reduces the risk of
damage to the battery. At the same time the operating time of the
truck is reduced. If a longer operating time is desired, the
parameter value can be increase by up to one unit.
Note!
Each change must be followed by renewed verification of the
parameter setting.

Verifying the parameter adjustment for valve

controlled batteries (Hawker/Exide)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator
shows a discharged battery (0% on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two hours.
Note!
Do not charge or discharge during this time.
4. Measure the voltage of the battery at room temperature.
If the voltage is under Uend (see table below) the parameter value
must be reduced. A value substantially above Uend reduces the
risk of damage to the battery. At the same time the operating time of
the truck is reduced. If a longer operating time is desired, the
parameter value can be increase by up to one unit.
Note!
Each change must be followed by renewed verification of the
parameter setting.

Battery type Battery voltage at rest, Uend

Hawker Evolution/Exide 24.24 V

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 Installation
Function and safety check
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4.5 Function and safety check

a,e
q b
c
n
d
m
f
k

p
o

j
Before the truck is put into operation, the following points must be
checked.

Pos. Inspection point Action Duration scale

a Operating control Check function 2:25 minutes
b Safety reversing switch Check function
c Horn Check function
d Steering Check function
e Brake Check function
f Emergency switch Check function
g Hydraulic system Check all components
h Drive unit Investigate possible noises and oil leaks
j Wheel Investigate damage, remove dirt etc.
k Chassis Investigate damage, remove dirt etc.
m Battery cover and lock Check function
n Battery Check acid and charging level
o Fork carriage Investigate damage, remove dirt etc.
p Support arms Investigate damage, remove dirt etc.
q Mast Investigate damage, remove dirt etc.

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 Installation
Function and safety check
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

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 Maintenance
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

5 – Maintenance

5.1 General
This chapter contains a general periodic maintenance schedule and a
more detailed description of the maintenance to be carried out.

5.2 Service intervals

The service intervals are for guidance only and do not need to be
strictly followed. The service technician should adapt these to local
requirements, however, it is important that the intervals coincide with
the minimum requirements of the truck manufacturer.
The service intervals are based on operating hours and can be adapted
to most standard 8-hour shifts. The following operating hours have
been used when calculating the intervals:
Daytime: 08.00-17.00 (20 h/week)
2 shifts: 06.00-14.00, 14.00-22.00 (40 h/week)
3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 h/week)
Make sure the truck undergoes regular maintenance at intervals of 750
operating hours. The safety, efficiency and expected service life of the
truck depend on the service and maintenance the truck receives.
Following completed service intervention, test drive the truck and
perform an operational inspection. See the Installation chapter under
the heading Function and safety checks.
For service and repairs, only use spare parts approved by truck
manufacturer.

5.3 Maintenance schedule

Service maintenance should be performed in intervals of 750 operating
hours or every 12 months, whichever occurs first.
The order in the maintenance schedule is not optimal for the working
order; it is simply sorted according to the C codes.

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Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Work area Pos. Action 750h/12m Estimat

ed time
0000 Chassis a Inspect cover hinges and X 5:20
locks. minutes
b Check signs and adhesive X including
labels. removal
of covers.
c Check for cracks and damage X
d Check the mast fixing bolts. X
e Check for cracks and damage X
to the motor fixing points.
f Secure the paper holder strap X
if necessary

d
Qmax XXXX kg b
a a

f b

d
b

M-PLATE

b A
B
b
c A
B
C D

C
D
E
E
F

*The M-label is only affixed on specially produced trucks.

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 Maintenance
Maintenance schedule
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Work area Pos. Action 750h/12m Estimat

ed time
0350 Support arms a Check for cracks and damage. X 1:30
b Inspect bushings and links for X minutes.
possible looseness1.
c Check for cracks and damage X
to the push rods1.
d Check all shafts, links and X
locking pins1.
1.Only applies to trucks with support arm lift (SWE120L, SWE140L and SWE200D)

g
e
c
a
f
b

d d

Work area Pos. Action 750h/12m Estimat

ed time
0380 Fork carriage e Check for cracks and damage. X 1:30
f Check the rollers for X minutes.
looseness.
g Check the load support X
(Option).
Inspect the fork stop screws X
(SWE120S)
Check that the battery locks X
are attached and work
properly, also check the
bracket on the battery tray.

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Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Work area Pos. Action 750h/12m Estimat

ed time
0560 Platform a Check for cracks and damage X 1:30
and mountings b Check the spring, and that the X minutes.
platform returns to upright position.

b
a

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 Maintenance
Maintenance schedule
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Work area Pos. Action 750h/12m Estimat

ed time
1700 Drive a Check the drive motor's X 4:30
motor attachment. minutes.
b Clean the drive motor. X
c Inspect for abnormal noise in the X
drive motor bearings.
2550 Drive d Inspect for abnormal noise X
gear e Check the mountings and play in X
the steering bearings.
3180 Brakes f Check for wear on the brake disc. X
Minimum brake disc thickness: 7.9
mm
g Check the gap of the parking brake X
when it is not applied.
Nominal brake gap: 0.3 mm
Minimum permitted gap: 0.2 mm
Maximum permitted gap: 0.5 mm.
Measuring must be done around
the entire pressure disc, both on
the inside and the outside.
h Clean the brake. X

f,g,h
c
b
a
e
d

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Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Work area Pos. Action 750h/12m Estima

ted
time
3500 Wheels a Check for wear on the drive wheel. X 2
b Check the nuts. X minutes
c Inspect castor wheel wear1 X
d Check for wear on support arm X
wheels
e Check whether the swivel wheel X
swings freely1
1.Not applicable for SWE120S

e d c b a

Wheels Standard Minimum

measurements, mm dimensions,
mm
Drive wheels 30 15
Castor wheel1 10 5

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 Maintenance
Maintenance schedule
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Wheels Standard Minimum

measurements, mm dimensions,
mm
Support arm 11 5.5
wheel
1.Not applicable for SWE120S

Work area Pos. Action 750h/12m Estima

ted
time
4110 Tiller arm a Check the mountings. X 1:45
b Inspect the operating X minutes
console for correct
mounting
c Check the mounting of X
the handle.
d Check the force and X
locking of the gas strut.
The tiller arm should
return to the top position
both from the bottom
position and from the
lower position where the
brake is applied.
Check that the braking
function is activated in
both upper and lower tiller
arm positions.

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Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

a
d

Work area Pos. Action 750h/12m Estimat

ed time
5000 Electrical a Inspect the connectors, X 4:30
system wiring harness (including minutes
the battery cables), cable
insulation and verify that all
cables can move freely.
b Inspect the contactors for X
correct operation.
c Check error code log, X
operating times and all the
segments on the display
d Clean and check that there X
is no play between the
steering box and the heat
dissipation plate.
e Check and tighten the cable X
connections.
f Check all switches and X
sensors.

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 Maintenance
Maintenance schedule
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

c
a

a,e
b
d f
a,e
a,e

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 Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Work area Pos. Action 750h/12m Estima

ted
time
6000 Hydraulic a Check wear on hoses and pipes. X 16
system b Check the oil level. X minutes
(Recommended window for the oil
level when forks are lowered
according to illustration)
c Check the mountings of the hydraulic X
unit.
d Inspect the hydraulic system for X
possible leakage.
e Change the oil and clean the oil tank. X
Note: Initially after 750 h/12 m, then
every 4500 h/36 m.
f Clean the oil strainer. X
Note: Initially after 750 h/12 m, then
every 4500 h/36 m.
6600 Lifting cylinder g Inspect the lifting cylinder for leakage. X
h Inspect the lifting cylinder for correct X
mounting
j Inspect the lifting cylinder (support X
arm lift) for leaks
k Inspect the cylinder (support arm lift) X
for correct mounting

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 Maintenance
Maintenance schedule
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

g,h

j,k

a,c,d,e,f 20 mm

Work area Pos. Action 750h/12m Estima

ted
time
7100 Mast a Check for any cracks or damage. X 16
b Check that there is no looseness in the X minutes
mast's mounting points.
c Check for play between the mast beam and X
the inner runner's rollers.
d Check the inner runner's side play. X
e Check for wear on lifting chains and 500 h
sprockets. See section "18.3 Main lift chain
system 7120".
f Check the adjustment of the lifting chains 500 h
See section "18.3 Main lift chain system
7120".
g Lubricate the inside surfaces of beam X
flanges

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 Maintenance
Maintenance schedule
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

d g
c

e e

e
e
b
b

— End of section —

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 Functions and parameters
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6 – Functions and parameters

6.1 General
The chapter “Function and parameters” provides a basic description of
the truck's main functions and the control system parameters.

6.2 Function description

The section "Function description" provides a basic description of the
truck's main functions.
• Event – Use of one of the truck's main functions is referred to as an
event. All events are indicated by a number.
• Prior events – Indicates events which must have taken place
immediately before the current event in order for the latter to be
performed correctly.
• Action(s) – An action that the operator must perform in order for an
event to happen.
• Influencing factors – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions – Describe the key events that can be checked
in order to confirm a function.
Note that “resulting conditions” show what is expected when no error
conditions are present.
Text within square brackets [ ] refers to the electrical component names
in the truck's wiring diagram.
{High} means ≈ 24 V and {low} ≈ 0 V unless otherwise stated.

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Functions and parameters
Function description
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Symbols on keypad and display

Symbol Description
ON button
This button is used to start the truck and
confirm entered settings
OFF button

Error code

Battery charge as a percentage

Parameter

Hour meter

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 Functions and parameters
Operating principle
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6.3 Operating principle

Event: 1. The battery is connected

Action(s) Connect the truck battery [G1]
Influencing Main power fuses OK [F1]
elements Operating circuit fuses OK [F50, F51]
Resulting The status LED for the transistor regulator is lit permanently [T1].
conditions
Event: 2. Start the truck
Preceding event(s) The battery is connected.
Action(s) Enter a valid PIN code and press the ON button on the keypad [S223].
Influencing The emergency stop [S21] has not been activated [T1:INP. SUPPLY+24V
elements DC] {high}.
Resulting The current lamp shines. Main display shows the hour meter for 4 seconds
conditions and after this the battery charge as a percentage of full charge.
The mechanical brake remains applied [Q1] [T1:OUT.BRAKE RELEASE]
{high}.
Event: 3. Lower the tiller arm to the drive position
Preceding event(s) Start the truck.
Action(s) Lower the tiller arm handle.
Influencing Sensor for tiller arm in drive position [B60].
elements
Resulting Tiller arm sensor in drive position activates [B60] [T1:INP. TILLER ARM IN
conditions DRIVE POS] {low}.
The main contactor output voltage goes {low} [T1:OUT. MAIN
CONTACTS]
The main contactor closes [Q10].

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Functions and parameters
Operating principle
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Event: 4. Driving in the fork direction

Preceding event(s) Lower the tiller arm to the drive position.
Action(s) Turn the speed control in the fork direction.
Influencing Speed control with Hall sensor [A5:S10-18].
elements Settings of operator parameters 4, 5 and 6 determine truck travel
performance.
Resulting [T1:OUT.BRAKE RELEASE] goes {low}.
conditions Brake coil [Q1] is activated, and the mechanical brake is released.
The pulsed current fed to the drive motor is proportional to speed control
actuation.
Event: 5. Driving in drive wheel direction
Preceding event(s) Lower the tiller arm to the drive position.
Action(s) Turn the speed control in the drive wheel direction.
Influencing Speed control with Hall-sensor [A5:S1-9].
elements Settings of operator parameters 4, 5 and 6 determine truck travel
performance.
Resulting [T1:OUT. BRAKE RELEASE] goes {low}.
conditions Brake coil [Q1] is activated, and the mechanical brake is released.
The pulsed current fed to the drive motor is proportional to speed control
actuation.
Event: 6. Neutral braking
Preceding Truck travels in fork or drive wheel direction.
event(s)
Action(s) Allow the speed control to return to the neutral position.
Influencing Setting of operator parameter 5.
elements
Resulting The drive motor [M1] works as a generator and via the transistor regulator
conditions [T1] converts the truck's kinetic energy into electricity, thus reducing the
truck’s speed. The excess energy, in the form of electricity, is fed back to
the battery [G1] helping to recharge it. The mechanical brake [Q1] is
activated when the truck stops. [T1:OUT.BRAKE RELEASE] goes {high}.

6– 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Functions and parameters
Operating principle
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Event: 7. Reversing braking

Preceding event(s) Truck travels in fork or drive wheel direction.
Action(s) Speed control turned to opposite travel direction.
Influencing Parameter 201.
elements
Resulting The drive motor [M1] works as a generator and via the transistor regulator
conditions [T1] converts the truck's kinetic energy into electricity, thus reducing the
truck’s speed. The excess energy, in the form of electricity, is fed back to
the battery [G1] helping to recharge it. The braking effect increases the
more the speed control is turned.
The mechanical brake [Q1] [T1:OUT. BRAKE RELEASE] is applied when
the truck stops.
Event: 8. Mechanical braking
Preceding event(s) Truck travels in fork or drive wheel direction.
Action(s) The tiller arm is folded completely up or down.
Influencing Sensor for tiller arm in drive position [B60].
elements
Resulting Sensor for tiller arm in drive position [B60] deactivated [T1: INP. TILLER
conditions ARM IN DRIVE POS] {low}.
When the tiller arm is completely raised or lowered, maximum permitted
brake reduction is applied for 200 ms or until the travel speed is lower than
0.8 m/s. After this, the mechanical brake [Q1] is applied. [T1:OUT.BRAKE
RELEASE] {high}.
Event: 9. Anti-collision safety switch
Preceding event(s) Truck travels in drive wheel direction.
Action(s) When driving in the drive wheel direction, the anti-collision safety switch
[A5:S17]is pressed.
Influencing Safety switch [A5:S17].
elements
Resulting The Hall-sensor [A5:S17] is immediately activated. The logic card [A5]
conditions interprets this signal as a command to the transistor regulator [T1] to
operate the drive motor at reduced speed in the fork direction for as long
as the anti-collision safety switch [A5:S17] is kept pressed. The command
signal for normal running of the drive motor from the speed control is
blocked until the speed control is released and returned to the neutral
position.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6– 5

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Functions and parameters
Operating principle
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Event: 10. Fork lifting

Preceding event(s) Start the truck.
Action(s) Press the fork lift button [A5:S19].
Influencing Main contactor [Q10].
elements Fuse [F1].
Fork lift button [A5:S19].
Battery status OK (battery's discharge indicator > 0 or battery charge >
20 %).
Resulting [T1:OUT. P-] goes {low}.
conditions Pump motor [M3] starts.
Event: 10. Fork lifting (SWE100)
Preceding event(s) Start the truck.
Action(s) Press the fork lifting button [A5:S19].
Influencing Main contactor [Q10].
elements Fuse [F1].
Fork lift button [A5:S19].
Battery status OK (battery's discharge indicator > 0 or battery charge >
20 %).
Resulting [T1:OUT. PUMP CONTACTOR] goes {low}.
conditions The pump contactor [Q25] closes, the pump motor [M3] starts.
Event: 11. Fork lowering
Preceding event(s) Start the truck or commence fork lifting.
Action(s) Press the fork lowering button [A5:S20].
Influencing Main contactor [Q10].
elements Fork lowering button [A5:S20].
Resulting [T1:OUT. LOWER VALVE] goes {low}, proportional valve [Q4] opens.
conditions
Event: 12. Support arm lift (SWE120L, 140L, 200D)
Preceding event(s) Start the truck.
Action(s) Press the button for support arm lift [A5:S21].
Influencing Main contactor [Q10].
elements Fuse [F1].
Button for support arm lift [A5:S21].
Battery status OK (battery's discharge indicator > 0 or battery charge >
20 %).
Resulting [T1:OUT. PUMP CONTACTOR] goes {low}.
conditions The pump contactor [Q25] closes, the pump motor [M3] starts.
Event: 13. Support arm lowering (SWE120L, 140L, 200D)
Preceding event(s) Start the truck or commence support arm lift.
Action(s) Press the button for support arm lowering [A5:S22].

6– 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Functions and parameters
Operating principle
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Influencing Main contactor [Q10].

elements Button for support arm lowering [A5:S22].
Resulting [T1:OUT. LOWER VALVE] goes {low}, proportional valve [Q4] opens.
conditions
Event: 14. Click-2-Creep
Preceding Start the truck.
event(s)
Action(s) Rapid double-actuation of the speed control to activate the function.
Set the tiller arm in the vertical position and drive the truck at creep speed
(2.5 km/h).
Influencing Main contactor [Q10].
elements Setting of factory parameter 1002.

Resulting [T1:OUT.BRAKE RELEASE] goes {low}.

conditions Brake coil [Q1] is activated, and the mechanical brake is released.
The pulsed current fed to the drive motor is proportional to speed control
actuation. “SLO” is shown on the display (blinking).
Event: 15. Turtle function (option)
Preceding Lower the tiller arm to the drive position.
event(s)
Action(s) Press [S206] to activate this function.
Turn the speed control in either direction.
Influencing Option button 1 [S206].
elements Setting of operator parameter 7 and service parameter 202.

Resulting [T1: OUT. BRAKE RELEASE] goes {low}.

conditions Brake coil [Q1] is activated, and the mechanical brake is released.
The pulsed current fed to the drive motor is proportional to speed control
actuation. The maximum travel speed is determined by operator
parameter 7. “SLO” is displayed (lights continuously).

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6– 7

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Functions and parameters
Hour meter
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

6.4 Hour meter

When switching on the truck, the hour meter is displayed and the hour
meter symbol is lit for 4 seconds.
The truck’s control system stores five different time values. The time
values are controlled by parameter 103. To display a desired value,
proceed as follows:
1. Ensure that the battery is connected.
2. Ensure that the truck is switched off. Press the OFF button.
3. Enter the appropriate PIN code. Note: Without pressing the ON
button.
4. Keep the horn button depressed until “H” is displayed, then release
the button. The hour meter symbol lights.
Press the speed control repeatedly to cycle through the different hour
meter values. The current time value will be displayed a short while
after this mode has been selected.

Hour recorder values Display

Value 1 = Key time
Total time truck has been in use.

