BT Toyota SWE100, 120, 120L, 120S, 140, 140L, 200D Repair Manual 7588855-040

Description

BT Toyota SWE100, 120, 120L, 120S, 140, 140L, 200D Repair Manual 7588855-040 – PDF DOWNLOAD

FILE DETAILS:

BT Toyota SWE100, 120, 120L, 120S, 140, 140L, 200D Repair Manual 7588855-040 – PDF DOWNLOAD

Language : English
Pages :306
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Toyota SWE100, 120 120L, 120S, 140, 140L, 200D Repair Manual 7588855-040 – PDF DOWNLOAD

1 Contents0
2 General introduction0
21 How to use this manual0
22 Warning levels and symbols0
23 Pictograms0
3 General safety rules0
31 Work safety0
32 Electrical system0
33 Safe lifting0
34 Truck modifications0
4 Operation and connection sequences0
Symbols on keypad and display0
41 Battery is connected0
42 Login via keypad0
43 Tiller arm lowered for driving0
44 Driving in fork direction0
45 Driving in the drive wheel direction0
46 Neutral position braking0
47 Reverse braking0
48 Mechanical braking0
49 Emergency reversal0
410 Fork lifting0
411 Fork lifting (SWE100)0
412 Support arm lift (SWE120L, 140L, 200D)0
413 Fork lowering0
414 Support arm lowering (SWE120L, 140L, 200D)0
415 Click-2-Creep0
416 Turtle function (option)0
5 Parameters0
51 General0
511 Show/change parameters0
512 Operator parameters0
513 Overview0
514 Connection to logged-in operator0
Description of operator parameters0
Parameters 3 and 4 – Acceleration/Deceleration0
Parameters 6 and 7 – Maximum travel speed0
52 General service parameters0
521 Overview0
522 Description0
Parameter 101/104 – Service/Log-out0
Parameter 102 – Operator access0
Parameter 103 – Start-up display0
Parameter 105/106 – Collision sensor sensitivity for X/Y (Optional)0
Parameter 107 – Battery size0
Table applicable to LWE140, 160, 180, 2000
Table concerning LWE2500
Table concerning SWE0
Verifying parameter settings for freely ventilated batteries (lead-acid batteries)0
Verifying the parameter setting for valve-regulated batteries (Exide)0
Parameters 109/110 – Built-in charger (option)0
Parameter 111 – Reset procedure after collision (option)0
Parameter 112 – Clear application data0
53 Service parameters, travel functions0
531 Overview0
532 Description0
Parameter 201 – Deceleration when reversing0
Parameter 202 – Maximum speed Turtle mode activated0
Parameter 203 – Maximum speed, forks above 18 m0
Parameter 204 – Maximum acceleration, forks above 18 m0
Parameter 205 – Maximum reversing, forks above 18 m0
Parameter 206 – Automatic speed reduction, forks above 18 m0
54 Service parameters, hydraulic functions0
541 Description0
Parameter 301 – Ramping value for lowering stop0
Parameter 302 – Fork, lowering speed0
Parameter 303 – EVP start mode0
Parameter 304 – EVP support arm lowering speed0
Parameter 305 – EVP slow lowering speed0
Parameter 306 – Activation of “Click-2-Creep” lifting/lowering0
Parameter 307 – Automatic support arm lowering (On/Off)0
Parameter 499 – (Not applicable)0
55 Factory parameters0
551 Overview0
552 Description0
Parameter 1001 – Truck type0
Parameter 1002 – Non-configurable options0
Parameters 1003-1042 – Optional functions0
Parameter 1044 – Master maximum speed0
Parameter 1045 – Type of battery in the truck0
Parameter 1046 – Adapting to special trucks0
Parameter 1101 – Built-in charger0
Parameter 1102 – Controls for hydraulic function0
Parameter 1110 – Reset voltage for BDI0
Parameter 1118 – Hardware version0
6 Installation and commissioning0
61 Transporting the truck0
62 Transporting the mast0
63 Safe lifting0
64 Installing the battery0
65 Using PIN codes0
651 General0
652 PIN code for resetting after a collision0
653 Programming PIN codes0
66 Programming PIN codes0
661 PIN code defaults0
67 Setting parameters0
68 Function and safety checks0
7 Maintenance0
71 Introduction0
72 Maintenance instructions0
721 Cleaning and washing0
722 High-pressure washers0
723 Degreasing agents0
724 Cleaning the exterior0
725 Cleaning the chain0
726 Cleaning the motor compartment0
727 Electric components0
73 Maintenance schedule0
8 Troubleshooting0
81 General0
Software compatibility0
82 Towing a defective truck0
Tow using a tow truck and tow wagon:0
83 Emergency driving mode0
84 Troubleshooting methods0
841 General initial troubleshooting0
842 Concluding troubleshooting0
85 Error code history0
86 Error code system0
87 Error codes0
88 Troubleshooting chart0
881 The truck cannot be driven0
882 Truck only travels at reduced speed0
883 The truck can be driven but behaves abnormally0
884 The truck can be driven, but some functions do not work0
Software compatibility0
Hardware compatibility matrix0
885 Defective hydraulic functions0
89 Built-in test function0
810 Digital input/output status0
8101 Test mode “9” –0
8102 Test function “10” – Logic card0
8103 Test mode “12” – Expansion unit SEU (option)0
811 Built-in test function for the tiller arm0
8111 Display test0
8112 Speed control0
8113 Safety reversing0
8114 Controls for lifting/lowering0
8115 Sensilift0
