service repair manual instant download

1. Repair manual 7590353 en
SPE120
SPE120L
SPE140
SPE140L
SPE140S
SPE160
SPE160L
SPE200
SPE200D
SPE200L

2. 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 ± 3 Nm
Emergency release of the parking brake,
page 11 - 6
Updated the transport screws.
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]
Translation of the original instruction

3. Table of contents
Repair manual 7590353 en
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

4. General introduction 1
Repair manual 7590353-040
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

5. 1 General introduction
Images and other information
1 - 1 Repair manual 7590353 en
1 General introduction
1
General introduction
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

6. 1 General introduction
Abbreviations
Repair manual 7590353 en 1 - 2
Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
1.4 Abbreviations
1.4
Abbreviations
Abbrevi-
ation
Meaning 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.

7. 1 General introduction
Abbreviations
1 - 3 Repair manual 7590353 en
Abbrevi-
ation
Meaning 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-
tem
Wireless communication.
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

8. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 4
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.
8.2.2.1.2.2 Installing a service cover
8.2.2.1.2.2
Installing a service cover
1. Fit the lower edge of the cover.
2. Turn in the cover.
3. Fit the screws
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

9. 8 Chassis C0000
Frame, chassis C0300
8 - 5 Repair manual 7590353 en
1. Undo the screws.
2. Remove the cover.
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

10. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 6
1. Pry loose the cover and move the cover downwards.
8.2.2.1.4.2 Installing an emblem cover
8.2.2.1.4.2
Installing an emblem cover
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.
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

11. 8 Chassis C0000
Frame, chassis C0300
8 - 7 Repair manual 7590353 en
1. Undo the screws and remove the cover.
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.
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
1. Remove the screws and remove the cover.
8

12. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 8
8.2.2.1.6.2 Installing a cover
8.2.2.1.6.2
Installing a cover
Part number: 7530299
1. Refit the cover.

13. 8 Chassis C0000
Frame, chassis C0300
8 - 9 Repair manual 7590353 en
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
f
e
d
c
b
a
Pos. Designation
a Roller on torsion tube
b Torsion tube
c Push rod
d Wheel fork
e Bushing wheel fork
f Bogie link
8

14. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 10
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 prop-
erty damage
Never work under raised forks without them being properly
secured in place.
2. Remove the load on the support arm wheels=45mm

15. 8 Chassis C0000
Frame, chassis C0300
8 - 11 Repair manual 7590353 en
3. Remove the initial lift cylinder
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

16. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 12
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

17. 8 Chassis C0000
Frame, chassis C0300
8 - 13 Repair manual 7590353 en
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

18. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 14
3. Fit the push rod in the wheel fork
4. Lower the rear chassis
5. Fit the mechanical stop to the lift rollers.

19. 8 Chassis C0000
Frame, chassis C0300
8 - 15 Repair manual 7590353 en
6. Fit the initial lift cylinder
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

20. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 16
1. Remove the pin
2. Remove the shaft
3. Remove the torsion tube from the push rod

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22. 8 Chassis C0000
Frame, chassis C0300
8 - 17 Repair manual 7590353 en
8.2.3.4.2 Installing a torsion tube
8.2.3.4.2
Installing a torsion tube
Model: SPE120L, SPE140L, SPE160L, SPE200D, SPE200L
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

23. 8 Chassis C0000
Frame, chassis C0300
Repair manual 7590353 en 8 - 18
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
1. Tap out the spring pin and shaft.
2. Remove the roller.

24. 8 Chassis C0000
Frame, chassis C0300
8 - 19 Repair manual 7590353 en
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.
2. Tap the shaft and spring pin into place.
Resetting
Installing a push rod, page 8 - 13
8