Value 2 = Operating time

Aggregate time either pump or drive motor has been in
operation.
Default display.
Value 3 = Drive motor time
Total time the drive motor has been in operation.

Value 4 = Pump motor time

Total time the pump motor has been in use.

Value 5 = Remaining time until next service.

Parameter 101 controls the initial value.

6– 8 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6.5 Parameters

6.5.1 General
The truck's steering system stores a number of parameters. These
parameters are used to configure the truck for correct operation in
specific settings and for a particular application. The parameters are
divided into three groups:
• Operator parameters – Adapts truck travel performance for a
specific operator or application. Operator parameters can be
changed at any time without a CAN service key.
• Service parameters – Used to adapt functional performance of the
truck. Service parameters can only be adjusted when a suitable
CAN service key is plugged into the truck. Please note that the
service parameters can be checked without any need for plugging in
a CAN service key, however it is not possible to change the values.
• Factory parameters – Parameters pre-set at the factory, which in
case of special requirements can be changed by a service
technician. As an example, these parameters indicate the truck
model and which controls to use for the hydraulic function. The
factory parameters cannot be changed with the CAN service key.
All parameters can be changed via a PC/PDA running TruckCom.

6.5.2 Show parameters

Proceed as follows to only display and verify the various truck settings:
1. Connect the CAN key or enter a PIN code, then press the horn
button and keep it depressed.
The display shows:
- Operating times and time remaining until next service (H)
- Error codes (E).
- Parameters (P).
- Hardware and software numbers (Pn).
- Display test function (d)
- Collision sensor log (c)
- Emergency drive mode (Ed)
- Calibration (CAL). Shortcut for setting parameter 108 = 1
2. Release the horn button when what you wish to view is displayed.
3. To scroll between the settings for each mode above, turn the speed
control.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6– 9

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

6.5.3 Setting the parameters

Proceed as follows to set parameters:
1. Connect the CAN key or enter a PIN code, then press the horn
button and keep it depressed. Release the horn button when the
display shows “P”.
The parameter symbol is lit continuously.
2. Turn the speed control to scroll to the desired parameter. Release
the control when the display shows the correct parameter number.
3. Press once on the horn button to change the value.
The parameter symbol starts blinking.
4. Change the value by turning the speed control.
5. Confirm the setting by pressing once more on the horn button.
The parameter symbol lights continuously once again.
6. Complete the programming by pressing the OFF button.

6 – 10 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6.5.4 Operator parameters

Note:
Changing specific truck parameters changes the truck's driving
properties. Do not change any parameter values without the
necessary know-how.

Parameter Designation/ Min./ Incr Def Description

unit Max. eme ault
nt
4 Acceleration, % 10/100 5 70 Determines the truck's
acceleration capacity. The
lower the value of this
parameter, the longer time
it takes for the truck to
accelerate to top speed.
5 Deceleration, % 10/100 5 90 Determines the braking
force when the speed
control is returned to
neutral position. The lower
the value of this
parameter, the longer the
time to reduce speed.
6 Maximum 30/100 5 90 Determines the maximum
speed, % travel speed.
7 Maximum 30/100 5 50 Determines the truck's
speed in turtle maximum travel speed
mode, % when the turtle mode has
been activated.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6 – 11

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Factory pre-set operator parameters

Upon delivery from the factory, the various operator profiles have
different values for operator parameters 4, 5 and 6. See the table
below.
The values for operator profiles 1 and 4-10 are the default values.

Operator Parameter Factory PIN

profile setting code
Operator profile 4 70 1
1 5 90
6 90
Operator profile 4 50 2
2 5 90
6 80
Operator profile 4 100 3
3 5 100
6 100

Note:
When replacing the firmware, the factory presettings of operator
profiles 2 and 3 are lost. In this case, all operator profiles are assigned
the same default values, i.e. the default values of operator profiles 1
and 4-10. To regain the factory settings, these values must be entered
anew, either manually or via a PC/PDA.

6 – 12 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6.5.5 Service parameters

Note:
Changing specific truck parameters changes the truck's driving
properties. Do not change any parameter values without the
necessary know-how.
Note:
Parameter 201 must be set to a value equal to or larger than the value
of parameter 5. If a value of any parameter is changed causing the
value of parameter 201 to become smaller than that of parameter 5,
then the value of parameter 201 will automatically be reset to 100.
When this parameter value is changed automatically, error code 2.002
is generated.
Note:
Make sure that service parameter 109 is set to the value for the battery
that is fitted, and that the correct battery capacity is set in parameter
110.
Note:
For Hawker Evolution batteries only the battery sizes 134Ah, 174Ah
and 201Ah may be used.
Before any service parameter can be adjusted, the CAN service key
must be connected to the connector [X41].

Param Designation/ Min./ Incr Def Description

eter unit Max. eme ault
nt
101 Service interval, 0/ 50 0 Specifies a limit when the next service
hours 2000 should take place. Error code 2.003 is
displayed when it is time for service.
0 = Service prompting switched off.
102 Operator 1/10 1 3 Determines the log-in method to be used
access and whether the operator should be able to
change operator parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with 100 PIN
codes
Values 5 and 6 = Keypad with DHU
Values 7 and 8 = ID unit
Values 9 and 10 = ID unit with DHU
Odd values = Open operator parameters
Even values = Operator parameters can
only be changed with a CAN key.
103 Hour counter 1/5 1 2 Determines a time value for the hour
option meter.
Fore more information, see the Hour meter
section in this chapter.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6 – 13

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Param Designation/ Min./ Incr Def Description

eter unit Max. eme ault
nt
104 Automatic log- 0/20 1 20 Determines the time until the truck is
out, minutes switched off when the keypad is used.
Time is counted down from when the latest
power consumer is used. Value 0 gives 4
hours.
105 Collision 0/100 1 0 Option. Indicates the degree of sensitivity
sensor, X level for what should be interpreted as a side
impact. Be sure to set this parameter when
installing the truck. For more information,
see the Installation chapter.
106 Collision 0/100 1 0 Option. Indicates the degree of sensitivity
sensor, Y level for what should be interpreted as a frontal/
rear-end impact. Be sure to set this
parameter when installing the truck. For
more information, see the Installation
chapter.
107 Battery setting, 1/20 1 9 9 = Large battery
Ah 13 = Medium battery
17 = Small battery
For more information, see the text below
the table.
108 Calibrating 1 1 1 = Calibration of proportional valve.
Automatically reset to zero after completed
calibration. See the chapter on hydraulics
for complete instructions on how to
perform the calibration.
109 Battery charger, 0/3 1 0 Determines what type of battery will be
battery type charged.
0 = No charging. Default setting. An error
code is displayed if this parameter has
been set to 0 when a battery charger has
been installed and factory parameter 1101
has been set to 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Size 134Ah,
174Ah, 201Ah.
3 = Exide gel-battery
For more information, see the Installation
chapter.

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Param Designation/ Min./ Incr Def Description

eter unit Max. eme ault
nt
110 Battery charger, 0/300 1 0 Determines the battery capacity.
battery (100/ (100) 0 (100) = No charging. Default setting. An
capacity, Ah 300) error code is displayed if this parameter
has been set to 0 (100) when a battery
charger has been installed and factory
parameter 1101 has been set to 1.
The value in brackets () indicates if the
truck has software version -006 or newer.
For more information, see the Installation
chapter.
111 Resetting 0/1 1 0 0 = A special PIN code is required to reset
following a the truck after a collision.
collision 1 = The truck can be reset using all the
activated PIN codes.
2 = Horn sounds once every five seconds.
3 = Options 1 and 2 combined.
201 Reverse 70/ 5 100 Specifies how hard the truck should brake
braking 100 when the speed control is turned fully in
the opposite direction.
Note: This value must not be set lower
than the value of parameter 5. If it is lower,
error code 2.002 is shown at start-up and
the value is not changed.
202 Creep speed -200/ 5 0 Determines the speed the truck will have
200 when it reaches the value set for the first
travel speed sensor.
-200 = Low speed for the first speed
sensor.
200 = High speed for the first speed sensor
203 Maximum 10/ 5 45 Determines the maximum speed of the
speed, % 100 truck when the forks are higher than 1.8 m.
204 Acceleration, % 10/ 5 45 Determines the maximum acceleration
100 capacity of the truck when the forks are
higher than 1.8 m. The lower the value of
this parameter, the longer time it takes for
the truck to accelerate to top speed.
205 Reverse 10/ 5 80 Determines how hard the truck will
braking, % 100 decelerate when the forks are higher than
1.8 m and the speed control is turned in
the opposite direction to the travel
direction.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6 – 15

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Param Designation/ Min./ Incr Def Description

eter unit Max. eme ault
nt
206 Deceleration, % 10/ 5 60 Determines the motor's braking power
100 when the speed control is placed in the
neutral position and the forks are above
1.8 m. The lower the value of this
parameter, the longer the time to
decelerate.
301 Lowering stop 3/20 1 7 Determines the closing ramp of the
ramp proportional valve.
302 Fork lowering 70/ 5 190 Determines the maximum lowering speed of
speed 255 the forks. This parameter can be adjusted
manually or can be set by using the
calibration function (parameter 108 = 1).
303 EVP start 30/ 5 90 Determines the start position of the
position 150 proportional valve. This parameter can be
adjusted manually or can be set by using the
calibration function (parameter 108 = 1).
304 EVP support 50/ 5 130 Determines the lowering speed of the
arms lowering 220 support arms. This parameter can be
speed adjusted manually or can be set by using the
calibration function (parameter 108 = 1).
305 EVP slow 40/ 5 105 Determines the slow lowering speed when
lowering speed 220 using "Click-2-Creep”. This parameter can be
adjusted manually or can be set by using the
calibration function (parameter 108 = 1).
306 Activate two 0/1 1 1 Activate “Click-2-Creep” lifting/lowering
lifting/lowering 0 = Off
speeds 1 = On
307 Activate 0/1 1 1 Activate automatic lowering of the support
automatic arms
lowering of the 0 = Off
support arms 1 = On

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6.5.6 Factory parameters

Setting of the truck factory parameters is done during production at the
factory. Factory parameters can only be changed using the TruckCom
software application in a PC or PDA.
Note:
Bear in mind that a change to specific truck parameters will change
the truck’s characteristics. Do not change any parameter values
without the necessary know-how. Only authorised service
technicians with personal user identity for TruckCom has the
authority to change factory settings. This may only be done if special
needs arise.
The user ID and time of parameter change are logged in the circuit
board of the handle.

Param Designation/ Min./ Incr Def Description

eter unit Max. eme aul
nt t
1001 Truck type 0/8 1 0 0 = Unknown truck type
1 = SWE100
2 = SWE120
3 = SWE140
4 = SWE120L
5 = SWE140L
6 = SWE200D
7 = SWE080L
8 = SWE120S
1002 Non-configurable 0/3 1 1 3 different functions are accessible
options via parameter 1002. These
functions are either active or
inactive. The functions do not
require any further adjustment and
are thus referred to as non-
configurable options.
0 = No option function
1 = Click-2-Creep
2 = Turtle function
3 = Both Click-2-Creep and Turtle
function.
1003 ConfOption Func1 0/13 1 0 Requires SEU

1004 ConfOption 0/255 1 0 Requires SEU

Func1Arg1
1005 ConfOption 0/255 1 0 Requires SEU
Func1Arg2
1006 ConfOption 0/255 1 0 Requires SEU
Func1Arg3
1007 ConfOption 0/255 1 0 Requires SEU
Func1Arg4

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Param Designation/ Min./ Incr Def Description

eter unit Max. eme aul
nt t
1008 ConfOption Func2 0/13 1 0 Requires SEU
1009 ConfOption 0/255 1 0 Requires SEU
Func2Arg1
1010 ConfOption 0/255 1 0 Requires SEU
Func2Arg2
1011 ConfOption 0/255 1 0 Requires SEU
Func2Arg3
1012 ConfOption 0/255 1 0 Requires SEU
Func2Arg4
1013 ConfOption Func3 0/13 1 0 Requires SEU
1014 ConfOption 0/255 1 0 Requires SEU
Func3Arg1
1015 ConfOption 0/255 1 0 Requires SEU
Func3Arg2
1016 ConfOption 0/255 1 0 Requires SEU
Func3Arg3
1017 ConfOption 0/255 1 0 Requires SEU
Func3Arg4
1018 ConfOption Func4 0/13 1 0 Requires SEU
1019 ConfOption 0/255 1 0 Requires SEU
Func4Arg1
1020 ConfOption 0/255 1 0 Requires SEU
Func4Arg2
1021 ConfOption 0/255 1 0 Requires SEU
Func4Arg3
1022 ConfOption 0/255 1 0 Requires SEU
Func4Arg4

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 Functions and parameters
Parameters
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Param Designation/ Min./ Incr Def Description

eter unit Max. eme aul
nt t
1023 Controls for 1/4 1 1 1= The rear lifting and lowering
hydraulic functions control is connected to the second
hydraulic function, while the front
control is connected to the first
hydraulic function.
2 = Rear lift and lowering control
connected to the first hydraulic
function and forward control
connected to second hydraulic
function.
3 = Both lifting and lowering
controls are connected to the first
hydraulic function. There are no
other hydraulic functions.
4= The analogue lifting and
lowering control is connected to the
first hydraulic function, while the
front control is connected to the
second hydraulic function.
1024 Brake configuration 0/1 1 0 0= 1.5KHz braking frequency
* see below 1= 8KHz braking frequency
1101 Battery charger, on- 0/1 1 0 0 = No battery charger installed
board 1 = Battery charger installed

* Matrix for hardware/software compatibility

See the matrix below for the correct setting of factory parameter 1024.
The setting depends on what version of transistor regulator the truck is
fitted with.
• Value 0 = 1.5 kHz (default value)
• Value 1 = 8 kHz

Transistor regulator Factory parameter 1024

Value = 0 Value = 1

243428/-001/-002 OK Not permitted

246889/-001/-002
246890/-001/-002
7513528-001/-newer Not OK
7513526-001/-newer recommended
7513527-001/-newer

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 6 – 19

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 Functions and parameters
Parameters
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Troubleshooting
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7 – Troubleshooting

7.1 General
This chapter describes the error codes that are displayed when the
truck is partially or completely disabled. Also described is the cause of
the problem together with corrective remedies.
The electronic control system of the truck has built-in error code display
and logging. Is case of an error, an error code is generated and
displayed, and the error code LED blinks.
The first time an error code is displayed, try to restart the truck to check
whether the error condition remains.
Note:
The request "Restart the truck" means that the battery connector
must be disconnected before attempting to start the truck again.

Software compatibility
Make sure that the logic card ICH [A5] and the transistor regulator ACT
[T1] and the battery charger BCU [A30] have the software from the
same software package.
Download and install the latest software package in order to maintain
full functionality.

Emergency travel mode

If truck for some reason stops operating and remains immobile in an
unsuitable place, it is possible to active the emergency travel mode to
move the truck out of the way.

1. Enter your PIN code.

2. Press the horn button and keep it depressed.
“Ed” is displayed.
3. Relase the horn button.
All lamps blink and “SLO” is displayed.
It is now possible to drive the truck, but exercise extreme caution. It is
not possible to brake by raising the tiller arm.
If the truck is on an incline, be even more careful when using the
emergency travel mode. If too much acceleration is used, there is a
risk the truck can roll away. To stop the truck, change the travel
direction to the opposite direction.
With some errors, the emergency travel mode will not operate. In
this case, it is not possible to receive information about the error.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7– 1

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Troubleshooting
Troubleshooting methods
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.2 Troubleshooting methods

7.2.1 General initial troubleshooting

Inled felsökningen

Har en felkod visats? Följ instruktionerna i

Eliminera osannolika fel
kapitlet Felsökning
Ja

Nej

Följ instruktionerna Välj ut och prioritera de

i felsökningsschemat mest sannolika
Ja orsakerna

Nej

Samla så mycket När du lokaliserat felet,

information som Var på arbetsplatsen
uppstod problemet? se instruktioner i
möjligt om problemet sektionen för åtgärder

När uppstod
problemet?

Vilka funktioner
är påverkade?

Vilka förhållanden
utlöste problemet?

Identifiera alla delar som

kan orsaka problemet.
Använd vid behov
kopplingsschema.

7– 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Troubleshooting methods
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.2.2 Concluding troubleshooting

Kör trucken på samma sätt
Avsluta felsökningen som den kördes när problemet
först uppstod.
Verifiera att problemet
inte uppstår igen.

Se till att alla

kablar och slangar Låt föraren köra trucken.
har satts tillbaka på ett Verifiera att problemet
korrekt sätt inte uppstår igen.

Genom återkoppling
Om du har kontaktat kan du bidra till en gemensam
Se till att de delar som har avdelning för teknisk support kunskapsdatabas.
tömts på vätska har blivit för att diskutera problemet, Detta är viktigt för fortsatt förbättrad
återfyllda till korrekt nivå hör av dig igen och berätta support till servicetekniker i fält.
hur du löste problemet.

Återskapa samma
förutsättningar som
gällde när problemet
först uppstod

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7– 3

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Troubleshooting
Error code history
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.3 Error code history

Up to 50 of the most recent error code events can be stored in a log
along with the hour meter reading when the error occurred. The error
code log displays error codes in chronological order starting with the
most recent one.
Proceed as follows to display the error code log:
1. Ensure that the battery is connected.
2. Ensure that the truck is switched off. Press the OFF button.
3. Enter the appropriate PIN code. Note: Without pressing the ON
button.
4. Keep the horn button depressed until “E” is displayed, then release
it. The error code symbol lights.
The most recent error is shown. The display alternates between the
error code and the hour meter reading at the time of the error. If the
error code log contains more than one error code, the codes can be
displayed by pressing repeatedly on the speed control.

7– 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error code system
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.4 Error code system

See the tables below for an explanation of the error code system.

Structure Description
G.ANN Example: 3.510
G (3) Group. Indicates which system is affected by the
error.
A (5) Error category. Describes the type of error that has
occurred and what happened.
NN (10) Error code

Group Description
1 Not used
2 Main control system and other
3 The drive system
4 The hydraulic system
5 Not used
6 Not used
7 Not used
8 Option.

