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![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](https://image.slidesharecdn.com/toyotabtspe140lelectricstackertruckservicerepairmanual-200920151553/75/Toyota-bt-spe140-l-electric-stacker-truck-service-repair-manual-2-2048.jpg)
Toyota bt spe140 l electric stacker truck service repair manual
- 1. Repair manual 7590353en SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D SPE200L
- 2. List of models: ModelT-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 Repairmanual 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 Repairmanual 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 Imagesand other information 1 - 1 Repair manual 7590353 en 1 General introduction1 General introduction 1.1 Images and other information1.1 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 symbols1.2 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 Pictograms1.3 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 Repairmanual 7590353 en 1 - 2 Additional information under the pictogram can, for example, indicate the number of cable ties to be cut. 1.4 Abbreviations1.4 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 cover8.2.2.1.2 Replacing a service cover 8.2.2.1.2.1 Removing a service cover8.2.2.1.2.1 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 cover8.2.2.1.2.2 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 cover8.2.2.1.3 Replacing a side cover 8.2.2.1.3.1 Removing a side cover8.2.2.1.3.1 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 cover8.2.2.1.3.2 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 cover8.2.2.1.4 Replacing an emblem cover 8.2.2.1.4.1 Removing an emblem cover8.2.2.1.4.1 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 cover8.2.2.1.4.2 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 cover8.2.2.1.5 Replacing an upper cover 8.2.2.1.5.1 Removing an upper cover8.2.2.1.5.1 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 cover8.2.2.1.5.2 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 cover8.2.2.1.6 Replacing a cover 8.2.2.1.6.1 Removing a cover8.2.2.1.6.1 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 cover8.2.2.1.6.2 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 C03508.2.3 Support arms, stabilizers C0350 8.2.3.1 Overview8.2.3.1 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 linkage8.2.3.2 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 rod8.2.3.3 Replacing the pressure rod 8.2.3.3.1 Removing a push rod8.2.3.3.1 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 rod8.2.3.3.2 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 tubes8.2.3.4 Replacing torsion tubes 8.2.3.4.1 Removing torsion tubes8.2.3.4.1 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 tube8.2.3.4.2 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 tube8.2.3.5 Replacing the roller on the torsion tube 8.2.3.5.1 Removing the roller on the torsion tube8.2.3.5.1 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 tube8.2.3.5.2 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