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Forklifts
SWE200D
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230 pages
Manual
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14 –
2
Repair
manual
SWE100, 120, 120L, 1
20S, 140, 140L, 200D
©
BT
Support arm wheel 3550
T code
V
alid from serial no.
Date
Order no.
841×842×843
6061850-
2012-08-30
258946-120
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125
127
Table of Contents
Main Page
Table of Contents
3
Contents
4
General Introduction
9
How to Use this Manual
9
Warning Symbols
10
Pictograms
10
Screws/Nuts
10
General Safety Rules
11
Safety While Working
11
Electrical System
12
Safe Lifting
13
Installation
15
General
15
Battery Installation
15
Battery Installation Safety
15
Install Battery
16
Programming PIN Codes
17
Standards for PIN Codes
18
Setting the Parameters
19
Adjusting the Parameters for Collision Sensor (Option)
20
Collision Sensor Parameters 105, 106 Och 111
20
Programming PIN for Resetting the Truck
21
Adjusting the Parameters for the Battery and Battery Charger
21
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
Function and Safety Check
25
Maintenance
27
General
27
Service Intervals
27
Maintenance Schedule
27
Functions and Parameters
39
General
39
Function Description
39
Symbols on Keypad and Display
40
Operating Principle
41
Hour Meter
46
Parameters
47
General
47
Show Parameters
47
Setting the Parameters
48
Operator Parameters
49
Factory Pre-Set Operator Parameters
50
Service Parameters
51
Factory Parameters
55
Matrix for Hardware/Software Compatibility
57
Troubleshooting
59
General
59
Software Compatibility
59
Emergency Travel Mode
59
Troubleshooting Methods
60
General Initial Troubleshooting
60
Concluding Troubleshooting
61
Error Code History
62
Error Code System
63
Error Codes
64
Troubleshooting Chart
81
The Truck Cannot be Driven
82
Truck Only Travels at Reduced Speed
83
The Truck Can be Driven but Behaves Abnormally
84
The Truck Travels, but some Functions Do Not Work
85
Software Compatibility
85
Hardware Compatibility Matrix
85
Defective Hydraulic Functions
86
Built-In Test Function
89
Digital Input/Output Status
90
Test Function "9" - Transistor Regulator
90
Test Function "10" - Logic Card
93
Test Function "12" - Expansion Unit SEU (Option)
94
Test Function for the Display
95
Chassis 0000
97
Support Arm 0350
97
Support Arm Lift, Lateral Adjustment
97
Adjusting the Kneeling Action
98
Motor Mounts 0450
99
Replacing Springs (Not Applicable for SWE120S)
99
Disassembling the Platform
101
Electric Drive Motor 1700
103
Components
103
Disassemble the Motor from the Truck
104
Tightening Torques - Drive Motor
107
Installing the Temperature Sensor
107
Cleaning
108
Drive Gear 2550
111
General
111
Components
111
Removing the Gear from the Truck (Not Applicable for SWE120S)
112
Removing the Gear from the Truck (Not Applicable for SWE120S)
114
Brakes 3180
115
Components
115
Releasing the Brake
116
Installing the Dust Shield
117
Installing the Dust Shield
119
Drive Wheel 3530
121
Replacing the Drive Wheel
121
Castor Wheels 3540
123
Components
123
Replacing the Castor Wheel
124
Support Arm Wheel 3550
125
Tiller Arm 4000
127
Tiller Arm Components
127
Disassembling the Tiller Arm
128
Replacing the Gas Strut
128
Replacing the Safety Sensor
129
Dismantling
129
Installation
129
Electrical Steering System - 4000
130
Tiller Arm Handle C4110
130
Components of the Tiller Arm Handle (New Model)
130
Components of the Tiller Arm Handle (Old Model)
132
Disassembly/Assembly of Tiller Arm Handle
134
Replacing the Horn Button/Switch
137
Replacement of Lift/Lower Button
137
Replacing the Button
138
Changing the Position of the Controls - Support Arm Lift / Fork Lift
139
Replacing the Safety Reversal Switch
140
Electrical Components
143
Replacing the Wiring Harness
143
Replacing the Transistor Regulator Cables
144
Replacing the Transistor Regulator
144
Hydraulic System 6000
147
General
147
Hygiene When Working on Hydraulics
148
Washing
148
Packaging
148
Handling
148
Storage
149
Carrying out Work
149
Hydraulic Unit 6100
150
Emptying the Hydraulic Tank
151
Hydraulic System, Bleeding
151
Cylinders with Bleeding Valve
151
Cylinders Without Bleeding Valve
151
Hydraulic Connections 6230
152
Quick Change Connector
152
Assembling the Quick Change Connector
152
Dismantling the Quick Change Connector
153
Hydraulic Calibration
154
Adjustment of the Pressure Limit Valve
155
Disassembling the Hydraulic Unit
157
Hydraulic Unit Tightening Torques
159
Lift Mast - 7000
161
Main Mast 7100
161
Components
161
Maintenance
162
Fixing Point
162
Lubrication
162
Fork Carriage 7420
163
Maintenance
163
Main Lift Chain System 7120
164
Checking the Chain Setting
164
Chain Inspection
164
Noise
164
Surface Rust
164
Rusty Links
164
Stiff Links
164
Bolt Rotation
165
Loose Bolts
165
Outline Wear
165
Stretching
166
Damage
167
Damaged Discs
167
Damaged Bolts
167
Dirty Chain
167
Cleaning
167
Lubrication
168
Replacing the Fork Carriage
169
Replacement of the Mast
171
Adjusting the Mast
175
Accessories
177
Spider Expansion Unit
177
TLS - Truck Log System
178
ID Unit
178
Toyota Wireless Information System (T.W.I.S.)
178
Built-In Battery Charger
179
Technical Data
179
Charging the Battery
180
Main Charging
180
Equalising Charging
180
Charging Completed
180
Appendices
181
General
181
Technical Data
183
Swe120L, Swe140L, Swe200D
186
Swe120S
189
Overflow Pressure for the Mast
192
General Tightening Torque
193
General
193
Galvanised Non-Oiled Bolts
193
Untreated, Oiled Bolts
193
Tools
195
MQS Connectors
195
AMP Connectors
197
AMP Connectors, Multilock Series 040
198
Molex Connectors
198
Grease Guns
199
Other Tools
200
Oil and Grease Specification
201
Electrical Components and Wiring Diagrams
203
Electrical Components
203
Wiring Diagram
207
List of Symbols
207
General Wiring Diagram
208
Wiring Diagram
209
Hydraulics Chart
221
Instructions for Disposal
223
General
223
Marking of Plastics
223
General Marking of Products and Packaging
223
Markings According to Standard
224
Abbreviations
224
Marking Examples
224
Pressure Vessels
225
Gas Struts
225
Sorting Categories
226
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