Error Description
category
0 Proceed with caution. This is primarily an
information code that indicates that some of the
truck functions have been reduced or do not
operate.
1-2 Minor error. Lifting and lowering of the forks are
disabled and the truck travel speed is reduced to
safety speed.
3 Not used
4 Critical error. The main contactor is open. The
truck stops.
5 Critical error. The main contactor is open. The
truck stops.

Code Description
00-09 Miscellaneous error codes.
10-19 Error codes related to CAN.
20-39 Error codes for specific units.
40-59 Error codes for short-circuited outputs.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7– 5

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Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Description
60-79 Error codes for open circuits.
80-99 Incorrect signals from sensors.

7.5 Error codes

Please note that some error codes are stored in the software and
disappear from the display, while other error codes remain on the
display and require that the truck be switched off and then on again for
the error code to disappear from the display.

Code Event Possible cause

Action
Main control unit
E141 Software download interrupted Transmission cable disconnected.
Restart the download in "Emergency
download" mode
2.001 Transistor regulator stops all functions. Emergency switch off has been
actuated.
Check:
• that the emergency switch off is not
pressed.
• cable 24.
• fuse [F51]
2.002 No event. Truck can be operated as usual. Some parameter values may be
outside the pre-set values. The
parameters will be reset to the default
values.
• Check the parameter settings.
• If the error code is followed by error
code 2.004, you must copy via
TruckCom configuration to the
transistor regulator[T1].
2.003 No event. Truck can be operated as usual. Time for service.
Check the service counter (hour meter
S). Maybe it was not reset following the
most recent service intervention.

7– 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
2.004 No event. Truck can be operated as usual. Values stored in the transistor regulator
back-up copy differ from the values
stored in the logic card of the handle in
terms of parameters, hour counter and/
or machine serial number.
Use TruckCom to check where the
correct data are stored. See table
7.6.4.
2.101 Safety speed, raising and lowering the The truck type has not been set.
forks not working. Alternatively, the value in the tiller arm
logic card [A5] is different from the
value in the transistor regulator [T1].
Reset data from backup, See section
"15.5.4 Disassembly/assembly of tiller
arm handle". If this does not help,
indicate the type of truck by entering
factory parameter 1001 (Truck type), or
see table 7.6.4.
2.102 Safety speed, raising and lowering the The set truck type does not support
forks not working. analogue lifting and lowering
operations.
Check the settings of factory
parameters 1001 (Truck type) and
1023 (Controls for hydraulic functions).
2.501 Main contactor opens. Low battery voltage <16.8V> for more
than 2 seconds
Charge the battery. Inspect all cables
and connectors
2.511 The main contactor is open. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in tiller arm handle.
2.514 The main contactor is open. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120.
• logic card in tiller arm handle.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7– 7

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Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
2.515 The truck cannot be started CAN communication error.
Check:
connectors and wiring harness
between the DHU [K110] and the ICH
logic card [A5]
2.520 The main contactor is open. Errors in software in tiller arm handle or
the microprocessor.
Download new software.
2.521 The main contactor is open. Defective safety reversing function.
Mechanical error or defective Hall
sensor in the safety reversing function.
Use TruckCom to check whether the
Hall sensor is defective.
2.522 The main contactor is open. Incorrect power supply to the Hall
sensor.
Use TruckCom to check whether the
Hall sensors are working.
2.523 The main contactor is open. Main contactor is not activated.
• Check if the main contactor is
working.
• Open the main contactor.
Drive system
3.001 Travel disabled until the speed control is • The speed control was not in the
reset to the neutral position. neutral position during start-up.
• Defective Hall sensors.
Check:
• speed control functionality
• via TruckCom that the Hall sensors
work.
3.002 The transistor regulator reduces current The transistor regulator's temperature
feed to 50%. exceeds +85°C. The driving may be
too intensive.
• Drive the truck less intensively.
• Check whether dirt has accumulated
around the transistor regulator. Too
much dirt can cause insufficient
cooling of the transistor regulator.

7– 8 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
3.003 The transistor regulator reduces current The engine's temperature exceeds
feed to 50%. +150°C. The driving may be too
intensive.
• Drive the truck less intensively.
• Check whether dirt has accumulated
around the motor. Too much dirt can
cause insufficient cooling of the
motor.
3.040 No event. Truck can be operated as usual. Incorrect power saving function in
holding mode.
• Internal transistor regulator error.
• Restart the truck.
• If the error persists, change the
transistor regulator.
3.080 The transistor regulator reduces current The temperature sensor for the
feed to 50%. transistor regulator shows abnormal
values.
• Internal transistor regulator error.
• Restart the truck.
• If the error persists, change the
transistor regulator.
3.081 The transistor regulator reduces current The motor temperature sensor shows
feed to 50%. abnormal values. The sensor could be
defective.
Check the cables (63/64) to the motor
temperature sensor.
3.101 Safety speed, raising and lowering the The transistor regulator is using pre-set
forks not working. current amplification. Internal error
• Internal transistor regulator error.
• Restart the truck.
• If the error persists, change the
transistor regulator.
3.120 Safety speed, raising and lowering the Incorrect checksum for the transistor
forks not working. regulator parameters.
• Internal transistor regulator error.
• Restart the truck.
• Reprogram the truck.
• If the error persists, change the
transistor regulator.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7– 9

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
3.121 Safety speed, raising and lowering the The transistor regulator cannot use the
forks not working. internal memory.
• Internal transistor regulator error.
• Restart the truck.
• Reprogram the truck.
• If the error persists, change the
transistor regulator.
3.140 Horn disabled. Safety speed. The horn output is short-circuited.
Check:
• connections and wiring harness
• cable 50
• the horn.
3.501 The main contactor is open. Faulty transistor regulator.
Check:
• the transistor regulator.
• factory parameter 1001 (Truck type).
If the error persists, change the
transistor regulator.
3.502 The main contactor is open. The logic card in the tiller arm handle
cannot download parameters to the
transistor regulator.
• Restart the truck.
• Replace the logic card in the tiller
arm handle.
• If the error persists, change the
transistor regulator.

7 – 10 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
3.510 The main contactor is open. CAN communication problem with the
transistor regulator at start-up.
Check in the following order:
• connections. Pull out the battery
connector [X1] and reconnect it
again. Start the truck.
• units. Connect TruckCom to load the
truck’s software. If the node/unit
ACT[T1] does not respond, try to
start a download of software in the
mode“Emergency download”.
• software. Make sure that ICH [A5]
and ACT [T1] have software from the
same software package.
• connections and wiring harness
• cables 119 and 120
• transistor regulator [T1], replace if
needed.
If the error remains, re-install the
transistor regulator [T1] and replace
the logic card [A5] of the handle.

3.511 The main contactor is open. The logic card of the tiller arm handle
does not receive CAN data from the
transistor regulator.
Check:
• connections and wiring harness
• cables 119 and 120
• the logic card in the tiller arm handle
and replace it if necessary.
If the error continues, change the
transistor regulator..

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 11

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
3.512 Transistor regulator stops all functions. The transistor regulator does not
receive CAN data from the logic card in
the tiller arm handle.
Check:
• connections and wiring harness
• cables 119 and 120
• the logic card in the tiller arm handle
and replace it if necessary.
If the error continues, change the
transistor regulator..
3.514 The main contactor is open. The logic card in the tiller arm handle
cannot send CAN data to the transistor
regulator.
Check:
• connections and wiring harness
• cables 119 and 120
• the logic card in the tiller arm handle
and replace it if necessary.
If the error continues, change the
transistor regulator..
3.515 Transistor regulator stops all functions. The transistor regulator has detected a
CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• the logic card in the tiller arm handle
and replace it if necessary.
If the error continues, change the
transistor regulator..
3.520 Transistor regulator stops all functions. The transistor regulator detects a
short-circuit in the power supply unit.
Check:
• the motor wiring harness
• the motor
• the transistor regulator.

7 – 12 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
3.521 Transistor regulator stops all functions. The transistor regulator has detected
low motor voltage.
Check:
• the motor wiring harness
• the motor
• the transistor regulator.
3.522 Transistor regulator stops all functions. The transistor regulator has detected
high motor voltage.
Check:
• the motor wiring harness
• the motor
• the transistor regulator.
3.523 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem in its own firmware
or hardware.
Internal transistor regulator error.
Reprogram the truck, both in the
handle and the transistor regulator.
3.524 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem in its own firmware
or hardware.
Internal transistor regulator error.
Reprogram the truck, both in the
handle and the transistor regulator.
3.525 Transistor regulator stops all functions. The transistor regulator has detected
that the motor phase is 0 (zero)
continuously.
Check:
• the motor wiring harness
• the motor
• the transistor regulator.
3.526 Transistor regulator stops all functions. The current measuring in the transistor
regulator is defective.
Internal transistor regulator error.
Replace the transistor regulator.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 13

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
3.527 Transistor regulator stops all functions. Defective software in the transistor
regulator.
Internal transistor regulator error.
Check that the latest software has
been downloaded to the transistor
regulator.
3.528 Transistor regulator stops all functions. Internal problem in the transistor
regulator microprocessor.
• Internal transistor regulator error.
Check that the latest software has
been downloaded to the transistor
regulator.
• If the error persists, change the
transistor regulator.
3.529 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem.
• Internal transistor regulator error.
Check the software.
• If the error persists, change the
transistor regulator.
3.530 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem.
• Internal transistor regulator error.
Check the software.
• If the error persists, change the
transistor regulator.
3.531 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem.
• Internal transistor regulator error.
Check the software.
• If the error persists, change the
transistor regulator.
3.532 Transistor regulator stops all functions. The transistor regulator has detected
an internal problem in the AD
converter.
• Internal transistor regulator error.
• Replace the transistor regulator.

7 – 14 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
3.533 Transistor regulator stops all functions. The charging voltage for the transistor
regulator capacitor indicates abnormal
values.
Check:
• connections and wiring harness
• cable 20
• the transistor regulator.
• pump contactor
If the error persists, change the
transistor regulator.
3.534 Transistor regulator stops all functions. The transistor regulator has detected a
problem with the speed sensor.
Excessive frequency fluctuations.
Check:
• connections and wiring harness
• the speed sensor and replace if
needed.
3.535 Transistor regulator stops all functions. Incorrect checksum for the transistor
regulator parameters.
Download the latest software to the
handle and the transistor regulator.
3.536 Transistor regulator stops all functions. The transistor regulator current supply
unit is outside the valid range.
Internal transistor regulator error.
Replace the transistor regulator.
3.537 Transistor regulator stops all functions. Multi-direction command issued by
handle.
Internal error in handle.
3.538 The main contactor is open. Unknown error in the transistor
regulator.
• Internal transistor regulator error.
Reprogram the transistor regulator.
• If the error persists, change the
transistor regulator.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 15

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
3.539 Transistor regulator stops all functions. The transistor regulator detects that the
battery voltage is not in the interval 18
V - 28.8 V.
Check:
• the wiring harness between the
battery and transistor regulator.
• the battery.
3.540 Transistor regulator stops all functions. The transistor regulator output to the
main contactor has short-circuited.
Check:
• connections and wiring harness
• the main contactor.
3.541 Transistor regulator stops all functions. The transistor regulator output to the
parking brake is short-circuited.
Check:
• connections and wiring harness
• the parking brake.
3.542 Transistor regulator stops all functions. One of the transistor regulator's circuits
to the main contactor, parking brake or
lowering valve is short-circuited to
+24 V at start-up.
Check
• connections and wiring harness
• main contactor
• parking brake
• the lowering valve.
3.560 Transistor regulator stops all functions. The transistor regulator output to the
main contactor has short-circuited.
Check:
• connections and wiring harness
• the main contactor.
3.561 Transistor regulator stops all functions. The circuit between the transistor
regulator and the main contactor coil is
open.
Check:
• connections and wiring harness
• the main contactor.

7 – 16 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
3.562 The transistor regulator interrupts all The transistor regulator output to the
functions parking brake is open.
Check:
• connections and wiring harness
• parking brake.
3.563 Transistor regulator stops all functions. The transistor regulator coil circuit to
the parking brake is open.
Check:
• connections and wiring harness
• parking brake.
3.580 Transistor regulator stops all functions. The main contactor is closed.
Check:
• connections and wiring harness
• the main contactor.
3.581 Transistor regulator stops all functions. Main contactor open.
Check:
• connections and wiring harness
• the main contactor.
• the main fuse [F1]
3.582 Transistor regulator stops all functions. The transistor regulator's output for
power supply has the wrong voltage.
Check:
• connections and wiring harness
• main contactor
• lowering valve
• brake
• pump contactor.
Internal transistor regulator error.
Change transistor regulator.
3.583 Transistor regulator stops all functions. Internal transistor regulator voltage
supply is not switched on.
Internal transistor regulator error.
Change transistor regulator.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 17

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
Hydraulic system
4.001 Lifting prevented until the analogue The analogue controller for lifting and
controller for lifting and lowering is back in lowering was not in the neutral position
the neutral position. at start-up. (Not applicable for
SWE100).
Do not actuate the speed control when
starting the truck.
Check:
• the cable in the handle
• the potentiometer. If defective,
replace the potentiometer.
4.101 Safety speed, raising and lowering the The analogue signals for lifting and
forks not working. lowering show abnormal values.
Do not actuate the speed control when
starting the truck.
Check:
• the wiring in the handle
• the potentiometer. If defective,
replace the potentiometer.
4.102 Safety speed, raising and lowering the The handle type does not match the
forks not working. setting of factory parameter 1023
“Controls for hydraulic functions”.
Check the setting of factory parameter
1023 and compare with the handle type
on the truck.
4.125 Safety speed, raising and lowering the Pump motor current feedback remains
forks not working. zero when the pump motor operates.
Defective current sensor in the
transistor regulator. Change transistor
regulator.
4.126 Safety speed, raising and lowering the Excessive pump motor current
forks not working. feedback at start-up and in holding
mode.
Defective current sensor in the
transistor regulator. Change transistor
regulator.

7 – 18 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
4.521 The main contactor is open. Pump motor voltage too low.
Check:
• the wiring harness between the
transistor regulator and the pump
motor
• the pump motor.
4.522 The main contactor is open. Pump motor voltage too high.
Check:
• the wiring harness between the
transistor regulator and the pump
motor.
• the pump motor.
4.540 Transistor regulator stops all functions. • The transistor regulator output to the
lowering valve is short-circuited.
• Internal short-circuit in the transistor
regulator.
• Inspect the connections and wiring
harness.
• Disconnect the wiring to the lowering
valve and try restarting the truck.
• If the error remains, replace the
lowering valve or the transistor
regulator.
4.541 Transistor regulator stops all functions. The transistor regulator output to the
lowering valve is short-circuited to B-.
Inspect the connections and wiring
harness.
4.560 Transistor regulator stops all functions. The transistor regulator output to the
lowering valve is open.
Check:
• connections and wiring harness
• the lowering valve coil.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 19

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
Option.
8.001 Safety speed, raising and lowering the The collision sensor has registered
forks not working. collision levels that are above the
stated limits.
• Drive carefully.
• Check the value limits for detection
of collision (service parameters 105
and 106).
8.002 Safety speed, raising and lowering the The truck has intentionally been
forks not working. disabled by TLS.
Reset the truck to normal operation.
8.003 No event. Truck can be operated as usual. Argument warning from Spider
expansion unit.
Check settings of option parameters.
8.010 No event. Truck can be operated as usual. CAN communication problem with the
battery charger at start-up.
• Inspect the connections and wiring
harness.
• Make sure that ICH [A5] and BCU
[A30] have compatible software. See
section "7.1 General".
8.011 No event. Truck can be operated as usual. The logic card in the tiller arm handle is
not receiving CAN data from the
battery charger.
Inspect the connections and wiring
harness.
8.014 No event. Truck can be operated as usual. The logic card in the tiller arm handle
cannot send CAN data to the battery
charger.
Inspect the connections and wiring
harness.
8.020 No event. Truck can be operated as usual. The battery charger is not connected to
the battery.
Inspect the connections and wiring
harness.
8.021 No event. Truck can be operated as usual. The battery charger has detected low
battery voltage.
Check battery status.

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 Troubleshooting
Error codes
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Code Event Possible cause

Action
8.022 No event. Truck can be operated as usual. The battery charger has detected high
battery voltage.
Check battery status.
8.023 No event. Truck can be operated as usual. The battery charger has detected low
charging temperature.
Charge the battery at normal
temperature.
8.024 No event. Truck can be operated as usual. The battery charger has detected high
charging temperature.
Check:
• for dirt in the battery charger. Clean if
necessary.
• that the fan is operating.
8.027 No event. Truck can be operated as usual. Serious error in the battery charger.
Replace the battery charger.
8.028 No event. Truck can be operated as usual. The battery charger has exceeded the
time limit for charging.
Check the battery.
8.029 No event. Truck can be operated as usual. The battery charger is charging more
than maximum capacity.
Check:
• battery
• service parameter 110.
8.030 No event. Truck can be operated as usual. Battery charger is installed in truck, but
has not been activated via factory
parameter 1101.
Check factory parameter 1101.
8.031 No event. Truck can be operated as usual. Incorrect setting of battery charger
parameter.
Restart the truck. Check that the truck
and battery charger use the correct
software.
8.032 No event. Truck can be operated as usual. If the error code is shown when
charging with a built-in charger,
parameter 109 is set wrongly.
Check service parameter 109.

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 Troubleshooting
Error codes
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Code Event Possible cause

Action
8.110 Safety speed, raising and lowering the CAN communication problem with
forks not working. Spider expansion unit 1 at start-up.
Inspect the connections and wiring
harness.
8.111 Safety speed, raising and lowering the CAN communication problem with
forks not working. Spider expansion unit 1.
Inspect the connections and wiring
harness.
8.114 Safety speed, raising and lowering the CAN communication problem with
forks not working. Spider expansion unit 2 at start-up.
Inspect the connections and wiring
harness.
8.115 Safety speed, raising and lowering the CAN communication problem with
forks not working. Spider expansion unit 2.
Inspect the connections and wiring
harness.
8.123 Safety speed, raising and lowering the Spider expansion unit 1 programme
forks not working. warning.
Check option parameters.
8.124 Safety speed, raising and lowering the Spider expansion unit 2 programme
forks not working. warning.
Check option parameters.

