BT SWE120 - Page 109

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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

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Table of Contents3
Contents4
General Introduction9
How to Use this Manual9
Warning Symbols10
Pictograms10
Screws/Nuts10
General Safety Rules11
Safety While Working11
Electrical System12
Safe Lifting13
Installation15
General15
Battery Installation15
Battery Installation Safety15
Install Battery16
Programming PIN Codes17
Standards for PIN Codes18
Setting the Parameters19
Adjusting the Parameters for Collision Sensor (Option)20
Collision Sensor Parameters 105, 106 Och 11120
Programming PIN for Resetting the Truck21
Adjusting the Parameters for the Battery and Battery Charger21
Parameter 107 - Battery Size23
Free Ventilated Batteries23
Verifying the Parameter Adjustment for Free Ventilated Batteries (Lead/Acid Batteries)24
Verifying the Parameter Adjustment for Valve Controlled Batteries (Hawker/Exide)24
Function and Safety Check25
Maintenance27
General27
Service Intervals27
Maintenance Schedule27
Functions and Parameters39
General39
Function Description39
Symbols on Keypad and Display40
Operating Principle41
Hour Meter46
Parameters47
General47
Show Parameters47
Setting the Parameters48
Operator Parameters49
Factory Pre-Set Operator Parameters50
Service Parameters51
Factory Parameters55
Matrix for Hardware/Software Compatibility57
Troubleshooting59
General59
Software Compatibility59
Emergency Travel Mode59
Troubleshooting Methods60
General Initial Troubleshooting60
Concluding Troubleshooting61
Error Code History62
Error Code System63
Error Codes64
Troubleshooting Chart81
The Truck Cannot be Driven82
Truck Only Travels at Reduced Speed83
The Truck Can be Driven but Behaves Abnormally84
The Truck Travels, but some Functions Do Not Work85
Software Compatibility85
Hardware Compatibility Matrix85
Defective Hydraulic Functions86
Built-In Test Function89
Digital Input/Output Status90
Test Function "9" - Transistor Regulator90
Test Function "10" - Logic Card93
Test Function "12" - Expansion Unit SEU (Option)94
Test Function for the Display95
Chassis 000097
Support Arm 035097
Support Arm Lift, Lateral Adjustment97
Adjusting the Kneeling Action98
Motor Mounts 045099
Replacing Springs (Not Applicable for SWE120S)99
Disassembling the Platform101
Electric Drive Motor 1700103
Components103
Disassemble the Motor from the Truck104
Tightening Torques - Drive Motor107
Installing the Temperature Sensor107
Cleaning108
Drive Gear 2550111
General111
Components111
Removing the Gear from the Truck (Not Applicable for SWE120S)112
Removing the Gear from the Truck (Not Applicable for SWE120S)114
Brakes 3180115
Components115
Releasing the Brake116
Installing the Dust Shield117
Installing the Dust Shield119
Drive Wheel 3530121
Replacing the Drive Wheel121
Castor Wheels 3540123
Components123
Replacing the Castor Wheel124
Support Arm Wheel 3550125
Tiller Arm 4000127
Tiller Arm Components127
Disassembling the Tiller Arm128
Replacing the Gas Strut128
Replacing the Safety Sensor129
Dismantling129
Installation129
Electrical Steering System - 4000130
Tiller Arm Handle C4110130
Components of the Tiller Arm Handle (New Model)130
Components of the Tiller Arm Handle (Old Model)132
Disassembly/Assembly of Tiller Arm Handle134
Replacing the Horn Button/Switch137
Replacement of Lift/Lower Button137
Replacing the Button138
Changing the Position of the Controls - Support Arm Lift / Fork Lift139
Replacing the Safety Reversal Switch140
Electrical Components143
Replacing the Wiring Harness143
Replacing the Transistor Regulator Cables144
Replacing the Transistor Regulator144
Hydraulic System 6000147
General147
Hygiene When Working on Hydraulics148
Washing148
Packaging148
Handling148
Storage149
Carrying out Work149
Hydraulic Unit 6100150
Emptying the Hydraulic Tank151
Hydraulic System, Bleeding151
Cylinders with Bleeding Valve151
Cylinders Without Bleeding Valve151
Hydraulic Connections 6230152
Quick Change Connector152
Assembling the Quick Change Connector152
Dismantling the Quick Change Connector153
Hydraulic Calibration154
Adjustment of the Pressure Limit Valve155
Disassembling the Hydraulic Unit157
Hydraulic Unit Tightening Torques159
Lift Mast - 7000161
Main Mast 7100161
Components161
Maintenance162
Fixing Point162
Lubrication162
Fork Carriage 7420163
Maintenance163
Main Lift Chain System 7120164
Checking the Chain Setting164
Chain Inspection164
Noise164
Surface Rust164
Rusty Links164
Stiff Links164
Bolt Rotation165
Loose Bolts165
Outline Wear165
Stretching166
Damage167
Damaged Discs167
Damaged Bolts167
Dirty Chain167
Cleaning167
Lubrication168
Replacing the Fork Carriage169
Replacement of the Mast171
Adjusting the Mast175
Accessories177
Spider Expansion Unit177
TLS - Truck Log System178
ID Unit178
Toyota Wireless Information System (T.W.I.S.)178
Built-In Battery Charger179
Technical Data179
Charging the Battery180
Main Charging180
Equalising Charging180
Charging Completed180
Appendices181
General181
Technical Data183
Swe120L, Swe140L, Swe200D186
Swe120S189
Overflow Pressure for the Mast192
General Tightening Torque193
General193
Galvanised Non-Oiled Bolts193
Untreated, Oiled Bolts193
Tools195
MQS Connectors195
AMP Connectors197
AMP Connectors, Multilock Series 040198
Molex Connectors198
Grease Guns199
Other Tools200
Oil and Grease Specification201
Electrical Components and Wiring Diagrams203
Electrical Components203
Wiring Diagram207
List of Symbols207
General Wiring Diagram208
Wiring Diagram209
Hydraulics Chart221
Instructions for Disposal223
General223
Marking of Plastics223
General Marking of Products and Packaging223
Markings According to Standard224
Abbreviations224
Marking Examples224
Pressure Vessels225
Gas Struts225
Sorting Categories226

BT SWE120 - Page 109

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