BT SWE 100 120 120L 120S 140 140L 160D 200D STACKER TRUCK SERVICE REPAIR MANUAL

BT SWE 100 120 120L 120S 140 140L 160D 200D STACKER TRUCK SERVICE REPAIR MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 1,208
FILE SIZE: 45.2MB

MODEL COVERED:

SWE100

SWE120

SWE120L

SWE120S

SWE140

SWE140L

SWE160D

SWE200D
                  

CONTENTS:

1 – Contents 3

2 – General introduction 9

2 1 How to use the manual 9

2 2 Warning symbols 10

2 3 Pictogram 10

2 3 1 Screws/nuts 10

3 – General safety rules 11

3 1 Safety while working 11

3 2 Electrical system 12

3 3 Safe lifting 13

4 – Installation 15

4 1 General 15

4 2 Battery installation 15

4 2 1 Battery installation safety 15

4 2 2 Install battery 16

4 3 Programming PIN codes 17

4 3 1 Standards for PIN codes 18

4 4 Setting the parameters 19

4 4 1 Adjusting the parameters for collision sensor (option) 20

Collision sensor parameters 105, 106 och 111 20

Programming PIN for resetting the truck 21

4 4 2 Adjusting the parameters for the battery and battery charger 21

4 4 3 Parameter 107 – battery size 23

Free ventilated batteries 23

Verifying the parameter adjustment for free ventilated batteries (Lead/acid batteries) 24

Verifying the parameter adjustment for valve controlled batteries (Hawker/Exide) 24