7 – 22 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Troubleshooting chart
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.6 Troubleshooting chart

The following section describes the type of errors that can occur
together with a description of their cause.
The troubleshooting is grouped according to symptoms:
• The truck cannot be driven.
• The truck can be driven but only at reduced speed
• The truck can be driven but behaves abnormally
• Defective hydraulic functions.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 23

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 Troubleshooting
Troubleshooting chart
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.6.1 The truck cannot be driven.

Symptom Influencing elements Possible cause

Mechanical brake cannot Sensor [B60] • Sensor in wrong position and
be applied. disrupted by metal
• Faulty sensor.
Tiller arm handle always "On" in Damaged wiring harness or
Travel mode incorrect plus/minus current
feed
Transistor regulator, input Broken transistor regulator
[T1:95].
Mechanical brake cannot Brake If the gap is greater than 0.6
be released. mm, the brakes may be difficult
to apply.
Sensor [B60] • Sensor in wrong position or
cannot be influenced normally
• Defective sensor
• Break in sensor wiring.
Transistor regulator, input Broken transistor regulator
[T1:95].
Transistor regulator, output
[T1:90].
Corrosion Brake has seized due to
corrosion
Truck cannot travel after Sensor [B60] • Sensor in wrong position and
start-up although steering disrupted by metal
handle was in raised
• Defective sensor
position.
Tiller arm handle always "On" in Damaged wiring harness or
Travel mode incorrect plus/minus current
feed
Transistor regulator, input Broken transistor regulator.
[T1:95].

7 – 24 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Troubleshooting chart
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.6.2 Truck only travels at reduced speed

Symptom Influencing elements Possible cause

Speed always reduced Click-2-Creep function Click-2-Creep function activated
Turtle function Turtle function activated
Operator parameter 6 - speed Operator parameter 6 has not
been set to the maximum value
Pulse transducer [B11] Defective or disconnected pulse
transducer [B11]
Motor cable connections • One of the phases U, V, W is
not connected
• Broken cable
Mechanical brake • Partially applied brake
• Incorrect gap.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 25

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 Troubleshooting
Troubleshooting chart
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.6.3 The truck can be driven but behaves

abnormally

Symptom Influencing elements Possible cause

Truck moves in the wrong Motor cable connections Incorrect U, V, W connections
direction.
Acceleration always Driver parameter 4 Value setting low.
reduced
Reversing braking always Service parameter 201 Value setting low.
reduced.
Neutral braking always Driver parameter 5 Value set too low
reduced
The truck cannot be Parameter 102. The Red off key Parameter 102 has been
switched off. on the keypad does not work. incorrectly set for the log-in unit
installed in the truck.
Speed always reduced Pulse sensor [B11] Defective, dirty or disconnected
pulse transducer [B11]
Motor cable connections • One of the phases U, V, W is
not connected
• Broken cable

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 Troubleshooting
Troubleshooting chart
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.6.4 The truck travels, but some functions

do not work.
Software compatibility
Make sure that correct software for logic card [A5] and transistor
regulator [T1] as well as battery charger [A30] are downloaded in the
truck. See section "7.1 General".

Hardware compatibility matrix

Make sure the correct software of the logic card [A5] and the transistor
regulator [T1] have been installed in the truck by referring to the matrix
below.

ACT was not replaced ACT replaced

transistor regulator[T1] transistor regulator[T1]
ICH was not replaced OK Warning 2.004. Use TruckCom
logic card [A5] to download new backup values.
Open TruckCom, and select
“Copy configuration to
secondary unit: ACT”

ICH replaced Error code 2.101. Use TruckCom Replace one node at a time and
logic card [A5] to upload new backup values. implement the corresponding
Select “Copy configuration to measure. See 17.2 and 16.5.2
primary unit: ICH”

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 27

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 Troubleshooting
Troubleshooting chart
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.6.5 Defective hydraulic functions

Symptom Influencing elements Possible cause/Remedy

The forks can be lowered but Low or no hydraulic pressure • Low oil level
not raised.
• Clogged suction filter
• Defective or wrongly adjusted
pressure limiting valve
• Defective hydraulic pump,
replace the hydraulic unit
Pump motor [M3] does not work • Hydraulic unit fuse [F3], 125
A, has blown; replace fuse.
Fore more information, see
the table Pump motor [M3]
does not operate below:
• Measure current and voltage
through and across the pump
motor [M3] respectively.
• Pump motor [M3] voltage/
current normal
• No current or voltage through/
across the pump motor [M3]
• Voltage across the pump
motor [M3], but no current
through it

7 – 28 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Troubleshooting chart
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Symptom Influencing elements Possible cause/Remedy

Forks can be raised but not The proportional valve [Q4] for • Measure current and voltage
lowered. lowering the forks does not through and across the valve
open: coil.
For more information See
“ Cont'd. The proportional
valve [Q4] for lowering the
forks does not open:” on
page 30.
• Solenoid valve voltage/
current normal
• No current or voltage through/
across the solenoid valve coil
• Voltage across solenoid valve
coil, but no current through
the coil
Forks can neither be raised Defective fuse [F50] 7.5 A Replace the fuse
nor lowered
Logic card [A5] faulty Replace the logic card
Defective transistor regulator Replace the transistor regulator
[T1]
Factory parameter 1023 Check the parameter value
settings

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 29

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 Troubleshooting
Troubleshooting chart
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Cont'd. Pump motor [M3] does not work:

Symptom Influencing elements Possible cause/Remedy
Pump motor [M3] voltage/ Mechanical fault in the pump Replace the hydraulic unit
current normal
No current or voltage through/ Damaged wiring or Check the wiring harness for
across the pump motor [M3] connections in the pump interruptions or short-circuits to
motor [M3] other electric components
Voltage across the pump motor Open circuit in the pump Replace the hydraulic unit
[M3], but no current through it motor [M3]

Cont'd. The proportional valve [Q4] for lowering the forks does not open:
Symptom Influencing elements Possible cause/Remedy
The proportional valve's [Q4] Mechanical fault in the Replace the hydraulic unit
current/voltage is normal proportional valve [Q4]
No or low current/voltage Damage to the proportional Check the wiring harness for
through/across the valve's [Q4] wiring harness or interruptions or short-circuits to
proportional valve's coil [Q4] connections other electric components
Defective tiller arm Hall sensor Replace logic card [A5]
for fork lowering
Transistor regulator [T1], output Replace the transistor regulator
108 “OUT.LOWER VALVE” [T1]
defective
Transistor regulator [T1], output Se the troubleshooting chart
82 “OUT. +24 V HIGH SIDE Truck cannot be driven
DRIVER” defective
Voltage across the Break in the proportional valve's Replace the hydraulic unit
proportional valve's coil [Q4], coil [Q4]
but no current through it

7 – 30 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Built-in test function
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.7 Built-in test function

The truck control system has a number of built-in test functions that can
be used to aid the troubleshooting process. To activate the test
functions:
1. Connect the CAN service key to [X41] and log in.
2. Battery status symbol is lit.
3. Press the horn button [S18] repeatedly to choose Built-in Test
function.
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.

Mod Flashing symbol Data shown in the display Normal value

e
1 Battery voltage (V)

2 Current across battery (A) -

3 The set speed value that is sent to the Min.: -142

transistor regulator Max: 142

4 Travel speed value from travel speed Min: approx. -140

sensor Max: approx. 140

5 Fork lowering on/off To: 1 Off: 0

Fork lifting on/off On: 2 Off: 0

6 Fork under mast sensor #1 On (0V): Down

Off (>5V): Up

7 N/A -

8 N/A -

9 Input/output status, transistor regulator -

[T1]

10 Input/output status, logic card [A5] -

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 31

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 Troubleshooting
Digital input/output status
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Mod Flashing symbol Data shown in the display Normal value

e
11 Maximum value registered by the collision Min.: 0
sensor (option) Max: 100

12 Status of inputs/outputs, expansion unit 1 -

(optional)

13 Status of inputs/outputs, expansion unit 2 -

(optional)

7.8 Digital input/output status

7.8.1 Test function “9” – Transistor regulator

In this setting, the digital inputs and outputs are tested by checking
specific segments on the display according to the following tables.

A
F G B

E C
1 2 3 4 D H

Position:
1 and 2: The transistor regulator's current value. What is the current
value in each input/output.
3 and 4: The transistor regulator's set point. Relating to what the
software value should be.
A – H: Reference to segment
One or more segments may be lit continuously at each position. The
indications can also be combined across several positions.
[xxx] in the table is the component designation
{nn} in the table is the wiring number in the electrical wiring diagram.

7 – 32 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Troubleshooting
Digital input/output status
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Current values
Function Pos 1 Pos 2 Pos 3 Pos 4
Fork under mast sensor #2 On: Forks down
A * * *
[B64] INP. MAST SWITCH 2 Off: Forks up
Main contactor [Q10]. On: Contactor closed
B * * *
Off: Contactor open
Parking brake [Q1] On: Brake released
C * * *
Off: Brake applied
Tiller arm in drive position [B60] On: Tiller arm in drive
INP. TILLER ARM IN DRIVE position
D * * *
POS. Off: Tiller arm in one of
the end positions
- E * * * Not assigned
Support arm in lower position.
On: Down
[B62] INP. SUPPORT ARM IN F * * *
Off: Up
LOWEST POS
Fork under mast sensor #1 On: Down
G * * *
[B63] INP. MAST SWITCH 1 Off: Up
- H * * * Not assigned
- * A * * Not assigned
- * B * * Not assigned
- * C * * Not assigned
- * D * * Not assigned
- * E * * Not assigned
Fork valve active. On: Valve open
* F * *
[Q22] OUT. FORK VALVE Off: Valve closed
Support arm valve active.
On: Valve open
[Q23] OUT. SUPPORT ARM ‘ G * *
Off: Valve closed
VALVE
- * H * * Not assigned

A
F G B

E C
D H

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 33

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 Troubleshooting
Digital input/output status
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Set points
Function: Pos 1 Pos 2 Pos 3 Pos 4
- * * A * Not assigned
Main contactor [Q10]. * * B * On: Contactor closed
OUT. MAIN CONTACTOR Off: Contactor open
- * * C * Not assigned
Parking brake [Q1] * * D * On: Brake released
OUT. BRAKE RELEASE Off: Brake applied
- * * E * Not assigned
Pump motor [M3] active * * F * On: Active
Off: Not active
Proportional valve [Q4] * * G * On: Affected
Off: Not affected
- * * H * Not assigned
Pump contactor [Q25]. * * * A On: Contactor closed
OUT. PUMP CONTACTOR1 Off: Contactor open

Fork valve [Q22] * * * B Not assigned

OUT. FORK VALVE2
Support arm valve [Q23] * * * C Not assigned
OUT. SUPPORT ARM VALVE2
Spare * * * D Not assigned
(Digital out 4)
- * * * E Not assigned
- * * * F Not assigned
- * * * G Not assigned
- * * * H Not assigned

A
F G B

E C
D H

1.Only applies to SWE100.

2.Applies only to SWE120L, 140L and 200D.

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 Troubleshooting
Digital input/output status
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.8.2 Test function “10” – Logic card

Function: Pos 1 Pos 2 Pos 3 Pos 4

- A * * * Not assigned
- B * * * Not assigned
- C * * * Not assigned
Front fork lift button [A5:S19] D * * * On: Button depressed
Front fork lowering button On: Button depressed
E * * *
[A5:S20]
Rear fork lift button [A5:S21] F * * * On: Button depressed
Rear fork lowering button On: Button depressed
G * * *
[A5:S22]
Sound signal control [S18] H * * * On: Button depressed
Outermost option button, right On: Button depressed
* A * *
side [S116]
Centre option button, right side On: Button depressed
* B * *
[S115]
Innermost option button, right On: Button depressed
* C * *
side [S114]
Outermost option button, left On: Button depressed
* D * *
side [S113]
Centre option button, left side On: Button depressed
* E * *
[S206]
Innermost option button, left On: Button depressed
* F * *
side [S111]
- ‘ G * * Not assigned
- * H * * Not assigned

A
F G B

E C
D H

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 7 – 35

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 Troubleshooting
Digital input/output status
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

7.8.3 Test function “12” – Expansion unit SEU

(option).

Function: Pos 1 Pos 2 Pos 3 Pos 4

Digital input 1 A * * * -
Digital input 2 B * * * -
Digital input 3 C * * * -
Digital input 4 D * * * -
Digital input 5 E * * * -
Digital input 6 F * * * -
Digital input 7 G * * * -
Digital input 8 H * * * -
Digital output 1 * A * * -
Digital output 2 * B * * -
Digital output 3 * C * * -
Digital output 4 * D * * -
- * E * * Not assigned
- * F * * Not assigned
- ‘ G * * Not assigned
- * H * * Not assigned

A
F G B

E C
D H

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 Troubleshooting
Test function for the display
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

7.9 Test function for the display

The digital display itself can be tested to verify all segments of the
display function correctly.
Proceed as follows to the test the display:
1. Ensure that the battery is connected.
2. Ensure that the truck is switched off. Press the OFF button.
3. Enter the appropriate PIN code. Note: Without pressing the ON
button.
4. Keep the horn button depressed until “d” is displayed, then release
it.
All segments and symbol icons must flash sequentially.

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 Troubleshooting
Test function for the display
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Chassis 0000
Support arm 0350
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

8 – Chassis 0000

8.1 Support arm 0350

8.1.1 Support arm lift, lateral adjustment

a
b

1. Loosen the locking nut

2. Adjust the lateral guides using the adjustment screw (b). There are
four adjustment screws.
3. Adjust the lateral guides so that there is no play but so that the
lowering does not jam.
4. Lock the adjustment screws position with the locking nut.

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Chassis 0000
Support arm 0350
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

8.1.2 Adjusting the kneeling action

The gap between the chassis pressure plate and the support arm link
roller must be between the minimum value of 0.4 and the maximum of
2.0.
1. Check the gap. A precondition for checking the gap is that the roller
is fitted and that they are in the lowered position.
2. Loosen the cylinder (a) if the gap is incorrect (6 mm Allen)
3. Place a suitable number of shims 7501642 under the cylinder (a).
4. Tighten the cylinder.
5. Check that the gap is correct.

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 Chassis 0000
Motor mounts 0450
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

8.2 Motor mounts 0450

8.2.1 Replacing springs (not applicable for

SWE120S)
Proceed as follows to replace the springs that press the drive unit
against the ground:
1. Remove the covers and the battery door.
The top cover is secured with Velcro tape. Be careful when
detaching the cover. Use of a suitable tool is recommended.
2. Lift out the battery.
3. Disconnect the cables to the drive motor and the pump motor and
also the wiring harness.
4. Disconnect the cable duct.

5. Unfasten the battery connector and the battery cable bracket.

6. Install the threaded M16 bar. See section "Tools".

7. (1) Washer and nut on the top side. (2) Screw the shaft into the

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 8– 3

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Chassis 0000
Motor mounts 0450
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

threaded hole and tighten with the nut.

8. Change the upper stop screws for M8 x 120, washers are not
needed.
9. Remove and discard the screws to the upper bracket.
10. Remove the lower screws.
11. Compress the spring assembly using the threaded bar until the lips
are clear.

12. Unload the springs by prying up the bracket using the threaded bar.

Note:
Check that the bushings do not get stuck or become damaged during
reassembly.

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 Chassis 0000
Disassembling the platform
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

8.3 Disassembling the platform

1. Apply a load on the platform and loosen the upper dampening stop
together with the spring cover plate.

2. Disassemble the platform from the truck by loosening the four

bolts.
3. Put the platform on the floor behind the truck with the spring facing
you and placing the other edge under the truck's foot guard.

4. Loosen all 8 screws securing the bracket, which the spring clamp is
pushing against.

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Chassis 0000
Disassembling the platform
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Note: Pay utmost attention when working with tensioned springs.

5. Relieve the spring using a crowbar or a large screwdriver and
carefully remove the bracket.
6. Pull out the axle and replace the part(s) that should be replaced.
7. Install in reverse order.

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 Electric drive motor 1700
Components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

9 – Electric drive motor 1700

9.1 Components

E
D

Pos. Description
A Speed sensor
B Connection, motor cables
C Motor: SWE120L/140/140L/200D 1.5kW
C Motor: SWE100/120/120S 1.0kW
D Temperature sensor
E Dust shield

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Electric drive motor 1700
Disassemble the motor from the truck
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

9.2 Disassemble the motor from the

truck
1. Remove the covers.
The top cover is secured with Velcro tape. Be careful when
detaching the cover. Use of a suitable tool is recommended.
2. Cut off the cable ties of the cable duct on the transistor regulator
side and disconnect cable connectors X5 and X60.

a
3. Loosen the operating console's mounting screws (a) and remove
the operating console and tiller arm.
4. Remove the brake's cable connection Q1.

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 Electric drive motor 1700
Disassemble the motor from the truck
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

5. Remove the speed sensor's cable connector B11.

6. Remove the temperature sensor B1

7. Remove the motor cables and unscrew the retaining screws of the
motor.
8. Lift the motor out of the truck.
9. If needed, remove the brake and the speed sensor.
Note:
Cover the drive gear to prevent loose items from falling into the drive
gear after the drive motor has been removed.
Install the motor in the reverse order.
See section "9.3 Tightening torques – Drive motor".
Note:
When installing the motor, it is very important that the motor is
aligned so that the grooves in the motor and the motor bracket are
exactly opposite each other before the mounting screws are fitted.
See illustration below.
Tighten the 4 drive motor mounting screws (a). The screws are
tightened cross-wise in two stages. In other words, do not tighten too
much the first time. See section "9.3 Tightening torques – Drive
motor".