8116 Keypad0
812 Checking the built-in battery charger0
9 Chassis 00000
91 Support arm 03500
911 Support arm lift, lateral adjustment0
912 Adjusting the kneeling action0
92 Motor mounts 04500
921 Replacing springs (not applicable for SWE120S)0
93 Removing the platform0
10 Electric drive motor 17000
101 Overview0
102 Removing the motor from the truck0
103 Removing the toothed wheel0
104 Removing motor bearings0
105 Removing the RPM sensor0
106 Installing the temperature sensor0
107 Drive motor tightening torques0
108 Cleaning0
11 Drive gear 25500
111 General0
112 Overview0
113 Removing the gear from the truck (not applicable for SWE120S)0
114 Removing the drive gear from the truck (SWE120S)0
115 Fitting grease nipples, steering bearings (Option)0
116 Lubrication the steering bearings (Option)0
117 Checking and changing the oil0
1171 Draining oil0
1172 Checking/refilling oil0
118 Replacing the wheel hub seal0
Removing the seal0
Fitting the seal0
1181 Replacing studs0
12 Brake system/Wheels C30000
121 Brake system – C31000
1211 Description0
Travel brake0
Parking brake0
Emergency brake0
122 Parking brake 31800
1221 Overview0
1222 Emergency release of the parking brake0
123 Removing the parking brake0
124 Fitting the parking brake0
125 Checking the air gap0
126 Drive wheel 35300
1261 Replacing the drive wheel0
127 Castor wheels 35400
1271 Overview0
1272 Castor wheel mounting0
1273 Replacing the castor wheel0
1274 Disassembling the castor wheel cradle0
128 Spring replacement0
1281 Removing springs0
1282 Fitting the spring0
129 Support arm wheel 35500
1291 Overview0
1210 Climber wheels0
12101 Overview0
13 Tiller arm 40000
131 Overview0
132 Removing the tiller arm0
133 Replacing the gas spring0
134 Replacing the safety sensor0
1341 Disassembly0
1342 Assembly0
135 Electrical steering system – 40000
1351 Tiller arm handle C41100
1352 Overview0
1353 Replacing the keypad C94200
1354 Replacing the upper cover C41100
Removing the upper cover0
1355 Replacing the tiller arm handle0
Removing the tiller arm handle0
Fitting the tiller arm handle0
1356 Replacing the logic card0
Removing the logic card0
Fitting the logic card0
1357 Checking the handle0
1358 Update the software0
1359 Replacing the signal button/switch0
13510 Replacing the lift/lower button0
13511 Replacing the sensilift0
13512 Replacing the stomach button0
13513 Changing the position of the controls – support arm lift/ fork lift0
14 Electrical components-50000
141 Li-ion battery (Hoppecke)0
1411 Resetting/restarting the battery0
142 Inspecting the battery0
143 Replacing the wiring harness0
1431 Replacing the transistor regulator wiring harness0
144 Replacing the transistor regulator0
15 Hydraulic system 60000
151 General0
152 Hydraulic hygiene0
1521 Washing0
1522 Packaging0
1523 Handling0
1524 Storage0
1525 Work procedures0
153 Hydraulic unit 61000
1531 Emptying the hydraulic tank0
1532 Hydraulic system, bleeding0
Cylinders with bleeding valve0
Cylinders without bleeding valve0
154 Hydraulic connections 62300
1541 Quick change connectors0
Connecting the quick change connector0
Disassembly of the quick change connector0
155 Hose rupture valve0
1551 Replacing the hose rupture valve0
156 Hydraulic calibration0
157 Adjusting the pressure limiting valve0
158 Disassembling the hydraulic unit0
159 Hydraulic unit tightening torques0
16 Mast C70000
161 Main mast 71000
1611 Components0
1612 Maintenance0
Fixing point0
Lubrication0
162 Fork carriage 74200
1621 Maintenance0
163 Main lift chain system 71200
1631 Checking the chain setting0
1632 Checking the chain0
Noise0
Surface rust0
Rusty links0
Stiff links0
Bolt rotation0
Loose bolts0
Outline wear0
Stretching0
Damage0
Damaged plates0
Damaged bolts0
Dirty chain0
1633 Cleaning0
1634 Lubrication0
1635 Adjustment0
164 Replacing the fork carriage0
165 Replacement of the mast0
166 Adjusting the mast0
17 Peripherals C80000
18 Accessories0
181 Spider expansion unit0
182 TLS – Truck log system0
183 ID unit0
184 I_Site0
185 DC/DC converter0
186 Collision sensor0
187 Built-in battery charger0
1871 Technical data0
1872 Charging the battery0
Main charging0
Equalising charging0
Charging completed0
19 Instructions for disposal0
191 General0
192 Marking of plastics0
1921 General marking of products and packaging0
1922 Marking according to the manufacturer’s standards0
Abbreviations0
Marking examples0
193 Pressure vessels0
1931 Gas struts0
194 Sorting categories0
20 Electrical components and wiring diagrams0
201 Electric components0
202 Wiring diagram0
2021 List of symbols0
2022 General wiring diagram0
2023 Wiring diagram0
21 Hydraulics chart0
22 Tools0
221 MQS contacts0
222 AMP connectors0
2221 AMP connectors, Multilock series 0400
223 Molex connectors0
224 Grease guns0
225 Other tools0
23 Oil and grease specification0
231 General tightening torques0
232 Oil and grease specification0

IMAGES PREVIEW OF THE MANUAL:

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