Toyota BT LPE200 Electric Pallet Truck Service Repair Manual

Repair manual 7572514

LPE200 LPE220 LPE250 LPE340BE

en

Translation of the original instruction List of models:

Model

T-Code

Valid from serial number

LPE200

1010

6304531-

LPE220

1010

6304531-

LPE250

1010

6304531-

LPE340BE

1010

6593220

Change history:

Date

Change

2017-11-01

Various updates

Change description

2018-01-01

Periodic maintenance, page 6 - 5

Updated maintenance list.

2018-03-01

General, page 13 - 23

Changed to block 1 as standard.

List of error codes, page 7 - 11

Clarified truck behaviour, 3:587 updated

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

New dust seal

Programming PIN codes, page 13 - 24 PIN code defaults, page 13 - 26

2018-05-25

PIN code at delivery, page 13 - 25

[New information]

PreOpCheck, page 17 - 4

[New information]

Parameter list, page 4 - 2

1142 added, 311/ 329 new value

Weighing system, page 13 - 28

New setting

Parameter list, page 4 - 2

Added configurable optional functions

Overview steering servo, page 12 - 45

New bracket

Technical data, page 8 - 43

Suspension/PT cylinder

Technical data, page 8 - 43

Suspension/PT cylinder

Technical data, page 8 - 42

Suspension/PT cylinder

Technical data, page 8 - 42

Suspension/PT cylinder

Technical data, page 8 - 43

Suspension/PT cylinder

Technical data, page 8 - 42

Suspension/PT cylinder

Technical data, page 8 - 44

Suspension/PT cylinder

Truck data

Added LPE340BE

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 7572514 en

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 7572514 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 7572514 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 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10 Transmission/Drive gear C2000 10 Transmission/Drive gear C2000

10.1 Drive unit, final gear C2500 10.1 Drive unit, final gear C2500

10.1.1 Drive unit/gear C2550 10.1.1 Drive unit/gear C2550

10.1.1.1 Overview 10.1.1.1 Overview

Part number: 7540136 7525837 7530286

b

10 c

d

a

e

Pos. a b c d e

Designation Transmission housing Motor bearing and packing box Steering bearings Seal and cover ring Stud M12X1.5

10 - 1

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.2 Overview 10.1.1.2 Overview

Part number: 7525839 7540133

c

d

b

e

a

Pos. a b c d e

Designation Seal and cover ring Transmission housing Motor bearing and packing box Steering bearings Stud M14X1.5

10.1.1.3 Description 10.1.1.3 Description

10.1.1.3.1 Design 10.1.1.3.1 Design

The drive gear is a two-stage angle gear that is integrated with the motor and brake assembly in a complete drive unit.

The drive gear is bolted to the chassis. At the top edge of the gear, the steering bearing and a gear ring for the steering motor (option) are fitted.

A complete reconditioning of the drive gear must be performed in the workshop by trained technicians.

10.1.1.3.2 Technical data 10.1.1.3.2 Technical data

Part number: 7525839 7540133 Description

Value

Type

Two-stage angle gear

Gear ratio

16.96

Oil quality

1.05 litres

Drive wheel

Ă˜ 250

Repair manual 7572514 en

10 - 2

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

Description

Value

Oil type

See Lubricants 22 - 2

specification,

page

10.1.1.3.3 Technical data 10.1.1.3.3 Technical data

Part number: 7540136 7525837 7530286 Description

Value

Type

Two-stage angle gear

Gear ratio

18.39

Oil quality

0.9 litres

Drive wheel

Ă˜ 230

Oil type

See Lubricants 22 - 2

specification,

10

page

10.1.1.4 Check the drive gear's attachment 10.1.1.4 Check the drive gear's attachment

1.

Check the drive gear's attachment. Tighten the screws if necessary. 23 N¡m

10.1.1.5 Checking for leaks in the drive gear 10.1.1.5 Checking for leaks in the drive gear

1.

Check the drive gear for leaks. If there are any leaks, change the oil seal, see Replacing the wheel hub seal , page 10 - 7.

10 - 3

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.6 Checking for noise in the drive gear 10.1.1.6 Checking for noise in the drive gear

1.

Listen for any abnormal noise in the drive gear bearings In case of noise: Check if the oil level is up to the bottom edge of the filler hole, see Lubricants specification, page 22 - 2.

Replace the steering bearing. Replacing the drive gear steering bearing , page 10 - 13

10.1.1.7 Replacing the drive gear 10.1.1.7 Replacing the drive gear

10.1.1.7.1 Removing the drive gear 10.1.1.7.1 Removing the drive gear

Preparations Removing the platform, page 8 - 78 Removing the platform [Fixed side guards], page 8 - 81 1.

Turn the drive wheel as much as possible in one direction.

2.

Switch off the truck and disconnect the battery connector.

WARNING Risk of personal injury and material and property damage For trucks with power steering, the truck battery must be disconnected when working on the drive gear/drive wheel.

â–ş

The drive wheel will automatically return to the original position when the truck is started.

Removing the drive motor [M1], page 9 - 19, Removing the drive motor [M1], page 9 - 21, Removing the drive motor [M1], page 9 - 23

Repair manual 7572514 en

10 - 4

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

3.