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 9– 3

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Electric drive motor 1700
Disassemble the motor from the truck
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Electric drive motor 1700
Tightening torques – Drive motor
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

9.3 Tightening torques – Drive motor

The drive motor tightening torques are depicted in the figure below:

3.5Nm
T30

3 + 0,5 Nm
10 mm

8 Nm
T30

9.4 Installing the temperature sensor

1. Cut off the wiring to the broken temperature sensor, and splice on
the new one.
2. Place the new temperature sensor on the motor.
3. Carefully clean the area and make sure all surfaces are dry.
4. Apply plastic steel by pushing out a string that is half the length of
the curing agent compared to the putty, then carefully mix the two
(be careful not to mix a larger amount than will be used in 5
minutes).
5. Apply a layer of plastic steel, at least 4 mm thick, and make sure the
repaired surface has an overlap of at least 2 cm.
6. Secure the steel plastic with masking tape and allow it to cure.
7. Remove the masking tape.
The temperature sensor should now be completely covered by
steel plastic.
8. Following curing, it is recommended to apply another layer of
plastic steel.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 9– 5

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Electric drive motor 1700
Cleaning
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

9.5 Cleaning
Keep the motor as clean as possible since this is a decisive factor for
correct operation. Regularly inspect the motor and motor compartment
for build-up of dust, oil and other contaminants.
Dirty and/or greasy components should be cleaned with a rag
moistened with solvent. Use a rag of lint-free cloth material. Do not use
too much solvent as it could penetrate into the motor parts.
After cleaning, dry the components thoroughly. The easiest way is by
heating.
Note:
Windings and insulation must not be heated over 125°C and not for
longer than 6 hours.

9– 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electric drive motor 1700
Cleaning
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Denna sida är avsiktligt lämnad tom

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Electric drive motor 1700
Cleaning
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Drive gear 2550
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

10 – Drive gear 2550

10.1 General
The drive gear is combined with the motor and brake assembly in a
complete drive unit.
The complete overhaul of the drive gear must be performed by the
supplier.

10.2 Components

Pos Description
a Drive gear
b Screw

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 10 – 1

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 Drive gear 2550
Removing the gear from the truck (not applicable for SWE120S)
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

10.3 Removing the gear from the truck

(not applicable for SWE120S)
1. Remove the covers.
The top cover is secured with Velcro tape. Be careful when
detaching the cover. Use of a suitable tool is recommended.
2. Cut off the cable ties of the cable duct on the transistor regulator
side and disconnect cable connectors X5 and X60.
3. Unscrew the retaining screws of the steering console and remove
the steering console and the tiller arm.
4. Disassemble the speed sensor and disconnect the cable
connections Q1 and B1.
5. Disconnect the motor cables and unscrew the retaining screws of
the motor

6. Lift the motor out of the truck.

7. Insert a 30 mm plug in the hole in the gear housing to prevent oil
leakage when the gear is removed from the truck.
8. Remove the cable duct.
9. Install the threaded M16 bar.

10 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Drive gear 2550
Removing the gear from the truck (not applicable for SWE120S)
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

10. Lift the motor bracket using the threaded rod until the drive wheel is
lifted approx. 4 mm from the floor.

11. Unscrew the retaining screws of the gear box.

12. Lift carefully approx. 125 mm lay the gear down on the floor.
13. Lift a further 100 mm, a total of 225 mm and pull it out to the rear
edge.

Steps 12, 13

Install in reverse order.

Please note the risk of crushing when installing the unit.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 10 – 3

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 Drive gear 2550
Removing the gear from the truck (not applicable for SWE120S)
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

10.4 Removing the gear from the truck

(not applicable for SWE120S)
1. Elevate the drive unit approx 190 mm.
2. Loosen the drive wheel.
3. Remove the covers.
The top cover is secured with Velcro tape. Be careful when
detaching the cover. Use of a suitable tool is recommended.
4. Cut off the cable ties of the cable duct on the transistor regulator
side and disconnect cable connectors X5 and X60.
5. Unscrew the retaining screws of the steering console and remove
the steering console and the tiller arm.
6. Disassemble the speed sensor and disconnect the cable
connections Q1 and B1.
7. Disconnect the motor cables and unscrew the retaining screws of
the motor
8. Lift the motor out of the truck.
9. Insert a plug in the hole in the gear housing to prevent oil leakage
when the gear is removed from the truck.
10. Unscrew the retaining screws of the gear box.
11. Put down the gear and pull it out to the rear edge.
Install in reverse order.
Put a wooden block under the gearbox later to facilitate subsequent
reassembly.

10 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Brakes 3180
Components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

11 – Brakes 3180
In normal use, the brake should not require any maintenance.

11.1 Components
I

A
C
F

G
E

Pos. no. Description

A Circlip
B Complete brake assembly
C Screw
D Key
E Hub
F Brake disc
G Flange
H Dust shield
I Cable bushing

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 11 – 1

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 Brakes 3180
Releasing the brake
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

11.2 Releasing the brake

Note:
The brakes should only be released when the truck needs to be
moved in connection with service and repair work.

A
The brakes on the truck can be released manually by screwing two
screws (M5) into the holes (A). The screws must be 30-35 mm long.
Note:
Remember to remove the screws before operating the truck again.

11 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Brakes 3180
Installing the dust shield
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

11.3 Installing the dust shield

Applicable to serial number up to and including 6140925

Step 1 Step 2 Step 3

Steps 4,5 and 6

Gap = minimum 0.2 Step 7

Step 9
Step 8

Step 12
Steps 10 and 11 T = 23

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 11 – 3

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 Brakes 3180
Installing the dust shield
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function
being partly or completely lost.
Method
Preconditions:
• Truck switched off and the battery disconnected
• Motor compartment open

1. Remove steering yoke and tiller arm from the truck as a unit (See
the repair manual). Note the position of the cable grommet so that
refitting is done correctly.
2. Unscrew the brake retaining screws and disconnect the cable.
3. Remove the brake unit from the truck. Note the position of the
brake so that refitting is done correctly.
4. Place the parking brake on a workbench with the magnet housing
facing downwards.
5. Clean the brake using compressed air. Clean from the inside
outwards.
6. Repeat the cleaning as necessary until a 0.2 mm feeler gauge can
be inserted. If there are particles that cannot be cleared away with
compressed air, these may be carefully scraped away.
Measure the air gap between the magnet housing of the brake unit
and the movable pressure disc. Measuring must be done around
the entire pressure disc, both on the inside and the outside.
Note:
It is extremely important that an air gap of min. 0.2 mm is maintained all
around the brake. If the prescribed measurement cannot be
maintained, the brake must be replaced

7. Turn over the parking brake, and press the dust shield into place.
8. Turn over the brake unit again, and place it with the magnet
housing facing downwards. Use a suitable blunt tool to press on
the dust shield so that it is level with the upper part of the magnetic
housing.
9. Check the position of the dust shield.
10. Refit the brake unit according to your notes, and reconnect the
connector.
11. The brake retaining screws are tightened with 5 Nm.
12. Refit the tiller arm and the steering yoke, and tighten the retaining
screws to 23 Nm.
Make sure that the cable grommet is fastened properly and
according to your notes, when fitting it to the brake unit.
Concluding procedures:
• Connect the battery and close the motor compartment cover.
• Start the truck and check that the brake works correctly.

11 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Brakes 3180
Installing the dust shield
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

11.4 Installing the dust shield

Applicable to serial number starting with 6140927

Step 1 Step 2 Step 3

Steps 4,5 and 6

Gap = minimum 0.2 Step 7 Steps 8

Steps 9 and 10
T = 5 Nm

Step 12
T = 23

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 11 – 5

https://www.besttruckmanuals.com/
 Brakes 3180
Installing the dust shield
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function
being partly or completely lost.
Method
Preconditions:
• Truck switched off and the battery disconnected
• Motor compartment open

1. Remove steering yoke and tiller arm from the truck as a unit (See
the repair manual). Note the position of the cable grommet so that
refitting is done correctly.
2. Unscrew the brake retaining screws and disconnect the cable.
3. Remove the brake unit from the truck. Note the position of the
brake so that refitting is done correctly.
4. Place the parking brake on a workbench with the magnet housing
facing downwards.
5. Clean the brake using compressed air. Clean from the inside
outwards.
6. Repeat the cleaning as necessary until a 0.2 mm feeler gauge can
be inserted. If there are particles that cannot be cleared away with
compressed air, these may be carefully scraped away.
Measure the air gap between the magnet housing of the brake unit
and the movable pressure disc. Measuring must be done around
the entire pressure disc, both on the inside and the outside.
Note:
It is extremely important that an air gap of min. 0.2 mm is maintained all
around the brake. If the prescribed measurement cannot be
maintained, the brake must be replaced

7. Turn over the parking brake, and press the dust shield into place.
8. Check the position of the dust shield.
9. Refit the brake unit according to your notes, and reconnect the
connector.
10. The brake retaining screws are tightened with 5 Nm.
11. Refit the tiller arm and the steering yoke, and tighten the retaining
screws to 23 Nm.
Make sure that the cable grommet is fastened properly and
according to your notes, when fitting it to the brake unit.
Concluding procedures:
• Connect the battery and close the motor compartment cover.
• Start the truck and check that the brake works correctly.

11 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Drive wheel 3530
Replacing the drive wheel
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

12 – Drive wheel 3530

12.1 Replacing the drive wheel

Step 1

Step 2

Step 4

Step 5

Method
DANGER!
Risk of crushing since a poorly supported truck could fall.
1. Pull out the battery.
2. Lift up the truck about 100 mm and support it with trestles.
3. Turn the drive wheel diagonally from one of the sides.
4. Unscrew the 5 nuts, and remove them along with the washers.
5. Lift out the wheel.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 12 – 1

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 Drive wheel 3530
Replacing the drive wheel
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Step 1 Step 2

Step 3

Step 4

Step 5

Installing the drive wheel on the truck

1. Fit the drive wheel.

×n 2. Fasten the screws and washers.

3. Tighten the screws crosswise - tightening torque:81 ± 19 Nm
s mm 4. Remove the trestles and lower the truck to the ground.
Step 3: s = 17, n = 5 5. Connect the battery.
Mv = 81Nm

12 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Castor wheels 3540
Components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

13 – Castor wheels 3540

This chapter does not apply to SWE120S

13.1 Components

Pos. Description Pos. Description

A Circlip H Screw
B Washer I Spacer
C Screw J Spacer
D Bracket K Bearing
E Washer L Guard
F Bearing M Nut
G Circlip

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 13 – 1

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 Castor wheels 3540
Replacing the castor wheel
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

13.2 Replacing the castor wheel

Step 2

Steps 3 and 4
Step 1

Step 5

Step 6

Method
DANGER!
Risk of crushing since a poorly supported truck could fall.
1. Support the truck in a secure manner.
2. Disconnect the truck battery
3. Unscrew the castor wheel.
4. Refit the castor wheel and its four fastening screws and washers.
5. Connect the battery.
6. Remove the support trestles.

13 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Support arm wheel 3550
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

14 – Support arm wheel 3550

c

Pos Name
a Screw
b Bracket
c Bogie wheel
d Single wheel
e Axle
f Locking ring

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 14 – 1

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 Support arm wheel 3550
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

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 Tiller arm 4000
Tiller arm components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

15 – Tiller arm 4000

15.1 Tiller arm components

A

T
B

E
S
D I
F J

R G
H K
Q
L

P M
N
O
V

Pos. Description Pos. Description

A Tiller arm M Indicator sleeve
B Rubber buffer N Plate
C Cylindrical bolt O Yoke
D Gas strut P Cable clamp
E Circlip Q Screw
F Rubber buffer R Yoke
G Bushing S Screw
H Threaded insert T6 Cover
I Spring pin U Cover
J Holder V Cable clamp
K Safety sensor B60 W Mounting screw for
cable clip
L Shaft

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 1

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 Tiller arm 4000
Disassembling the tiller arm
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15.2 Disassembling the tiller arm

1. Remove the inspection cover.
2. Remove the cover (T).
3. Unscrew the retaining screws of the yoke (R).
4. Remove the cable clip (P) by pressing on it with your thumbs and
lifting it up. Remove the clip through the hole in the control console.
Note:
Do not attempt to pry it out with a screwdriver.
5. Cut off the cable ties of the cable duct on the transistor regulator
side and disconnect cable connectors X5 and X60.
Assemble in reverse order.

15.3 Replacing the gas strut

1. Remove the cover (T).
2. Remove the cable clamp mounting screw (W)
3. Remove the adjusting screw (Q).
4. Remove the locking mechanism (E) from the locking shaft (C) of
the gas strut
5. Remove the locking shaft (c) of the gas strut.
6. Remove the gas strut.
Assemble in reverse order.
Note:
Pay attention during assembly and make sure no cables are pinched.

15 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tiller arm 4000
Replacing the safety sensor
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

15.4 Replacing the safety sensor

15.4.1 Dismantling
1. Remove the gas strut. See section "15.3 Replacing the gas strut".
2. Drive in the shaft's (L) spring pin (I). Use a suitable implement and
drive the spring pin all the way into the shaft.
3. Drive out the shaft (L) approx. 5 mm to clear the hole for the spring
pin. Take care not to pinch the indicator sleeve (M).
4. Turn the shaft (L) so that the back of the indicator sleeve (M)
becomes accessible.
5. Remove the indicator sleeve (L).
To prevent damaging the indicator sleeve, pry it loose from both
sides at the same time.
6. Knock out the shaft (L).
Note:
Make sure the tiller arm does not drop and damages the wiring
harness.
7. Remove the cable clip mounting screw (W).
8. Remove the sensor's mounting screw (W).
9. Remove connector B60 from the sensor (K).
10. Remove the sensor.

15.4.2 Installation
1. Fit the sensor (K)
2. Fit connector B60 to the sensor.
3. Put some Loctite on the threads of the sensor mounting screw (S),
or replace the screw. Screw in the screw.
4. Fit the cable clip mounting screw (W).
Note:
The cable must be routed to the right of the sensor (K), towards the
spring pin.
5. Knock out the spring pin (I) from the shaft (L) and fit the shaft.
6. Fit the indicator sleeve and turn the shaft so that the sleeve is
turned towards the sensor. Turn it just so much that the spring pin
can enter the shaft.
7. Use a suitable implement and drive the spring pin into the yoke (O)
and the shaft (L). The spring pin must be driven so far that the
implement enters the yoke to a depth of approx. 19 mm. See
illustration.
19
m

8. Fit the gas strut. See section "15.3 Replacing the gas strut".
m

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 3

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

9. Check the safety sensor for correct operation.

15.5 Electrical steering system – 4000

15.5.1 Tiller arm handle C4110

15.5.2 Components of the tiller arm handle

15 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

(new model)
G H

C
I
F

Y
B
D

A
E

K J
L

S
T
M

X
K
L
R

P
Q O

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 5

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15.5.3 Components of the tiller arm handle

(old model)

G
A
F I
C

A B
D

K
J
L

S
T
M

X
K
L

Q P
O

15 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Pos. Description Pos. Description

Speed control/travel
A Symbol board M
direction selector
B Push button N Display
C Push button O Cable clip
D Safety reversing push button P Cable clip
E Spring Q Cover
F Logic card R Plug
Cover, transparent
G Seal S
plastic
H Spring T6 Seal
I Cover U Handle
J Seal V Cover
K Horn button X Wiring harness
L Signal switch Y Butterfly switch

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 7

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15.5.4 Disassembly/assembly of tiller arm

handle

Step 2
Step 1

Step 3 Step 4

15 – 8 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Step 5

Step 6

Step 10

Step 13

Step 15 Step 16
Step 14

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 9

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Warning!!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure you take the necessary steps to prevent static electricity,
ESD protection, before starting work on the steering module.

Disassembling
1. Disconnect the truck battery.
2. Detach the keypad and disconnect it from the logic card
3. Remove the screws holding the upper cover and keep hold of the
upper cover to prevent damage to the logic card cable
4. Disconnect the CAN connection to the logic card
5. Remove the screws holding the cover over the logic card and
carefully lift away the cover.
Tip: Hold a finger between the cover and the shaft for the speed
control buttons to prevent the speed control assembly from falling
down.
6. Lift off the speed control assembly
7. If the logic card is to be replaced, disconnect its connectors and lift
out the logic card.

Assembly
8. Fit the new logic card in place and connect it.
9. Check the cable connection on the logic card and that the contacts
are correctly connected.
10. Fit the speed control assembly in position. Hook the ends of the
spring around two the lugs in the cover
11. Fit the cover in place and screw it down. Make sure the conduit
entry is intact and correctly positioned.
12. Check that:
– the controls can move normally
– The conduit entry is correctly positioned also in the cover
13. Connect the CAN bus connection to the logic card
14. Screw together the upper and the lower part of the handle
15. Connect the keypad and screw it in position
16. Connect the truck battery
17. Test drive the truck and check the functions of the handle
18. If a new logic card without software has been installed, use
TruckCom to download software and reset the parameters.
See the TruckCom manual.

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

15.5.5 Replacing the horn button/switch

1: Disassemble the tiller arm handle. See section
"15.5.4 Disassembly/assembly of tiller arm handle".
2: Remove the button using a screwdriver as shown in the illustration

3: Remove the connection for the switch on the logic board

4: Press out the switch from its bracket
5: Fit the new switch and connect the cable to the logic board
6: Align the button with the catch and secure it by hand.
7: Assemble the tiller arm handle. See section "15.5.4 Disassembly/
assembly of tiller arm handle".

15.5.6 Replacement of lift/lower button

1: Disassemble the tiller arm handle. See section
"15.5.4 Disassembly/assembly of tiller arm handle".
2: Remove the button by placing a screwdriver in the holes (A):

A A

3: Unscrew the plate holding the arm and remove the arm
4: Press the springs together and fit the button in place. Snap the
button in place by hand.
5: Assemble the tiller arm handle. See section "15.5.4 Disassembly/
assembly of tiller arm handle".

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 11

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15.5.7 Replacing the button

1. Press out the button laterally with the fingers.
2. Place a screwdriver as illustrated and carefully pry out the button.

3. Unscrew the button-holder and arm.

Assemble in reverse order.

15 – 12 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

15.5.8 Changing the position of the controls -

support arm lift / fork lift
1. Pry off the lift control buttons using a thin screwdriver and switch
the positions with the rear buttons.

