Toyota BT SPE120 Electric Stacker Truck Service Repair Manual

Repair manual 7590353

SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D

SPE200L

en

Translation of the original instruction List of models:

Model

T-Code

Valid from serial number

SPE120

1013

6375610-

SPE120L

1014

6375610-

SPE140

1013

6375610-

SPE140L

1014

6375610-

SPE140S

1015

6375610-

SPE160

1013

6375610-

SPE160L

1014

6375610-

SPE200

1013

6375610-

SPE200D

1014

6375610-

SPE200L

1014

6375610-

Change history:

Date

Change

Change description

2015-02-09

New truck model

Completely new issue

2017-09-01

General update

Updated version

2018-03-23

General, page 13 - 21

Changed to block 1 as standard.

List of error codes, page 7 - 11

Clarified truck behaviour, 3:587 updated

Checking the split pins / securing pins, page 15 - 7 Fitting the lift cylinder, page 14 - 27

Added torque to cylinder mount, top beam 47 Âą 3 Nm

Emergency release of the parking brake, Updated the transport screws. page 11 - 6 Parameter list, page 4 - 2

1142 added, 311/ 329 new value

Periodic maintenance, page 6 - 8

Deleted 500h

PIN code for resetting the truck, page 13 - 22 Programming PIN codes, page 13 - 22 Diagram, page 19 - 2

Modified diagram F53 changed to 20 A

PIN code defaults, page 13 - 24 Weighing system, page 13 - 25

New setting

Overview, page 11 - 2

New dust seal

PIN code at delivery, page 13 - 23

[New information]

PreOpCheck, page 17 - 4

[New information]

Table of contents

General introduction

1

General safety rules

2

Operating principle

3

Parameters

4

Installation

5

Maintenance

6

Troubleshooting

7

Chassis C0000

8

Motors C1000

9

Transmission/Drive gear C2000

10

Brake/wheel/track system C3000

11

Steering system C4000

12

Electrical system C5000

13

Hydraulics/Pneumatics C6000

14

Work function - lifting masts C7000

15

Auxiliary equipment, installation equipment C8000

16

Optional equipment/Extra equipment C9000

17

Instructions for disposal

18

Wiring diagram

19

Hydraulics schematics

20

Tools

21

Service data and grease specifications

22

Technical data

23

Index

24

Repair manual 7590353 en

General introduction

1

1.1

Images and other information ............................................................................................................................ 1 - 1

1.2

Warning levels and symbols .............................................................................................................................. 1 - 1

1.3

Pictograms ......................................................................................................................................................... 1 - 1

1.4

Abbreviations ..................................................................................................................................................... 1 - 2

Repair manual 7590353-040

1 General introduction Images and other information

1 General introduction 1 General introduction

1

1.1 Images and other information 1.1 Images and other information

Images and other information used in this manual may differ from your truck depending on model or optional equipment.

1.2 Warning levels and symbols 1.2 Warning levels and symbols

The following warning levels and symbols are used in the repair manual: DANGER Indicates a dangerous situation that – if not avoided – will cause death or serious bodily injury.

WARNING Indicates a dangerous situation that – if not avoided – could possibly cause death or serious bodily injury.

CAUTION Indicates a dangerous situation that – if not avoided – will cause a slight or minor bodily injury.

NOTICE Used in connection with actions that can cause material damage but not bodily injury.

Used to attract attention and to give information about various actions.

1.3 Pictograms 1.3 Pictograms

Symbol

Procedure

Symbol

Procedure

Visual inspection of condition, wear and loose connections.

Component replacement.

Cleaning

Measurement

Checks for leaks.

Check that screws, nuts, etc. are tightened to torque.

Listening for noise.

Lubrication, application.

Check of functions.

Calibration

Adjustment

Welding

Disassembly/removal

Assembly/installation

Open

Close

Refilling

Emptying

Update

Charging

Lift

Lower

An example of another type of pictogram is “Cut cable ties”:

1-1

Repair manual 7590353 en

1 General introduction Abbreviations

Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.

1.4 Abbreviations 1.4 Abbreviations

Abbrevi- Meaning ation

Explanation

ACC

Alternate Current Combi

Motor control, hydraulics and drive.

ACH

Alternate Current Hydraulic

Motor control, hydraulics.

ACT

Alternate Current Traction

Motor control, drive.

ADU

Automation Display Unit

Display used for automated applications for control inputs and visual feedback from the automatic system.

ACU

Automation Camera Unit

Camera equipment used for automatic applications in order to identify empty places in racking, etc.

ACP

Automation Control Panel

Control panel used for automated applications for control inputs and visual feedback from the automatic system.