Undo and remove the screws to the drive gear.

4.

Lift the truck 100 mm and support it on trestles.

10 WARNING Risk of crushing under the truck Risk of crushing since a poorly supported truck could fall down.

â–ş

Secure the truck in a safe manner.

5.

Remove the gear from the truck.

6.

Mark the position of the steering bearing.

10 - 5

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.7.2 Installing the drive gear 10.1.1.7.2 Installing the drive gear

1.

Lift the drive gear in place.

Turn the wheel towards you (rearwards) to facilitate the lift.

2.

Rotate the steering bearing to the right position; see marking.

3.

Lower the truck and position the gear in place.

4.

Fit the drive gear.

Remember to tighten the screws crosswise

Repair manual 7572514 en

10 - 6

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

Resetting Installing the drive motor [M1], page 9 - 25 Installing the drive motor [M1], page 9 - 27 Installing the drive motor [M1], page 9 - 29 Installing the platform, page 8 - 81 Fitting the platform [Fixed side guards], page 8 - 83

10.1.1.8 Replacing the wheel hub seal 10.1.1.8 Replacing the wheel hub seal

10.1.1.8.1 Removing the wheel hub seal 10.1.1.8.1 Removing the wheel hub seal

Disassembling the drive wheel, page 11 - 17 1.

Remove the cover ring using a screwdriver or similar to remove the seal.

10 - 7

Repair manual 7572514 en

10

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

2.

Remove the seal using a screwdriver or similar to remove the seal.

1.

Fit the seal. Tap lightly to get it into the right position.

10.1.1.8.2 Installing the wheel hub seal 10.1.1.8.2 Installing the wheel hub seal

Repair manual 7572514 en

10 - 8

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

2.

Fit the cover ring. Tap it lightly into place.

Installing a drive wheel, page 11 - 18

10 10.1.1.9 Drive gear oil change 10.1.1.9 Drive gear oil change

1.

Empty the oil from the drive gear. Empty the drive gear oil, page 10 - 10, Empty the drive gear oil, page 10 - 11

2.

Fill oil into the drive gear. Filling oil in the drive gear, page 10 - 12, Filling oil in the drive gear, page 10 - 13

10 - 9

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.9.1 Empty the drive gear oil 10.1.1.9.1 Empty the drive gear oil

Repair manual 7572514 en

1.

Undo and remove the oil plug on the lower part of the gear housing.

2.

Drain all old oil into a suitable receptacle.

3.

Clean away dirt and metal shavings from the oil plug.

4.

Install the oil plug, tighten to 20 N¡m.

10 - 10

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.9.2 Empty the drive gear oil 10.1.1.9.2 Empty the drive gear oil

1.

Undo and remove the oil plug on the lower part of the gear housing.

10 2.

Drain all old oil into a suitable receptacle.

3.

Clean the oil plug of any dirt and shavings. Refit the oil plug, tighten to 20 N¡m.

10 - 11

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.9.3 Filling oil in the drive gear 10.1.1.9.3 Filling oil in the drive gear

Repair manual 7572514 en

1.

Remove the oil filler plug on the upper part of the gear housing.

2.

Top up with oil up to the lower edge of the hole to reach the correct level, Lubricants specification, page 22 - 2.

3.

Screw in the plug.

10 - 12

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.9.4 Filling oil in the drive gear 10.1.1.9.4 Filling oil in the drive gear

1.

Remove the oil filler plug on the upper part of the gear housing.

10 2.

Top up with oil up to the lower edge of the hole to reach the correct level, Lubricants specification, page 22 - 2.

3.

Screw in the plug.

10.1.1.10 Replacing the drive gear steering bearing 10.1.1.10 Replacing the drive gear steering bearing

10.1.1.10.1 Removing the drive gear steering bearing 10.1.1.10.1 Removing the drive gear steering bearing

Part number: 7525839 7540133 Removing the drive gear, page 10 - 4

10 - 13

Repair manual 7572514 en

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10 Transmission/Drive gear C2000 Drive unit, final gear C2500

1.

Undo and remove the screws to the steering bearing.

2.

Lift away the steering bearing.

10.1.1.10.2 Removing the drive gear steering bearing 10.1.1.10.2 Removing the drive gear steering bearing

Part number: 7540136 7525837 Removing the drive gear, page 10 - 4 1.

Repair manual 7572514 en

Undo and remove the screws to the steering bearing.

10 - 14

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

2.

Lift away the steering bearing.

10 10.1.1.10.3 Installing the drive gear steering bearing 10.1.1.10.3 Installing the drive gear steering bearing

Part number: 7525839 7540133 1.

Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.

Installing the drive gear, page 10 - 6

10 - 15

Repair manual 7572514 en

10 Transmission/Drive gear C2000 Drive unit, final gear C2500

10.1.1.10.4 Installing the drive gear steering bearing 10.1.1.10.4 Installing the drive gear steering bearing

Part number: 7540136 7525837 1.

Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.

Installing the drive gear, page 10 - 6

10.1.1.11 Stud replacement 10.1.1.11 Stud replacement

10.1.1.11.1 Removing a stud 10.1.1.11.1 Removing a stud

Disassembling the drive wheel, page 11 - 17

Repair manual 7572514 en

10 - 16