2. Make sure the lips catch when the new buttons are inserted.
3. Connect a PDA or PC and use TruckCom to change parameter
1023 to 2.
4. Start the truck and make sure the change is correct.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 13

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15.5.9 Replacing the safety reversal switch

1. Remove the keypad by loosening the screw and disconnect the
connector.

×1
2,5 mm

2. Loosen the screws securing the upper part of the tiller arm.

×4
4 mm

3. Disconnect the CAN connector.

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 Tiller arm 4000
Electrical steering system – 4000
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

4. Loosen the screws until the switch brackets come loose.

×3
3 mm

5. Remove the button by unhooking the locks on both sides.

6. Assemble in reverse order.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 15 – 15

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 Tiller arm 4000
Electrical steering system – 4000
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

15 – 16 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components
Replacing the wiring harness
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

16 – Electrical components

16.1 Replacing the wiring harness

A
B

X5
C
X21
X60

Pos. Description
A Connector lock
B Connector, female part
C Bracket
D Connector, male part

Proceed as follows when replacing the wire harness:

1. When separating X connectors, press in the connector lock (A) to
the female part (B) and pull upwards.
2. Disconnect the female part (B) of the connector from the male part
(D).
3. Then remove the male part (D) by pulling it downwards.

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 Electrical components
Replacing the wiring harness
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

The bracket (C) remains on the connector panel.

16.1.1 Replacing the transistor regulator

cables

Keep the following in mind if it becomes necessary to disconnect the

connector (A) of the transistor regulator:
• First press down on the bracket clamp (B).
• Then lift up the connector lever (C).

16 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components
Replacing the transistor regulator
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

16.2 Replacing the transistor regulator

Note:
This action requires access to TruckCom!

D C

1. Remove the inspection cover.

2. Cut off the cable ties of the cable duct on the transistor regulator
side.
3. Disconnect the connectors (A) from the connector bracket.
4. Loosen the screws (D) and fold away the connector bracket.
5. Disconnect all cables and connectors from the transistor regulator.
6. Loosen the mounting nuts (B) of the back plate.
7. Remove the transistor regulator.
Take out the back plate starting from the upper edge, then turn it in
the truck's drive wheel direction to remove it from the truck.
8. Unscrew the transistor regulator from the back plate (C).
Assembly is done in reverse.
After installation of the new transistor regulator, the truck will display
error code 2.004.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 16 – 3

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 Electrical components
Replacing the transistor regulator
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

1. Connect TruckCom.
2. Select “Copy truck configuration”.
3. Select “Copy configuration to secondary unit: ACT”

16 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Hydraulic system 6000
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17 – Hydraulic system 6000

17.1 General
Remember to take the following safety measures before you beging
working with the truck's hydraulic system:
• Release the system's pressure gradually.
• Use paper or a stiff piece of cardboard when checking for possible
leakage. Do not use hands.
• Take care as the oil in the transmission and hydraulic systems may
be hot.
DANGER!
If you come into contact with hot transmission and hydraulic oil there
is a risk of burns. Allow the truck to cool down before changing the
oil.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 1

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 Hydraulic system 6000
Hygiene when working on hydraulics
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

17.2 Hygiene when working on

hydraulics
NOTE:
Risk of malfunction.
If contaminants get into the hydraulic system there is a risk of
malfunctions in parts of or in the entire hydraulic system. There is also
a risk of serious damage to incorporated components.
Observe the following instructions at all times when working on
hydraulic systems.
NOTE!
Only new and clean oil should be put into the hydraulic system. If the
oil is polluted, the hydraulic components will be damaged.

17.2.1 Washing
Wash hydraulic components, including hydraulic hoses and pipes,
using filtered cleaning fluid, in a manner suitable for that component.
The cleaning fluid is to have a cleanliness code of 19/16/13 according
to ISO4406:1999, or alternatively 16/13 according to ISO4406:1987.
Components can be blown clean using dry filtered air when this is the
only practically feasible cleaning method.

17.2.2 Packaging
After cleaning all openings must be sealed using protective plugs.
Connection faces must be protected against damage caused by
handling and against the ingress of dirt.
Completely dry components can be packaged in plastic bags or boxes
with lids.
Packaging (protective plugs, masking, plastic bags etc.) must not be
removed until immediately before components are to be fitted, and then
in a workplace that is adapted for the handling of hydraulic
components.
Tape must never be used without subsequent cleaning.
Protective plugs are to be stored in plastic bags or boxes with lids until
they are used.
Plugs and plastic bags are to be discarded after use.

17.2.3 Handling
Hydraulic components are to be handled and transported with great
care.
Transport packaging is to be used throughout the chain of operations.
This packaging is to be clean and free of swarf etc.

17 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Hydraulic system 6000
Hygiene when working on hydraulics
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17.2.4 Storage
Hydraulic components are to be handled and stored so:
• that corrosion does not occur
• that they are shielded from dust and dirt particles
• that mechanical deformation does not occur

17.2.5 Carrying out work

When work is being carried out on hydraulic systems, observe a level
of cleanliness such that contaminants do not get into the system.
Machining by chip removal must never take place at the same, or close
to a workplace at which work is carried out on hydraulic systems.
The service technician is to ensure that components being used are
thoroughly deburred and cleaned.
Closures for pipe ends or other openings must not be removed until the
component is being connected to its mated component.
NOTE:
All hydraulic components that have not been washed such as pipe
unions and nipples must be blown clean prior to fitting.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 3

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 Hydraulic system 6000
Hydraulic unit 6100
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

17.3 Hydraulic unit 6100

o n
m

b
i
c

h
g

f
e

Pos. Name Pos. Name

a Pump motor [M3] h Hydraulic fork connection
b Magnetic valve, support arm selection i Pressure limit valve
[Q23]1
c Magnetic valve, fork selection [Q22]1 k Max. oil level
d Proportional valve, lowering [Q4] m Filling cap
e Tank (suitable oil volume 5 l) n Pump motor cable connection
f Screw o Pump motor cable connection
g Hydraulic connection, support arm
1.Only applies to SWE120L, SWE140L and SWE200D

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 Hydraulic system 6000
Hydraulic unit 6100
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17.3.1 Emptying the hydraulic tank

1. Loosen all cables and tubes to the hydraulic unit.
2. Loosen the hydraulic unit from the truck by releasing the clamps
that surround the pump motor.
3. Loosen the tank from the hydraulic unit by loosening screw (f).

17.3.2 Hydraulic system, bleeding

Cylinders with bleeding valve
1. Loosen all bleeding screws 2 revolutions.
2. Lift slowly at a constant rate until the forks begin to rise (30-40 cm).
3. Close the bleeding screws.
4. Lower the forks and continue to press the lowering button for 10-15
s.
5. Top up with oil.
6. Lift the forks to max.
7. Lower and check the oil level.

Cylinders without bleeding valve

1. Lift slowly at a constant rate until the forks begin to rise.
2. Lower the forks and continue to press the lowering button for 10-15
s.
3. Repeat a couple of times.
4. Top up with oil.
5. Lift the forks to max.
6. Lower to min.
7. Allow to stand approx. 30 min (info for customer).

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 5

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 Hydraulic system 6000
Hydraulic connections 6230
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

17.4 Hydraulic connections 6230

17.4.1 Quick change connector

Assembling the quick change connector

1. Place the assembly stop (1) on the male fitting and make
sure that the dismantling ring (2) runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly
stop makes contact with the female fitting.
3. The coupling is now made and locked.

17 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Hydraulic system 6000
Hydraulic connections 6230
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Dismantling the quick change connector

1. Remove the assembly stop (with the aid of a screwdriver or

similar tool).
2. Push the male fitting all the way into the female fitting.
3. Pull the male fitting out of the female fitting.
4. Refit the assembly stop on the male fitting.
5. Place protective plugs on the valve and hose.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 7

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 Hydraulic system 6000
Hydraulic calibration
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

17.5 Hydraulic calibration

In order to handle the proportional valve’s tolerance a calibration func-
tion can be used. To activate calibration mode, service mode “cal” must
be set at “1” and the truck restarted. When a calibration is carried out
the service key must be connected and maximum rated weight loaded
on the forks.
In calibration mode “strt” will appear on the display pending one of the
two signal buttons being pressed. The calibration starts when one of
the signal buttons is pressed. The lowering valve then opens slowly. As
soon as the operator feels the lowering movement of the forks the sig-
nal button must be released.Wait until the display “end” appears on the
display and then restart the truck. Service parameter 108 resets auto-
matically after a calibration has been carried out.
The calibration process affects the following parameters:
• The fork’s maximum lowering speed (parameter 302)
• The proportional valve’s start position (parameter 303)
• The supporting leg’s lowering speed (parameter 304)
• Slow lowering speed (parameter 305)
All parameters can be adjusted manually after a calibration.

17 – 8 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Hydraulic system 6000
Adjustment of the pressure limit valve
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17.6 Adjustment of the pressure limit

valve

Location of the valve

The truck must be able to handle the rated load on the forks.
Place a rated load on the forks and verify that the truck is able to lift it.
If the truck cannot lift the rated load:

c
b
a

1. Prise off the sealing cap (a) around the pressure limiting valve
using a screwdriver.
2. Loosen the protective cover (b) (17 mm) by turning it anti-
clockwise. Remove the protective cover and washer inside it.
3. Loosen the lock nut (c) (17 mm) by turning it anti-clockwise.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 9

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 Hydraulic system 6000
Adjustment of the pressure limit valve
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

4. Screw in the adjustment screw clockwise until the truck is able to lift
the load without problems.
5. Tighten the lock nut (c) clockwise.
6. Refit the washer and protective cover (b).
7. Push a new sealing cap (a) around the pressure limiting valve
Once the truck is able to lift the rated load, add a further 100 kg onto
the forks. Verify that the truck cannot lift the load.
If the truck is able to lift 100 kg more than its rated load:

1. Prise off the sealing cap (a) around the pressure limiting valve
using a screwdriver.
2. Loosen the protective cover (b) (17 mm) by turning it anti-
clockwise. Remove the protective cover and washer inside it.
3. Loosen the lock nut (c) (17 mm) by turning it anti-clockwise.
4. Unscrew the adjusting screw anti-clockwise until the truck cannot
lift the load.
5. Tighten the lock nut (c) clockwise.
6. Refit the washer and protective cover (b).
7. Push a new sealing cap (a) around the pressure limiting valve

17 – 10 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Hydraulic system 6000
Disassembling the hydraulic unit
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17.7 Disassembling the hydraulic unit

Before commencing any work on the hydraulic unit, make sure the
forks have been fully lowered.

Step 1.

Step 2.

×n
s mm

s: 13 mm, n: 2off

Step 3.
1. Disconnect the hydraulic hose. See section “17.4.1 Quick change
connector”.
2. Undo the motor cables using a spanner.
3. Disconnect electrical connection to the lowering valve.
© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 11
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 Hydraulic system 6000
Disassembling the hydraulic unit
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Step 5.

×n
s mm

Step 4. s: 7mm, n: 1off

×n
s mm

s: 6mm, n: 1off

Step 6.

4. Loosen the hydraulic unit bracket and lift the unit out of the truck.
5. Loosen the clamp in order to detach the tank from the motor, and lift
the motor and valve block away from the tank.
6. Remove and clean the strainer, then reattach it in the correct
position.
7. Change the oil and clean the tank.
8. Reassemble everything in reverse order. See section
“17.8 Hydraulic unit tightening torques”.
NOTE:
Take care of the hydraulic unit seals when refitting it

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 Hydraulic system 6000
Hydraulic unit tightening torques
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

17.8 Hydraulic unit tightening torques

The hydraulic unit tightening torques are depicted in the picture below:

10 + 2 Nm
10 mm

8,5 +- 0,5
0,5 Nm

13 mm

45 + 5 Nm
24 mm

45 + 5 Nm
24 mm

5 +- 0,8
0,8 Nm

4 +- 0,5
0,5 Nm

7 mm

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 17 – 13

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 Hydraulic system 6000
Hydraulic unit tightening torques
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Lift mast – 7000
Main mast 7100
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

18 – Lift mast – 7000

18.1 Main mast 7100

18.1.1 Components

a
a

Pos Description Tightening torque

.
a Upper mast fixing 189 ± 8 Nm
points.
b Lower mast fixing 83 ± 4 Nm
points.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 1

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 Lift mast – 7000
Main mast 7100
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

18.1.2 Maintenance
Fixing point
According to the maintenance chart, the mast mounting bolts (8) should
only be visually inspected and not re-tightened on inspection. If the
mast needs to be replaced or if the bolts have come loose, then be sure
to use new bolts and washers. The tightening torque should be
according to the torque table.

Lubrication

Lubricating the beam

1 The inside of the beam flanges are lubricated with (Q8
Rembrandt EP2).

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 Lift mast – 7000
Fork carriage 7420
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

18.2 Fork carriage 7420

Pos. Description
a Shims
b Roller

18.2.1 Maintenance
• Check that the play in the fork carriage is not excessive.
• Adjust with shims (a) if needed.
• There are rollers with different diameters (c) to compensate for any
wear on the guide rails.

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 Lift mast – 7000
Main lift chain system 7120
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

18.3 Main lift chain system 7120

18.3.1 Checking the chain setting

The lifting chains must be adjusted at regular periods due to stretching;
see below. The chain 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.

18.3.2 Chain inspection

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

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

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

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
lubricated.
The chain must be replaced.

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.

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 Lift mast – 7000
Main lift chain system 7120
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

The chain must be replaced

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 must be replaced

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

The chain must be replaced

Outline wear

H2 H3

P = Pitch.
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lifting chain has a specific nominal disc height (defined as H2 in
the figure). As the truck is used, the lifting chain wears radially on the
© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 5
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 Lift mast – 7000
Main lift chain system 7120
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

side that rolls over the chain wheel. The minimum disc height (defined
as H3 in the figure) denotes the minimum permitted value of the disc
height.

Maximum permitted outline wear is 5% of the height H2. If a lifting chain

reaches the maximum level of wear, the chain must be replaced.
The nominal and minimum disc heights for each lifting chain are stated
in the table in the section “Stretching”.

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

Type of Nominal Minimum Pitch P Nominal chain Maximum

chain disc disc (mm) length for 20/30/ permitted chain
height H2 height H3 50 discs (mm) length for 20/30/50
( mm) (mm) 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 one reason why
the chain stretches. The chain should be replaced if stretching is more
than 2%.

18 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Lift mast – 7000
Main lift chain system 7120
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Damage

The chain should be replaced if damaged in any way.

Damaged discs
If a disc on the chain is broken, it can be because of overloading or
corrosion.

The chain must be replaced.

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 must be replaced.

Dirty chain
If a chain is very dirty replacement is recommended first and foremost.
It can also be removed and cleaned as set out in the chapter
“Cleaning”.

18.3.3 Cleaning
If a chain is very dirty, replacement is recommended.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 7

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 Lift mast – 7000
Main lift chain system 7120
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

The chain must be blown dry using compressed air and lubricated
directly after cleaning.
Note:
Use degreasing agents with care, as these may contain abrasives.

18.3.4 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
Note:
The lubricant must not contain substances such as molybdenum
disulphide, PTFE or such.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operation
- 100 hours when operating 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 particularly important that the
part of the chain that runs over the chain wheel 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
Lubrication
< - 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
* Similar products from other manufacturers may be used.
Note:
Do not use a special rust protective agent to prevent
rust on the lifting chains.
These agents impair lubrication of the chains. Regular lubrication is
the best method to prevent rusting.

18 – 8 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Lift mast – 7000
Replacing the fork carriage
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

18.4 Replacing the fork carriage

1. Lift the fork carriage with an overhead crane or with another truck to
take the load off the chain.

2. Remove the chain bolt.

3. Lower the fork carriage.

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 Lift mast – 7000
Replacing the fork carriage
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

4. Lift the inner guides.

5. Remove the fork carriage.

6. Install in reverse order.

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 Lift mast – 7000
Replacement of the mast
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

18.5 Replacement of the mast

We use a Duplex Hilo mast in this example.
1. Start by disconnecting the fork carriage according to the example
above.
2. Disconnect all connectors to the lift height switches.

3. Remove the spiral hose.

4. Disconnect the main hydraulic hose from the T-connector.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 11

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 Lift mast – 7000
Replacement of the mast
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

5. Connect a hose plug in the hose to stop the oil flow.

6. Lift out the battery.

7. Lower the mast and secure it in both lifting points with an overhead
crane or using another truck.See section "23.5 Other tools".

18 – 12 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Lift mast – 7000
Replacement of the mast
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

8. Remove the lower finger protectors and the bracket for the
hydraulic hose on the cylinder.

9. Remove the four bolts holding the mast.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 13

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 Lift mast – 7000
Replacement of the mast
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

10. Make sure that the mast is freed, and lift it past the guide lugs.

11. Attach the new mast in reverse order.

18 – 14 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Lift mast – 7000
Adjusting the mast
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

18.6 Adjusting the mast

The angle of the mast must be checked after replacement. Make sure
that the truck is standing on a level surface when checking. Fit shims
according to the instructions below if needed.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 18 – 15

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 Lift mast – 7000
Adjusting the mast
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Tighten the screws that hold the mast

See section "18.1.1 Components".with the correct tightening torque.

18 – 16 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Accessories
Spider expansion unit
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

19 – Accessories

19.1 Spider expansion unit

The Spider expansion unit, or the SEU, allows the main logic card to
handle a greater number of inputs and outputs. The SEU does not have
its own truck controller logic, which means that a defective SEU can be
replaced without the replacement affecting any truck functions.
The SEU is used for modification of the truck to meet special customer
requirements. .

Electronic
card

Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus

Pump
controller

CAN service
connector

Motor
Controller

The figure above shows how the SEU is used to allow a greater number
of functions to be controlled via the CAN bus. SEU has a 42 pin,
multipin contact that manages all inputs, outputs, CAN and power
supply signals.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 19 – 1

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 Accessories
TLS - Truck log system
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

19.2 TLS - Truck log system

See the separate manual that is included with the truck log system.

19.3 ID unit
See the separate manual that is supplied with the software.

19.4 Toyota Wireless Information

System (T.W.I.S.)
See the separate manual that is supplied with the software.