AUX

Auxiliary

Outside equipment

BCU

Onboard system

BDI

Battery Discharge Indicator

Unit indicating the state of battery charge.

BMS

Battery Management System

A interface for battery to truck communication.

CAN

Controller Area Network

A standardised interface that enable communication between different electrical units.

CID

Central Information Display

Display with menu-based information system that is used as the primary communication tool between operator and truck.

DHU

Data Handling Unit

DX

Duplex

Mast with two sections.

EPS

Electronic Power Steering

Complete steering servo with its own motor control.

ESO

Emergency Switch Off

Emergency stop switch.

FCM

Fuse Central Module

Fuse panel.

FCU

Fork Control Unit

Unit for fork functions.

GFU

General Function Unit

Unit for general functions.

HPS

Height Pre-Select

Height pre-selection

ICH

Integrated Control Handle

IPM

Intelligent Power Module

Power control unit

LID

Load Information Display

Display that provides the operator information such as lift height, load weight and height preselection.

LGU

Laser Guidance Unit

Laser guidance unit

LSU

Laser Scanner Unit

Laser scanner that detects objects.

MC

Main Contactor

Main contactor

MCU

Main Control Unit

Main control unit.

MLD

Multi Load Detection

Sensor for automatic detection of loads, etc.

PDA

Personal Digital Assistant

A compact, portable handheld computer.

PPS

Personal Protection System

Personal protection system.

PTC

Positive Temperature Coefficient

Electrical property that causes resistance to increase with temperature.

SAU

Secondary Automation Unit

Device used for automatic control in order to have enough I/O.

Repair manual 7590353 en

1-2

1 General introduction Abbreviations

Abbrevi- Meaning ation

Explanation

SCU

Secondary Control Unit

Secondary control unit

SEU

Spider Expansion Unit

Expansion unit

SF

Shuttle Forks

Telescoping fork unit.

SR

Safety Relay

Relay to disconnect power to certain components in order to stop all movements.

SPLC

Safety PLC

Device used in automation applications for control with SR and UAC.

SSU

Shock Sensor Unit

Shock sensor that registers any collision.

TBD

To Be Defined

Means that the instruction/chapter will be added at a later date.

TCS

Truck Control System

The truck control system that communicates with units.

TH

Turret Head

Turret head fork unit

I-Site

Toyota Wireless Information Sys- Wireless communication. tem

TX

Triplex

Mast with three sections.

UAC

Unit for Automation Control

Device used for automated control of an operator-less truck. UAC will build an extra CAN and a power system for automation by itself

VNA

Very Narrow Aisle

Narrow aisles

VRE

Very narrow aisle Rider Electric

1-3

1

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

8.2.2.1.2 Replacing a service cover 8.2.2.1.2 Replacing a service cover

8.2.2.1.2.1 Removing a service cover 8.2.2.1.2.1 Removing a service cover

1.

Undo the screws.

2.

Turn out the upper edge of the cover.

3.

Carefully remove it from the rubber seal.

1.

Fit the lower edge of the cover.

2.

Turn in the cover.

3.

Fit the screws

8.2.2.1.2.2 Installing a service cover 8.2.2.1.2.2 Installing a service cover

8.2.2.1.3 Replacing a side cover 8.2.2.1.3 Replacing a side cover

8.2.2.1.3.1 Removing a side cover 8.2.2.1.3.1 Removing a side cover

Removing a service cover, page 8 - 4

Repair manual 7590353 en

8-4

8 Chassis C0000 Frame, chassis C0300

1.

Undo the screws.

2.

Remove the cover.

8

8.2.2.1.3.2 Installing a side cover 8.2.2.1.3.2 Installing a side cover

1.

Hook the side cover into the upper cover and install. Make sure the washers are seated in the rubber grommets.

2.

Fit the screws.

Resetting Installing a service cover, page 8 - 4

8.2.2.1.4 Replacing an emblem cover 8.2.2.1.4 Replacing an emblem cover

8.2.2.1.4.1 Removing an emblem cover 8.2.2.1.4.1 Removing an emblem cover

Removing a side cover, page 8 - 4

8-5

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

1.

Pry loose the cover and move the cover downwards.

1.

Insert the pins in the holes and press the snap lock so that it engages. Fitting is easier if you take one side at a time.

8.2.2.1.4.2 Installing an emblem cover 8.2.2.1.4.2 Installing an emblem cover

Installing a side cover, page 8 - 5

8.2.2.1.5 Replacing an upper cover 8.2.2.1.5 Replacing an upper cover

8.2.2.1.5.1 Removing an upper cover 8.2.2.1.5.1 Removing an upper cover

Removing an emblem cover, page 8 - 5

Repair manual 7590353 en

8-6

8 Chassis C0000 Frame, chassis C0300

1.