4 5 Function and safety check 25

5 – Maintenance 27

5 1 General 27

5 2 Service intervals 27

5 3 Maintenance schedule 28

6 – Functions and parameters 37

6 1 General 37

6 2 Function description 37

Symbols on key pads and display 38

6 3 Principle functions 39

6 4 Timer 44

6 5 Parameters 45

6 5 1 General 45

6 5 2 Show parameters 45

6 5 3 Enter the parameters 46

6 5 4 Operator parameters 47

Factory installed driver parameters 48

6 5 5 Service parameters 49

6 5 6 Factory parameters 52

7 – Troubleshooting 55

7 1 General 55

Software compatibility 55

Emergency travel mode 55

7 2 Troubleshooting methods 56

7 2 1 Troubleshooting general introduction 56

7 2 2 Completed troubleshooting 57

7 3 Error code history 58

7 4 Error code system 59

7 5 Error codes 60

7 6 Troubleshooting diagram 76

7 6 1 The truck cannot be driven 77

7 6 2 The truck can only be driven at reduced speed 78

7 6 3 The truck can be driven but behaves abnormally 79

7 6 4 The truck can be driven but lacks certain functions 79

Software compatibility 79

Matrix for hardware compatibility 80

7 6 5 Faulty hydraulic functions 81

7 7 Built-in test function 84

7 8 Status of digital inputs/outputs 85

7 8 1 Test function “9” – Transistor regulator 85

7 8 2 Test function “10” – Logic card 88

7 8 3 Test function “12” – Expansion unit SEU (optional) 89

7 9 Testing display function 90

8 – Chassis 0000 91

8 1 Support arm 0350 91

8 1 1 Support arm lift, lateral adjustment 91

8 1 2 Adjusting the kneeling movement 92

8 2 Motor fixing points 0450 93

8 2 1 Replacing springs (not applicable for SWE120S) 93

8 3 Removing the platform 95

9 – Electrical drive motor 1700 97

9 1 Components 97

9 2 Disassemble engine and truck 98

9 3 Tightening torque Drive motor 100

9 4 Fitting the tempreature sensor 100

9 5 Cleaning 101

10 – Drive gear 2550 103

10 1 General 103

10 2 Components 103

10 3 Removing the gear from the truck (not applicable for SWE120S) 104

10 4 Removing the gear from the truck (not applicable for SWE120S) 106

11 – Brake 3180 107

11 1 Components 107

11 2 Release of brakes 108

12 – Drive wheel 3530 109

12 1 Changing drive wheel 109

13 – Castor wheel 3540 111

13 1 Components 111

13 2 Changing castor wheel 112

14 – Support arm wheel 3550 113

15 – Tiller arm 4000 115

15 1 Components in tiller arm 115

15 2 Removing tiller arm 116

15 3 Changing gas spring 116

15 4 Changing the safety sensor 117

15 4 1 Dismantling 117

15 4 2 Assembly 117

15 5 Components in tiller arm handle 118

15 5 1 Removing the tiller arm handle 119

15 5 2 Replacing the logic card 119

15 5 3 Changing signal button/switch 120

15 5 4 Changing raising/lowering button 121

15 5 5 Changing push button 121

15 5 6 Changing the position of the controls – support arm lift/fork lift 122

15 5 7 Changing a switch for safety reversing 123

16 – Electrical components 125

16 1 Changing wiring harness 125

16 1 1 Changing the transistor regulator’s wiring harness 126

16 2 Replacing the transistor regulator 127

17 – Hydraulic system 6000 129

17 1 General 129

17 2 Hygiene when working on hydraulics 130

17 2 1 Washing 130

17 2 2 Packaging 130

17 2 3 Handling 130

17 2 4 Storage 131

17 2 5 Carrying out work 131

17 3 Hydraulic unit 6100 132

17 3 1 Emptying the hydraulic tank 133

17 3 2 Hydraulic system, bleeding 133

Cylinders with bleeding valve 133

Cylinders without bleeding valve 133

17 4 Hydraulic connections 6230 134

17 4 1 Quick change connector 134

Assembling the quick change connector 134

Dismantling the quick change connector 135

17 5 Hydraulic calibration 136

17 6 Adjustment of the pressure limit valve 137

17 7 Disassembling the hydraulic unit 139

17 8 Hydraulic unit tightening torques 141

18 – Lift mast – 7000 143

18 1 Main mast 7100 143

18 1 1 Components 143

18 1 2 Maintenance 144

Mounting 144

Lubrication 144

18 2 Fork carriage 7420 145

18 2 1 Maintenance 145

18 3 Main lift chain system 7120 146

18 3 1 Checking the chain setting 146

18 3 2 Inspecting the chain 146

Noise 146

Surface rust 146

Rusty links 146

Stiff links 146

Bolt rotation 147

Loose bolts 147

Plate wear 147

Elongation 148

Damage 149

Damaged plates 149

Damaged bolts 149

Dirty chain 149

18 3 3 Cleaning 149

18 3 4 Lubrication 150

18 4 Changing the fork-lift trolley 151

18 5 Changing the stand 153

19 – Accessories 157

19 1 Spider expansion unit 157

19 2 TLS – Truck log system 158

19 3 ID unit 158

19 4 Toyota Wireless Information System T W I S 158

19 5 Built-in battery charger 159

19 5 1 Technical data 159

19 5 2 Battery charging 160

Main charge 160

Uneven charging 160

Charging complete 160

20 – Appendices 161

20 1 General 161

21 – Technical data 163

21 1 SWE100, SWE120, SWE140 163

21 2 SWE120L, SWE140L, SWE200D 166

21 3 SWE120S 169

21 4 Overflow pressure for the mast 172

22 – General tightening torque 173

22 1 General 173

22 2 Galvanised non-oiled bolts 173

22 3 Untreated, oiled bolts 173

23 – Tools 175

23 1 MQS contacts 175

23 2 AMP contacts 177

23 2 1 AMP contacts Multilock series 040 178

23 3 Molex contacts 178

23 4 Grease guns 179

23 5 Other tools 180

24 – Oil and grease specification 181

25 – Electrical components and wiring diagram 183

25 1 Electrical components 183

25 2 Wiring diagram 187

25 2 1 Index of symbols 187

25 2 2 Overview diagram 188

25 2 3 Wiring diagram 189

26 – Hydraulics chart 201

27 – Instructions for disposal 203

27 1 General 203

27 2 Marking of plastics 203

27 2 1 General marking of products and packaging 203

27 2 2 Marking to BT Standard 204

Abbreviations 204

Example of marking 204

27 3 Pressure vessels 205

27 3 1 Gas damper 205

27 4 Sorting categories 206