19 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Accessories
Built-in battery charger
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

19.5 Built-in battery charger

Note:
When installing a battery charger as an aftermarket procedure,
TruckCom is needed in order to set all parameters. TruckCom is not
needed when replacing an existing battery charger. Tighten the
battery charger mounting nuts (A) with a maximum of 1.6 Nm.
The battery charger is set for the battery if the truck is delivered from
the factory with a battery installed.
If the truck is delivered without a battery, the client or a technician must
set the correct parameter according to type and size of the battery.

19.5.1 Technical data

Designation SMCO 24/30
Dimensions, mm 240x111x77
Weight, kg 1.7
Ambient temperature, ºC -25 - +40 (freely vented batteries)
+15 - +30 (valve regulated batteries)
Supply voltage, V AC 195-264
Rated voltage, V DC 24
Rated current, A 30
Maximum output, W 800

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 19 – 3

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 Accessories
Built-in battery charger
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

19.5.2 Charging the battery

To start charging, open the battery compartment cover and connect the
charger connector to a wall outlet.
Note:
Prior to commencing charging, switch off the truck and disconnect all
other electrical connections to the truck.
When the truck is charging, the following is shown on the display:

Main charging
During the charging process, lines appear sequentially from left to right.
The battery symbol and the OFF button blink.

Equalising charging
Four lines at the left in the display light continuously while four lines on
the right appear sequentially. The battery symbol and the OFF button
blink.

Charging completed
The battery capacity value and unit (Ah) appear alternately in the
display. The battery symbol is lit continuously, while the OFF button
blinks.
Disconnect the connector from the wall outlet when the battery has
been charged. The OFF button is then lit continuously. The truck is now
ready for use.

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 Appendices
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

20 – Appendices

20.1 General
In the chapter Appendices, you can quickly find the following
information:
• technical data
• general tightening torques
• tools
• oil and grease specifications
• electrical components and wiring diagrams
• hydraulics chart
• instructions for disposal.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 20 – 1

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 Appendices
General
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

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 Technical data
SWE100, SWE120, SWE140
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

21 – Technical data

21.1 SWE100, SWE120, SWE140

Model SWE100 SWE120 SWE140
Drive motor
Type Iskra AML7108 Iskra AML7109
Output, kW 1,0, 1,5
Duty cycle S2-60 min
Weight, kg 9 10,5
Brake
Type Warner PK10
Braking force, Nm 15
Output, W 51/13
Resistance, coil, Ω 10,5-12,0
Nominal play in actuated position, 0,3
mm
Minimum thickness of brake disc, 7,9
mm
Thickness of a new brake disc, mm 8,2
Transmission/gear
Type Kordel Genius 5.72.02.1
Gear ratio 30,204
Oil volume, litres 0,8
Oil type 100 % synthetic
API GL-5,SAE 75W-90

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 Technical data
SWE100, SWE120, SWE140
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Model SWE100 SWE120 SWE140

Wheel
Drive wheel, mm 230
Wheel pressure (kg/mm²) 0,2 0,22 0,24
Axle pressure without load, kg 350 400 450
Axle pressure at rated load, kg 350 400 450
Tightening torque wheel bolts, Nm 81±19
Support arm wheel, mm 125
Axle pressure without load, kg 235 285 285
Axle pressure at rated load, kg 1185 1445 1640
Castor wheel, mm 85
Axle pressure without load, kg 230 250 200
Axle pressure at rated load, kg 280 290 245
Hydraulic system
Output, kW 2,2
Duty cycle, %
Minimum carbon brush length, mm
Minimum commutator thickness/
diameter, mm
Pressure at rated load, bar
Overflow pressure, bar
Pump flow, litres/minute
Tank volume, litres
Oil type ISO VG32
Normal temperature ISO 6743-4 category HM
< 0oC ISO VG27.5
ISO 6743-4 category HV
Fuses
Drive motor circuit, A 125
Pump motor circuit, A 125
Control circuits, A 7,5

21 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Technical data
SWE100, SWE120, SWE140
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Model SWE100 SWE120 SWE140

Battery compartment, Batteries
Capacity, Ah 150 225
Weight, kg 158 214
Driving speeds
Without load, km/h 6,0
Without load, m/s 1,7
With rated load, km/h 6,0
With rated load, m/s 1,7
Lift/lowering speed
Lift without load, m/s 0,28 0,28 0,25
Lift with rated load, m/s 0,14 0,12 0,11
Lowering without load, m/s 0,38 0,38 0,38
Lowering with rated load, m/s 0,38 0,38 0,37
Gradient capabillity
With rated load, % 8 8 8
Measurement
Short 1831 - -
Medium 1888 1906 1901
Long 1938 1956 1951
Lift height 3300 4500 4755
Weight
Truck without battery, Medium 650 715 715

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 21 – 3

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 Technical data
SWE120L, SWE140L, SWE200D
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

21.2 SWE120L, SWE140L, SWE200D

Model SWE120L SWE140L SWE200D
Drive motor
Type Iskra AML7109
Output, kW 1,5
Duty cycle S2-60 min
Weight, kg 10,5
Brake
Type Warner PK10
Braking force, Nm 15
Output, W 51/13
Resistance, coil, Ω 10,5-12,0
Nominal play in actuated position, 0,3
mm
Minimum thickness of brake disc, 7,9
mm
Thickness of a new brake disc, mm 8,2
Transmission/gear
Type Kordel Genius 5.72.02.1
Gear ratio 30,204
Oil volume, litres 0,8
Oil type 100 % synthetic
API GL-5,SAE 75W-90

21 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Technical data
SWE120L, SWE140L, SWE200D
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Model SWE120L SWE140L SWE200D

Wheel
Drive wheel, mm 230
Wheel pressure (kg/mm²) 0,24 0,24 0,27
Axle pressure without load, kg 450 450 570
Axle pressure at rated load, kg 450 450 570
Tightening torque wheel bolts, Nm 81±19
Support arm wheel, mm 125
Axle pressure without load, kg 265 265 215
Axle pressure at rated load, kg 1345 1525 1155
Castor wheel, mm 85
Axle pressure without load, kg 220 220 100
Axle pressure at rated load, kg 340 360 360
Hydraulic system
Output, kW 2,2
Duty cycle, %
Minimum carbon brush length, mm
Minimum commutator thickness/
diameter, mm
Pressure at rated load, bar
Overflow pressure, bar
Pump flow, litres/minute
Tank volume, litres
Oil type ISO VG32
Normal temperature ISO 6743-4 category HM
< 0oC ISO VG27.5
ISO 6743-4 category HV
Fuses
Drive motor circuit, A 125
Pump motor circuit, A 125
Control circuits, A 7,5

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 21 – 5

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 Technical data
SWE120L, SWE140L, SWE200D
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Model SWE120L SWE140L SWE200D

Battery compartment, Batteries
Capacity, Ah 225
Weight, kg 214
Driving speeds
Without load, km/h 6,0
Without load, m/s 1,7
With rated load, km/h 6,0
With rated load, m/s 1,7
Lift/lowering speed
Lift without load, m/s 0,25
Lift with rated load, m/s 0,12 0,11 0,12
Lowering without load, m/s 0,28
Lowering with rated load, m/s 0,39 0,38 0,39
Gradient capabillity
With rated load, % 9 8 9
Measurement
Short -
Medium 1910
Long 1960
Lift height 3300 3255 2100
Weight
Truck without battery, Medium 715 715 665

21 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Technical data
SWE120S
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

21.3 SWE120S
Model SWE120S
Drive motor
Type Iskra AML7108
Output, kW 1,0
Duty cycle S2-60 min
Weight, kg 9
Brake
Type Warner PK10
Braking force, Nm 15
Output, W 51/13
Resistance, coil, Ω 10,5-12,0
Nominal play in actuated position, 0,3
mm
Minimum thickness of brake disc, 7,9
mm
Thickness of a new brake disc, 8,2
mm
Transmission/gear
Type Kordel Genius 5.72.02.1
Gear ratio 30,204
Oil volume, litres 0,8
Oil type 100 % synthetic
API GL-5,SAE 75W-90

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 Technical data
SWE120S
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Model SWE120S
Wheel
Drive wheel, mm 230
Wheel pressure (kg/mm²) 0,32
Axle pressure without load, kg 675
Axle pressure at rated load, kg 635
Tightening torque wheel bolts, Nm 81±19
Support arm wheel, mm 100
Axle pressure without load, kg 340
Axle pressure at rated load, kg 1580
Castor wheel, mm -
Axle pressure without load, kg -
Axle pressure at rated load, kg -
Hydraulic system
Output, kW 2,2
Duty cycle, %
Minimum carbon brush length,
mm
Minimum commutator thickness/
diameter, mm
Pressure at rated load, bar
Overflow pressure, bar
Pump flow, litres/minute
Tank volume, litres
Oil type ISO VG32
Normal temperature ISO 6743-4 category HM
< 0oC ISO VG27.5
ISO 6743-4 category HV
Fuses
Drive motor circuit, A 125
Pump motor circuit, A 125
Control circuits, A 7,5

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 Technical data
SWE120S
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Model SWE120S
Battery compartment, Batteries
Capacity, Ah 225
Weight, kg 214
Driving speeds
Without load, km/h 6,0
Without load, m/s 1,7
With rated load, km/h 6,0
With rated load, m/s 1,7
Lift/lowering speed
Lift without load, m/s 0,21
Lift with rated load, m/s 0,11
Lowering without load, m/s 0,24
Lowering with rated load, m/s 0,33
Gradient capabillity
With rated load, % 8
Measurement
Short -
Medium 1946
Long 1996
Lift height 4755
Weight
Truck without battery, Medium 795

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 Technical data
Overflow pressure for the mast
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

21.4 Overflow pressure for the mast

Mast (rated load) Pressure for Pump flow Recommended

rated load rate at rated overflow pressure
(on the main load (from the
lift for the graph for the
HiLo mast) hydraulic
unit)
Simplex (1000 kg) 140 Bar 7.1 165 Bar

Simplex (1,200kg) 165 Bar 6.5 190 Bar

Tele (1000 kg) 145 Bar 7.0 170 Bar

Tele (1,200kg) 170 Bar 6.4 195 Bar

Tele ClearView 150 Bar 6.8 175 Bar

(1000 kg)
Tele ClearView 175 Bar 6.3 200 Bar
(1,200 kg)
Tele ClearView 200 Bar 5.9 225 Bar
(1,400 kg)
Duplex HiLo (1200 kg) 150 Bar 6.8 170 Bar

Duplex HiLo (1,400 kg) 170 Bar 6.4 190 Bar

Triplex HiLo (1200 kg) 185 Bar 6.2 210 Bar

Triplex HiLo (1,400 kg) 210 Bar 5.8 235 Bar

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 General tightening torque
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

22 – General tightening torque

22.1 General
Millimetre threads M3 to M24. The following applies under ideal
conditions, e.g. steel against steel.
Note!
Experience has shown that if you adjust the torque wrench to the
values for untreated bolts, you will also achieve the correct torque
value for galvanised bolts. Do not tighten more than the values set
out in the tables otherwise the bolts may be destroyed.

22.2 Galvanised non-oiled bolts

Tightening torque (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

22.3 Untreated, oiled bolts

Tightening torque (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

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 General tightening torque
Untreated, oiled bolts
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

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 Tools
MQS connectors
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

23 – Tools

23.1 MQS connectors

Tools Number Use

257841 MQS Basic toolbox.

The box contains:

1 x pliers including tools
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
contacts (male and female) with
prewired cables and splicing sleeves.
Used to replace damaged contacts on
the truck.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 23 – 1

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 Tools
MQS connectors
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Tools Number Use

257842 MQS refill box.
Use to refill the “MQS 257843 complete
toolbox”.

The refill box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75
mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x sealings
200 x blind plugs

257843 MQS complete toolbox.

Contains 4 pliers including tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25-0.5 mm2,
MQS Std&Clean body 0.5-0.75 mm2

Puller for 2, 3, 4, 6, 8 and 12-pin male

and female contacts.

23 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tools
AMP connectors
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

23.2 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 Use

151080 (PT) Removal tool for pins/
sleeves

213296 (JPT) Removal tool for pins/

sleeves

213298 (MPT) Removal tool for pins/

sleeves

1=163787 (JPT) Crimping tool for sleeves

2=163788 (JPT)

1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Crimping tool for pins
2=213549 (JPT) For 0.5–2.5 mm2

1
2

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 23 – 3

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 Tools
Molex connectors
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

23.2.1 AMP connectors, Multilock series 040

Figure Number Use

213130 Pin removal tool

213129 Crimping tool for pins

23.3 Molex connectors

16
9
8
1

Figure Number Use

156937 Crimping tool for pins/
sleeves

156936 Crimping tool for pins/

sleeves

23 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Tools
Grease guns
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

23.4 Grease guns

Figure Number Use

24981 Tool with pointed nozzle for applying
grease. Length 170 mm.

755132 Single-hand grease gun with straight

pressure tube and nozzle.

755142 Two-hand grease gun with angled

pressure tube and nozzle.

755152 Two-hand grease gun with hose and

nozzle.

755145 Lubricating hose 450 mm

755146 Lubricating hose 750 mm
755147 Lubricating hose 1500 mm

202154PM Pointed nozzle for grease guns, to

apply grease in recessed nipples.
Fits grease guns with hose and
pressure tube. Length 125 mm.
755140 Nozzle for tall grease nipples. Fits
grease guns with hose and pressure
tube.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 23 – 5

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 Tools
Other tools
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

23.5 Other tools

Figure Number Use

156263 Service key (CAN)

1=7521083 Service instrument

1 2=163973 (CASTOR USB)
for programming

08-13022 Drive gear puller

Threaded bar M16x500mm

3x M16 nuts and one washer
V11-1666 Lifting tools
Masts

23 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Oil and grease specification
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

24 – Oil and grease specification

Tabell 1: Oil and grease specification

Lubricant type Specification Use
Grease S213366 Storage and bushings
Q8 Rubens WB
Hydraulic oil See table below Hydraulic system
Transmission oil Synthetic Gear
API GL-5
SAE 75W-90
Grease See table below Chains
Grease Grafloscon Gear rim
A-G1 (Klüber)
Grease 755701-040 Castor wheel
Grease S213366 Mast
Q8 Rubens WB

Hydraulic oil
Ambient Viscosity class Specification
temperature
< 0°C VG 27.5 ISO 6743-4 category HV
DIN 51524 part 3= HVLP
> 0°C VG 32 ISO 6743-4 category HM
DIN 51524 part 2 = HLP

Chain grease
Ambient Viscosity class Recommended products*
temperature
> - 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
* Similar products from another manufacturer may be used.

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 24 – 1

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 Oil and grease specification
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

Denna sida är avsiktligt lämnad tom

24 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components and wiring diagrams
Electrical components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

25 – Electrical components and

wiring diagrams

25.1 Electrical components

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

Symbol Description Function: Remarks

A5 Logic card Tiller arm logic card
A5:S1-18 Hall sensor Speed control forward/backward
A5:S17 Hall sensor Safety reverse
A5:S19 Hall sensor Fork lift control
A5:S20 Hall sensor Fork lowering control
A5:S21 Hall sensor Support arm lift control
A5:S22 Hall sensor Support arm lower control
A30 Battery charger On-board battery charger Option

B1 Temperature Drive motor temperature sensor

sensor
B11 Pulse converter Speed sensor
B60 Inductive switch Mechanical application of brakes
B62 Inductive switch Support arms, lowered position.
B63 Inductive switch Mast switch 1
B64 Inductive switch Mast switch 2
B90 Collision sensor Option

F1 Fuse Main fuse 125 A

F50 Fuse Operating circuit A5 7.5 A
F51 Fuse Work circuit T1 7.5 A
F52 Fuse Optional equipment Option

G1 Battery 24 V

K110 Data handling unit Unit for data handling Option

(DHU)

M1 Motor Drive motor

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 1

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 Electrical components and wiring diagrams
Electrical components
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

M3 Motor Pump motor

Symbol Description Function: Remarks
P4 Horn
P5 Warning lamp Option
P6 Display Truck function display

Q1 Electro-mechanical Mechanical brake

brake
Q4 Proportional valve Lowering
Q10 Contactor Main contactor
Q221 Solenoid valve Fork selector

Q231 Solenoid valve Support arm selector

Q252 Contactor Contactor, pump motor

S18 Switch Horn button

S21 Switch Emergency stop switch
S97 Switch Warning lamp P5 Option
S206 Switch Turtle function Option
S111 Switch Option button Option
S113 Switch Option button Option
S114 Switch Option button Option
S115 Switch Option button Option
S116 Switch Option button Option
S223 Keypad/Smart card Log-in with PIN code
S224 Controls Sensi-lift Option

T1 Transistor
regulator
T7/T8 DC/DC converter T7=24V/12V Option
T8=24V/24V
T20 Antenna T.W.I.S. Option

X1 Connection Battery
X21 Port DC/DC converter Option
X40 Port CAN communication (Extra I/O)
X41 Port CAN communication (External)
1.Applies only to SWE120L, 140L and 200D.
2.Only applies to SWE100.