Undo the screws and remove the cover.

8

8.2.2.1.5.2 Installing an upper cover 8.2.2.1.5.2 Installing an upper cover

1.

Position the cover and screw it in place.

2.

Fit the cover to the CAN connector.

1.

Remove the screws and remove the cover.

Installing an emblem cover, page 8 - 6

8.2.2.1.6 Replacing a cover 8.2.2.1.6 Replacing a cover

8.2.2.1.6.1 Removing a cover 8.2.2.1.6.1 Removing a cover

Part number: 7530299

8-7

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

8.2.2.1.6.2 Installing a cover 8.2.2.1.6.2 Installing a cover

Part number: 7530299 1.

Repair manual 7590353 en

Refit the cover.

8-8

8 Chassis C0000 Frame, chassis C0300

8.2.3 Support arms, stabilizers C0350 8.2.3 Support arms, stabilizers C0350

8.2.3.1 Overview 8.2.3.1 Overview

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L

f

e d c b

a

Pos. a b c d e f

Designation Roller on torsion tube Torsion tube Push rod Wheel fork Bushing wheel fork Bogie link

8-9

Repair manual 7590353 en

8

8 Chassis C0000 Frame, chassis C0300

8.2.3.2 Checking the linkage 8.2.3.2 Checking the linkage

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L 1.

Check for cracks and other damage on the linkage. Replacing torsion tubes, page 8 - 15

8.2.3.3 Replacing the pressure rod 8.2.3.3 Replacing the pressure rod

8.2.3.3.1 Removing a push rod 8.2.3.3.1 Removing a push rod

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L 1.

Lift the forks and secure them.

WARNING Risk of personal injury and material and property damage Never work under raised forks without them being properly secured in place.

2.

Repair manual 7590353 en

Remove the load on the support arm wheels=45mm

8 - 10

8 Chassis C0000 Frame, chassis C0300

3.

Remove the initial lift cylinder

8

4.

Remove the mechanical stops to the lift rollers

5.

Lift the rear chassis so much that the rollers are halfway visible Make sure nothing is in the way when lifting, e.g. E-bar (option)

8 - 11

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

Repair manual 7590353 en

6.

Support the rear chassis=130mm

7.

Remove the shaft at the torsion tube fitting.

8.

Remove the pin and the shaft at the front torsion tube fitting

8 - 12

8 Chassis C0000 Frame, chassis C0300

8

9.

Pull the torsion tube and the push rod backwards

8.2.3.3.2 Installing a push rod 8.2.3.3.2 Installing a push rod

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L

1.

Fit the torsion tube and push rod.

2.

Fit the shaft at the torsion tube fitting.

8 - 13

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

Repair manual 7590353 en

3.

Fit the push rod in the wheel fork

4.

Lower the rear chassis

5.

Fit the mechanical stop to the lift rollers.

8 - 14

8 Chassis C0000 Frame, chassis C0300

6.

Fit the initial lift cylinder

8

7.

Lower the forks and the support arms

8.2.3.4 Replacing torsion tubes 8.2.3.4 Replacing torsion tubes

8.2.3.4.1 Removing torsion tubes 8.2.3.4.1 Removing torsion tubes

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L Preparations Removing a push rod, page 8 - 10

8 - 15

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

Repair manual 7590353 en

1.

Remove the pin

2.

Remove the shaft

3.

Remove the torsion tube from the push rod

8 - 16

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8 Chassis C0000 Frame, chassis C0300

8.2.3.4.2 Installing a torsion tube 8.2.3.4.2 Installing a torsion tube

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L

8

1.

Fit the torsion tube on the push rod.

2.

Fit the shaft and the pin.

Resetting Installing a push rod, page 8 - 13

8 - 17

Repair manual 7590353 en

8 Chassis C0000 Frame, chassis C0300

8.2.3.5 Replacing the roller on the torsion tube 8.2.3.5 Replacing the roller on the torsion tube

8.2.3.5.1 Removing the roller on the torsion tube 8.2.3.5.1 Removing the roller on the torsion tube

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L Preparations Removing a push rod, page 8 - 10

Repair manual 7590353 en

1.

Tap out the spring pin and shaft.

2.

Remove the roller.

8 - 18

8 Chassis C0000 Frame, chassis C0300

8.2.3.5.2 Fit the roller on the torsion tube 8.2.3.5.2 Fit the roller on the torsion tube

Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L 1.

Fit the roller.

8

2.

Tap the shaft and spring pin into place.

Resetting Installing a push rod, page 8 - 13

8 - 19

Repair manual 7590353 en