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