25 – 2 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components and wiring diagrams
Electrical components
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

A5:S22 A5:S21 A5:S1-9 A5:S10-18 A5

1
10

18

A5:S17 A5:S20 A5:S19

P6

S113 S116
S206 S115
S111 S114

S18:1 S18:2

A5:S20
A5:S22
A5:S19 A5:S21
A5:S17

S223

X41

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 3

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 Electrical components and wiring diagrams
Electrical components
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

S21
X1

G1

T7/T8

F50, F51, F52

F1 Q25

Q10

X21

X40

B90

T1

A30

25 – 4 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components and wiring diagrams
Wiring diagram
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

25.2 Wiring diagram

25.2.1 List of symbols

Tabell 2: List of symbols

Symbol Description Symbol Description
Truck battery Emergency switch off NC

Fuse Switch, pressure (weight)

operated

Horn Sensor, inductive NO

Motor, a.c. 1 Sensor, inductive NC

Contactor Variable resistance

(potentiometer)

Brake coil (normally applied) Push switch NO

Coil for hydraulic magnetic valve Multi-pin connect

Pressure sensor, analogue NO = Normally open

P NC = Normally closed

1.AC = Alternating Current

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 5

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 Electrical components and wiring diagrams
Wiring diagram
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

25.2.2 General wiring diagram

F51

6 (+) B+ F1 S21
24 (83) +24V
40 (-) B- U

T1
B60 DRIVE MOTOR V M1
72 (95) TILLER ARM W
IN DRIVE POS.
Q10
MAIN CONTACTOR (106) 31

+
G1

-
Q1
B62 BRAKE RELEASE (90) 32
74 (94) SUPPORT ARM Q4 40
IN LOW POS 1
PROP. LOWER VALVE (108) 33

+24V (82) 30
B63 F
70 (86) MAST SWITCH 1 M3
SWE100
EXT.
Q25 EQUIP.
OUT PUMP CONTACTOR (107) 34
B64
71 (101) MAST SWITCH 2 M3
PUMP MOTOR 5
Q22
B65 FORK VALVE (98) 80
74 (87) INP. SUPPORT ARM, AT TOP POS.
Q23
81
SUPPORT ARM VALVE (110)
OPTION 20
(84) ENABLE/PRE-CHARGE P4
1 2
B11
61 (104) CH A, SPEED SENSOR
62 (103) CH B, SPEED SENSOR SIGNAL HORN (112) 50 F52

B1 63 (92) THERMAL SENSOR

(DRIVE MOTOR) +5V SPEED SENSOR (85) 60
25
+24VDC
64 40
CAN HIGH/LOW NEGATIVE SPEED/ (105) 0VDC T7/T8 X23
(99/100) THERMAL SENSOR 12VDC/24VDC 26
119/120 0VDC 41
OPTION

20 20 F50 1 1
24 24
119/120
(3/4) 119/120 119/120
CAN HIGH/LOW (X3/X3) (3/4)
A2:S17 P5
B90 CAN HIGH/LOW Hall SAFETY 20 CAN HIGH/LOW
20 (1) +24V DC REVERSE 40 RED (+) POS. VOLT.
40 (2) 0V DC 20 (X3) +24V DC A2:S21 BLACK (-) NEG. VOLT.
40 (X3) 0V DC Hall SUPPORT ARM
OPTION LIFT S97 OPTION A30
A2:S22 MAINS, VAC
(X1 1) HORN 2 Hall SUPPORT ARM MAINS, VAC
(X4 1) HORN 1 LOWER MAINS, EARTH
A2:S1-S9 A2:S10-S18
S18:2 OPTION
Hall Hall SPEED
S18:1 REF.
(X4 2) VALUE KEYBOARD / 119/120
(X1 2) (2/3)
A5 SMART CARD CAN HIGH/LOW
(X11)
(X2:1/2) TURTLE S223 X41
20 (1) +24V DC
+24V DC (X3) 20 40 (8) 0V DC
S206 0V DC (X3) 40 T20
K110
(X2:1/3) TURTLE
CAN HIGH (X3) 119 ANTENNA
CAN LOW (X3) 120 OPTION
(X8:1) +5V DC
S224 (X8:2) FORK LIFT/LOWER
+ A (X12)
DISPLAY
(X8:3) OUT 0V DC
P6
-
Based on 236986 rev. F

25 – 6 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 40
Sh. 2

© BT
1 MOTOR CONTROLLER
Sh. 3 T1
7,5A
Order no..

X21 S21 X21 F51 G1

258946-120

24 24/BN 1 2 21/WH 21 6 1 2 1 + - 40
Sh. 3 INP. B-
7,5A
F50
20
84 INP. ENABLE / PRE-CHARGE

20
Sh. 4

6
Date

INP. B+

Repair manual
PUMP MOTOR
2D2 1D1 5
M3 OUT. P-
2012-08-30

Q10
30 1 2 31
Sh. 2 106 OUT. MAIN CONTACTOR

2
OUT. U
DRIVE MOTOR

3
M1 OUT. V

4
OUT. W
6061850-

B11
1 60
85 OUT. +5V SPEED SENSOR
B11
B11
RD BU 2 61
104
25.2.3 Wiring diagram

INP. CH A, SPEED SENSOR

Valid from serial no.

B11
BK WH 3 62
103 INP. CH B, SPEED SENSOR

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B1 B1
GN 1 63
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR RD
2

B11 B1
4 64

SWE100, 120, 120L, 120S, 140, 140L, 200D

105 OUT. NEGATIVE SPEED / THERMAL SENSOR

1/11 PROD F
236986
T code

25 – 7
841×842×843
Electrical components and wiring diagrams
Wiring diagram
 40
Sh. 3

25 – 8
1 MOTOR CONTROLLER T code
Sh. 3 T1
7,5A
X21 S21 X21 F51 G1
24 24/BN 1 2 21/WH 21 1 2 1 + - 40
Sh. 2 INP. B-
841×842×843

7,5A
F50
20
Wiring diagram

F1 84 INP. ENABLE / PRE-CHARGE

125A
PUMP MOTOR
A1/1D1 A2/2D2 10 1 2 6 6
M3 INP. B+

20
Sh. 4

Q10

Repair manual
30 1 2 31
Sh. 2 106 OUT. MAIN CONTACTOR

Q25
6061850-

1 2 34
107 OUT. PUMP CONTACTOR

2
OUT. U
DRIVE MOTOR
Valid from serial no.

3
M1 OUT. V

4
OUT. W

B11
Date

1 60
85 OUT. +5V SPEED SENSOR
B11
B11
2012-08-30

RD BU 2 61
104 INP. CH A, SPEED SENSOR
Electrical components and wiring diagrams

B11
BK WH 3 62
103 INP. CH B, SPEED SENSOR

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B1 B1
GN 1 63
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR RD

B11
4 64
105 OUT. NEGATIVE SPEED / THERMAL SENSOR

SWE100, 120, 120L, 120S, 140, 140L, 200D

1/12 PROD F
243986
Order no.
258946-120

(SWE100)

© BT
 © BT
Order no..
258946-120

ONLY STACKER WITH "SUPPORT ARM LIFT"

Date

Repair manual
MOTOR CONTROLLER
T1
2012-08-30

24 24
Sh. 1 3 83 INP. +24V, "HIGH SIDE DRIVER"

X20 Q22 X20

1 2 80
98 OUT. FORK VALVE

X20 Q23 X20

1 2 81
110 OUT. SUPPORT ARM VALVE
6061850-

P4
IN
2 1 50
112 OUT. SIGNAL HORN

30 30
Sh. 1 82 OUT. +24V, "HIGH SIDE DRIVER"
Valid from serial no.

Q1
1 2 32
90 OUT. BRAKE RELEASE

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Q4
1 2 33
108 OUT. PROP. VALVE

119/RD 119/RD
Sh. 4 99 INP. CAN HIGH

SWE100, 120, 120L, 120S, 140, 140L, 200D

120/WH 120/WH
Sh. 4 100 INP. CAN LOW
T code

2/11 PROD F

25 – 9
236986
841×842×843
Electrical components and wiring diagrams
Wiring diagram
 25 – 10
T code
841×842×843

IF B63 NOT FITTED

Wiring diagram

MOTRO CONTROLLER
T1

X20 X63 X63 X20

24 70
Sh. 2 86 INP. MAST SWITCH, 1

X20 X63
40
Sh. 1 4
X20 X63 X63 X20
71

Repair manual
101 INP. MAST SWITCH, 2

X20 X63
6061850-

EXTERNAL EQUIPMENT

IF B64 NOT FITTED

B60
X65 X65
NOTE! YE 1 2 GN 72
95 INP. TILLER ARM IN DRIVE POS.
EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL
Valid from serial no.

3
CONNECTED TO THE TRUCK FRAME.
X65

IF B62 NOT FITTED

Date

B62
X20 X20
1 2 74
94 INP. SUPPORT ARM, IN LOWEST POS.
2012-08-30

3
X20
Electrical components and wiring diagrams

B65
X20 X20

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1 2 73
87 INP. SUPPORT ARM, AT TOP POS.
3

X20

SWE100, 120, 120L, 120S, 140, 140L, 200D

3/11 PROD F
Order no.

236986
258946-120

© BT
 © BT
Order no..
258946-120

ELECTRONIC CARD TILLER ARM

A5

X5 A5
120/WH OG 3 120
Sh. 2 7 X3 CAN LOW

X5 A5
119/RD RD 7 119
Sh. 2 7 X3 CAN HIGH
Date

X5 A5

Repair manual
40 BN 2 40
Sh. 3 7 X3 INP. 0V DC
2012-08-30

X5 A5
20 BK 6 20
Sh. 1 9 X3 INP. +24V DC

X41 A5
1 20 VT 5 20
X3 OUT.+24V DC

A5
2 40 GY 1 40
X3 OUT. 0V DC

CAN, SERVICE CONNECTOR

A5
3 119 WH 8 119
X3 CAN HIGH
6061850-

A5
4 120 PK 4 120
X3 CAN LOW

X8:1
Valid from serial no.

OUT. +5V DC
FORK LIFT/LOWER

X8:2 INP. A_IN

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X8:4 OUT. 0V DC

SWE100, 120, 120L, 120S, 140, 140L, 200D

4/11 PROD F
236986
T code

25 – 11
841×842×843
Electrical components and wiring diagrams
Wiring diagram
 25 – 12
T code

DISPLAY ELECTRONIC CARD TILLER ARM

P6 A5
841×842×843
Wiring diagram

X1 1 X12 1 +5V DC

X1 2 X12 2 SI
DISPLAY
P6

X1 3 X12 3 SCK
8 8 8 8

Repair manual
X1 4 X12 4 ENABLE
6061850-

X1 5 X12 5 LCLK

X1 6 X12 6 0V DC
Valid from serial no.

S18:1
1 2
X4 1 INP. HORN 1

X4 2 OUT. OV DC HORN 1

S18:2
Date

1 2
X1 1 INP. HORN 2
2012-08-30

X1 2 OUT. 0V DC HORN 2
Electrical components and wiring diagrams

S113
1 2
X2:1/2 TURTLE

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OPTION
X2:1/3 TURTLE

SWE100, 120, 120L, 120S, 140, 140L, 200D

5/11 PROD F
236986
Order no.
258946-120

© BT
 Electrical components and wiring diagrams
Wiring diagram
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

6/11 PROD F
236986
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
A5

SMART CARD
KEY BOARD / SMART CARD

3
6
9
I
2
5
8
0
1
4
7
S223

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 13

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 25 – 14
T code
841×842×843

OPTION
ONBOARD CHARGER
Wiring diagram

BCU
A30

1 (RED) RED
Sh. 3 8 + OUT. POSITIVE CHARGER VOLTAGE

40 (BLACK) BLACK

Repair manual
Sh. 4 8 - OUT. NEGATIVE CHARGER VOLTAGE
6061850-

X40
120/WH 120/WH
Sh. 4 9 4 INP. CAN LOW

X40
119/RD 119/RD
Valid from serial no.

Sh. 4 9 3 INP. CAN HIGH

MAINS CONNECTOR
Date

MAINS, VAC
2012-08-30
Electrical components and wiring diagrams

MAINS, VAC

https://www.besttruckmanuals.com/
MAINS, EARTH

7/11 PROD F

SWE100, 120, 120L, 120S, 140, 140L, 200D

236986
Order no.
258946-120

© BT
 Electrical components and wiring diagrams
Wiring diagram
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

8/11 PROD F
236986
OUT. 12VDC / 24VDC
DC/DC CONVERTER

INP. +24VDC

OUT. 0VDC
INP. 0VDC
T7 / T8

25

40

26

41
(T7=24V/12V, T8=24V/24V)
DC/DC CONVERTER
OPTION

26

41
X23
X21

X21

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 15

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 Electrical components and wiring diagrams
Wiring diagram
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

9/11 PROD F
236986
INP. +24V DC

INP. 0V DC

CAN HIGH

CAN LOW
SHOCK SENSOR
B90

4
20

40

120/WH
119/RD
SHOCK SENSOR
OPTION

X40

X40

X40

X40

25 – 16 Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D © BT

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 Electrical components and wiring diagrams
Wiring diagram
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

10/11 PROD F
236986
INP. ANTENNA
INP. +24V DC

INP. 0V DC
CAN HIGH

CAN LOW
K110
DHU

8
20

40
120/WH
119/RD
DATA HANDLING UNIT (DHU)

T20
OPTION

X40

X40

X40

X40

© BT Repair manual SWE100, 120, 120L, 120S, 140, 140L, 200D 25 – 17

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 Electrical components and wiring diagrams
Wiring diagram
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

11/11 PROD F
236986
1
P5
3
220
WARNING LIGHT
OPTION

2
S97
1
X40

X40

— End of section —

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 Hydraulics chart
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

26 – Hydraulics chart

p
a o

c
n

m
g
i k
h

Pos. Description Pos. Description

a Lift cylinder, support arm1 h Tank
b Magnetic valve, fork selection [Q22]1 i Filter
c Magnetic valve, support arm selection k Filter
[Q23]1
d Proportional valve, lowering [Q4] m Air filter
e Non-return valve n Flow regulator valve
f Pressure limit valve, max 230 Bar o Lift cylinder, forks
g Pump p Hose fracture valve
1.Only applies to SWE120L, SWE140L and SWE200D

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 Hydraulics chart
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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 Instructions for disposal
General
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

27 – Instructions for disposal

27.1 General
The disposal instructions were developed to support our company's
objective of protecting the environment. By recycling materials,
resources can be utilised more efficiently, while reducing emissions.
The following instructions specify the proper sorting category of the
materials used in the various truck components. To achieve optimum
sorting, all components should be disassembled to a level
corresponding to the sorting categories.

27.2 Marking of plastics

27.2.1 General marking of products and

packaging
Markings on plastics consist of three arrows, a number and usually also
a designation of the plastic material used. The picture shows the
marking for polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – Polyethylene with high density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with low density
• 05: PP – Polypropylene (see picture)
• 06: PS – Polystyrene
• 07: O – Other

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 Instructions for disposal
Marking of plastics
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

27.2.2 Markings according to Standard

Standards: 58-02-001, 58-02-003 and 58-02-004.
A few examples of markings are presented below. For more
information, please refer to the standards above.
The product material and trade name of each item are indicated
between arrows, e.g. >PP<.

Abbreviations
- ABS: acrylonitrile/butadiene/styrene
- HDPE: High Density Polyethylene
- LDPE: Low Density Polyethylene
- PA: Polyamide
- PA6: Amide resin 6
- PA66: Amide resin 66
- PBT: Polybutylene terephtalate
- PC: Polycarbonate
- PET: Polyethylene terephtalate
- PMMA: Plexiglas
- POM: Polyoxymethylene, Polyformaldehyde
- PP: Polypropylene
- PUR: Polyurethane

Marking examples
Products made from a single substance
ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and
carbonate plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<

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 Instructions for disposal
Pressure vessels
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

27.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been
depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas struts and accumulators
used in hydraulic systems.

27.3.1 Gas struts

WARNING!
Gas struts have extremely high internal pressure. To prevent injury,
always follow the instructions of the manufacturer.
Wear safety goggles when disassembling struts.
To allow the gas to escape, only open and disassemble gas struts as
prescribed by the manufacturer. An example of how to perform this is
given for "Stabilus Lift-O-Mat/Inter-stop":

2 1

ca 20 mm

1: Drill or cut a hole in the cylinders, approximately 20 mm from the

bottom.
2: Drill or cut a hole in the recess at the piston rod end.

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 Instructions for disposal
Sorting categories
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

27.4 Sorting categories

• Plastic and rubber material
• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Cables
• Hazardous waste
• Complex materials - large amounts in several categories but non-
combustible and not hazardous
• Combustible material (including small plastic and rubber parts)
• Please return batteries to the manufacturer.

Component Category Comment

Chassis • Iron/steel
Inspection covers, • Iron/steel
sheet metal
• Handle: >ABS:<
Inspection covers, • Plastic Sort according to the
plastic material marking
Forks and frames • Iron/steel
Operator's platforms • Iron/steel, including any gas Be sure to depressurise
dampers dampers
• Mats, cushions: combustible
Roofs and overhead • Iron/steel
guards
Side gates and • Iron/steel
operator protection
• Plastic handles: >PA:<
• Crush protectors: >PMMA:<
Hydraulic unit • Oil Ensure that the system
has been depressurised.
• Hydraulic hoses: Oil-polluted
Carefully drain all oil.
material
Any accumulators should
• Oil tank: >PP< be emptied of gas and if
• Motor, valves: Electronic possible opened.
components
• Pump: Iron/steel
• Accumulator: Iron/steel

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 Instructions for disposal
Sorting categories
Order no.. Date Valid from serial no. T code
258946-120 2012-08-30 6061850- 841×842×843

Component Category Comment

Travel motors • Motor: Electronic components
• Cables
• Parking brake: Hazardous waste
Drive gears • Iron/steel Carefully drain all oil
• Oil Hazardous waste
Wheels • Tire tread: Plastic according to If the tread and hub
marking cannot be separated,
then sort the wheel as
• Hub: Iron/steel
complex material
Tiller arms • Electronic components Be sure to depressurise
dampers
• Cables
• Iron/steel, also gas dampers
Electrical system • Logic cards, transistor regulators, Hazardous waste
Expansion unit SEU, contactors:
Electronic components
• Cables
• Small batteries Hazardous waste
• Fluorescent tubes Hazardous waste.
Because of the chemical
content in fluorescent
tubes, do not destroy
them.
Obsolete fluorescent
tubes must be packaged
and transported
according to local
regulations.
Masts • Mast beams, rollers, cylinders, Oil-polluted components
hydraulic pipes: Iron/steel should be handled as
hazardous waste
• Hydraulic hoses: Oil-polluted ()
• Cables
• Sensors/switches: Electronic
components
• Plastic components: According to
marking or as combustible waste
Chargers and • Electronic components
connectors
• Cables

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 Instructions for disposal
Sorting categories
T code Valid from serial no. Date Order no.
841×842×843 6061850- 2012-08-30 258946-120

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https://www.besttruckmanuals.com/
 © BT
SE-595 81 Mjölby
Sweden
www.toyota-forklifts.eu

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