BT Toyota Electric Forklift SPE120XR, SPE120XRD Repair manual

Description

BT Toyota Electric Forklift SPE120XR, SPE120XRD Repair manual –  PDF DOWNLOAD

FILE DETAILS:

BT Toyota Electric Forklift SPE120XR, SPE120XRD Repair manual –  PDF DOWNLOAD

Language : English
Pages :300
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Toyota Electric Forklift SPE120XR  SPE120XRD Repair manual –  PDF DOWNLOAD

1 Index0
2 General introduction0
21 How to use this manual0
22 Warning symbols0
23 Pictograms0
231 Screws/Nuts0
232 Other pictograms0
3 General safety rules0
31 Work safety0
32 Electrical systems0
33 Safe lifting0
34 Truck modifications0
4 Operation and connection sequences0
41 Description of functions0
411 Operating principle0
5 Parameters0
51 Parameter settings0
511 General0
512 Show parameters – CAN key not connected0
513 Show the parameters – CAN key connected0
514 Setting operator parameters0
515 Setting the service parameters0
516 Summary of operator parameters0
517 Description of operator parameters0
# 2 – Maximum speed, high speed range0
# 3 – Maximum acceleration0
# 4 – Neutral braking effect0
# 6 – Maximum speed, low speed range0
# 7 – Maximum speed, “Turtle” range0
518 Summary of service parameters0
519 Description of service parameters0
# 10 – PIN code0
Programming a new PIN code:0
Deleting an existing PIN code:0
# 14 – Creep speed0
#15 – Non-configurable options0
Setting non-configurable options0
#16 – Configurable option #10
#17 – Configurable option #20
#18 – Configurable option #30
#19 – Configurable option #40
#20 – Hour meter selection0
#21 – Battery size0
# 22 – Maximum fork lowering speed0
#23 – Stop ramp, fork lowering0
# 25 – Service interval0
#26 – Selection of hydraulic unit0
30 – Reset voltage for BDI0
# 31 – Max load, inner & outer fork pairs0
#35 – Log off0
# 36 – Calibration0
#37 – Steering offset0
# 38 – Steering servo activation0
# 39 – Login method & operator parameter access0
Extended keypad – General0
Expanded keypad – Programming0
5110 Configurable “Option” parameters0
Parameters #16–19 configurable optional functions0
6 Installation and commissioning0
61 Transporting the truck0
62 Transporting the mast0
63 Safe lifting0
64 Taking into operation0
641 Battery0
Safety for battery handling0
Installation of/replacing the battery0
642 Parameter setting0
643 Test driving and checks0
7 Maintenance0
71 Introduction0
72 Safety precautions for maintenance work0
73 Maintenance instructions0
731 Cleaning and washing0
High-pressure washers0
Degreasing agents0
Cleaning the truck exterior0
Cleaning the chain0
Cleaning the motor compartment0
Cleaning electrical components0
74 Checks for cracks0
741 Visual inspection0
742 Crack detection0
Crack detection with liquid penetrant0
Crack detection with magnetic yoke0
75 Periodic maintenance0
751 Every 500 operating hours/6 m0
752 Every 1000 operating hours/12 m0
753 Every 3000 operating hours/36 m0
754 Lubrication chart0
8 Troubleshooting methods0
81 Initial troubleshooting0
82 Concluding troubleshooting0
83 Troubleshooting using error codes0
831 Error code log0
832 Warning codes0
833 Error codes0
834 Transistor regulator error codes0
Resetting errors0
Safety0
84 Auxiliary functions0
841 Built-in test function0
Test mode 2: digital inputs/outputs0
842 Display test mode0
85 Troubleshooting chart0
851 The truck cannot be driven0
852 The truck can be driven but only at reduced speed0
853 The truck can be driven but behaves abnormally0
854 Hydraulic system blocked or becomes blocked by a specific operation0
855 Hydraulic system operates but behaves abnormally0
856 Steering servo error0
9 Frame/Chassis C00000
91 Inspection covers C03400
911 Opening the motor compartment0
912 Close the motor compartment0
92 Motor suspension C04500
921 Components0
922 Removing the motor suspension0
923 Spring replacement0
93 Operator platform C05600
931 Components0
932 Removing the platform0
933 Fitting the operator platform0
10 Motors C1000 – Action0
101 Pump motor C17100
1011 Replacing the pump motor0
102 Drive motor, C17600
1021 Overview0
1022 Removing the drive motor0
1023 Fastening the drive motor0
1024 Disassembling the drive motor0
1025 Assembling the drive motor0
1026 Cleaning0
11 Drive gear C20000
111 Drive gear C20000
112 Overview0
113 Removing the drive gear from the truck0
114 Installing the drive gear in the truck0
115 Oil check or change0
1151 Checking/refilling the oil0
1152 Oil change0
116 Replacing the drive shaft seal0
1161 Dismantling0
1162 Installation0
117 Leakage from top cover0
12 Brakes and wheels C30000
121 Parking brake C33700
1211 Overview0
1212 Maintenance0
Basic adjustment of the clearance0
Replacing the brake disc0
122 Drive wheel C35300
1221 Replacing the drive wheel0
123 Support/castor wheels – 35400
1231 Components0
1232 Replacing the castor wheel0
124 Support arm wheel – 35500
1241 Component overview0
1242 Replacing the wheel0
13 Steering system C40000
131 Tiller arm handle C41100
1311 Tiller arm handle components0
1312 Disassembling/assembling the steering unit handle0
Disassembly0
Assembly0
1313 Replacing the signal button/switch0
1314 Replacement of lift/lower button0
1315 Replacing the lift control for simultaneous lift0
132 Electric steering servo C43000
1321 General0
1322 Component parts, steering servo0
133 Adjustment0
1331 Reference sensor0
1332 Calibration0
Parameter 360
Parameter 370
134 Replacing the steering angle potentiometer0
14 Electrical system C50000
141 General0
1411 Terminology0
1412 Version numbers0
1413 Description of steering system0
1414 Spider expansion unit (SEU)0
1415 Speed limitation0
1416 Hour meter and battery charge level0
1417 Reset voltage for BDI0
1418 TLS – Truck log system (optional)0
General0
Registration0
Logging in/out SD160
Logging in/out S160
Collision sensor0
Settings0
1419 ID unit (optional)0
14110 Warning lamp0
142 Transistor regulator0
1421 General0
1422 Technical specifications – Curtis 12430
143 Sending units and sensors C58000
1431 Inductive sensors0
144 Electrical system C50000
145 Battery C51100
1451 Battery recommendations0
1452 Changing the battery0
Battery installation/replacement using a battery changing table0
Battery installation/replacement using a lifting device0
146 Senders and sensors C53800
1461 Replacing the position sensor with 18 m XR/XRD0
1462 Replacing the position sensor for the secondary lift0
1463 Adjusting the sensor for the secondary lift0
1464 Replacing the reference sensor for the steering servo0
Calibration0
15 Hydraulic system C60000
151 System description0
Simultaneous lift (main lift and secondary lift)0
Main lift0
Working pressure0
PowerTrak system0
152 Hydraulic unit C61000
1521 Overview SPE120 XRD0
1522 Tightening torque for hydraulic unit0
153 Installation instructions, hydraulic hoses SPE120 XRD0
1531 Overview SPE120 XR0
154 Main valve C62100
1541 Pressure limiting valve0
1542 Pressure sensor0
155 Hose rupture valve0
156 Hydraulic system C60000
157 Hydraulic hygiene0
1571 Washing0
1572 Packaging0
1573 Handling0
1574 Storage0
1575 Work procedures0
1576 Emptying the tank0
1577 Filling the tank0
1578 Removing/installing the hydraulic unit0
1579 Replacing the tank0
SPE120 XRD0
SPE 120XR0
15710 Replacing the oil pump0
15711 Bleeding the hydraulic system0
158 Main valve C62100
1581 Replacing the main valve0
1582 Replacing the valve0
Valve calibration0
1583 Replacing the valve solenoid0
1584 Replacing pressure filter [PF] SPE120XRD0
1585 Quick change connector0
Overview0
Assembling the quick change connector0
Dismantling the quick change connector0
159 Main lift C66100
1591 Removing lift cylinder from the mast0
1592 Assembling the cylinder in the mast0
1510 Lift cylinder secondary mast C66700
16 Mast/Lift system C70000
161 Main mast C71000
1611 Replacing/removing mast XRD0
1612 Replacement/installation of the mast0
1613 Replacing/fitting the fork yoke0
1614 Adjusting the mast inclination0
162 Secondary mast C72000
1621 Removing the secondary mast/cylinder0
1622 Installing the secondary mast/cylinder0
1623 Adjusting and shimming the secondary mast0
163 Main lift chain system C17200
1631 Check0
1632 Lubrication0
1633 Adjustment0
1634 Replacing the chain0
164 Forks C74100
1641 Overview0
General0
Inspection0
Inspection intervals0
Surface cracks0
Difference in height between the fork tips0
Position lock0
Marking legibility0
Fork blades and back of fork carriage0
Mounting fixtures on the fork0
1642 Forks, repairs and testing0
Repairs0
Testing the yield point0
Forks-general0
17 Options – 90000
171 Component overview, TWIS (Toyota Wireless Information System)0
172 DC/DC converter0
1721 Installation of the DC/DC converter and 12 V socket0
1722 Wiring diagram, DC/DC converter0
18 Instructions for disposal0
181 General0
182 Marking of plastics0
1821 General marking of products and packaging0
1822 Marking according to the manufacturer’s standards0
Abbreviations0
Marking examples0
183 Pressure vessels0
1831 Gas dampers0
184 Sorting categories0
19 Wiring diagram0
191 Overview of electrical equipment0
1911 Component location0
1912 Component list0
192 List of symbols0
193 Overview0
194 Wiring diagrams0
20 Hydraulics schematics0
201 SPE120XRD0
2011 Hydraulic pump0
2012 Reach0
202 SPE120XR0
203 Hydraulic pump0
2031 Reach0
21 Tools0
211 AMP connectors0
212 AMP connectors, Multilock series 0400
213 Super Seal connectors0
214 Molex connectors0
215 Other tools0
22 Service data and grease specifications0
221 General tightening torques0
2211 Galvanised, non-oiled screws0
2212 Untreated, oiled screws0
222 Oil and grease specification0
23 Technical data0

IMAGES PREVIEW OF THE MANUAL:

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