BT TOYOTA SPE120XR, SPE120XRD REPAIR MANUAL 7550623-040 – PDF DOWNLOAD

Description

BT TOYOTA SPE120XR, SPE120XRD REPAIR MANUAL 7550623-040 – PDF DOWNLOAD

FILE DETAILS:

BT TOYOTA SPE120XR, SPE120XRD REPAIR MANUAL 7550623-040 – PDF DOWNLOAD

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

BT TOYOTA SPE120XR, SPE120XRD REPAIR MANUAL 7550623-040 – PDF DOWNLOAD

1. Index.............................................................................0
2. General introduction..............................................................0
	2.1 How to use this manual.......................................................0
	2.2 Warning symbols..............................................................0
	2.3 Pictograms...................................................................0
		2.3.1 Screws/Nuts............................................................0
		2.3.2 Other pictograms.......................................................0
3. General safety rules..............................................................0
	3.1 Work safety..................................................................0
	3.2 Electrical systems...........................................................0
	3.3 Safe lifting.................................................................0
	3.4 Truck modifications..........................................................0
4. Operation and connection sequences................................................0
	4.1 Description of functions.....................................................0
		4.1.1 Operating principle....................................................0
5. Parameters........................................................................0
	5.1 Parameter settings...........................................................0
		5.1.1 General................................................................0
		5.1.2 Show parameters – CAN key not connected................................0
		5.1.3 Show the parameters – CAN key connected................................0
		5.1.4 Setting operator parameters............................................0
		5.1.5 Setting the service parameters.........................................0
		5.1.6 Summary of operator parameters.........................................0
		5.1.7 Description of operator parameters.....................................0
			# 2 - Maximum speed, high speed range....................................0
			# 3 - Maximum acceleration...............................................0
			# 4 - Neutral braking effect.............................................0
			# 6 - Maximum speed, low speed range.....................................0
			# 7 - Maximum speed, “Turtle” range......................................0
		5.1.8 Summary of service parameters..........................................0
		5.1.9 Description of service parameters......................................0
			# 10 - PIN code..........................................................0
			Programming a new PIN code:..............................................0
			Deleting an existing PIN code:...........................................0
			# 14 – Creep speed.......................................................0
			#15 – Non-configurable options...........................................0
			Setting non-configurable options.........................................0
			#16 - Configurable option #1.............................................0
			#17 - Configurable option #2.............................................0
			#18 - Configurable option #3.............................................0
			#19 - Configurable option #4.............................................0
			#20 - Hour meter selection...............................................0
			#21 - Battery size.......................................................0
			# 22 - Maximum fork lowering speed.......................................0
			#23 - Stop ramp, fork lowering...........................................0
			# 25 - Service interval..................................................0
			#26 - Selection of hydraulic unit........................................0
			30 – Reset voltage for BDI...............................................0
			# 31 - Max. load, inner & outer fork pairs...............................0
			#35 – Log off............................................................0
			# 36 - Calibration.......................................................0
			#37 – Steering offset....................................................0
			# 38 - Steering servo activation.........................................0
			# 39 - Login method & operator parameter access..........................0
			Extended keypad - General................................................0
			Expanded keypad – Programming............................................0
		5.1.10 Configurable “Option” parameters......................................0
			Parameters #16–19 configurable optional functions........................0
6. Installation and commissioning....................................................0
	6.1 Transporting the truck.......................................................0
	6.2 Transporting the mast........................................................0
	6.3 Safe lifting.................................................................0
	6.4 Taking into operation........................................................0
		6.4.1 Battery................................................................0
			Safety for battery handling..............................................0
			Installation of/replacing the battery....................................0
		6.4.2 Parameter setting......................................................0
		6.4.3 Test driving and checks................................................0
7. Maintenance.......................................................................0
	7.1 Introduction.................................................................0
	7.2 Safety precautions for maintenance work......................................0
	7.3 Maintenance instructions.....................................................0
		7.3.1 Cleaning and washing...................................................0
			High-pressure washers....................................................0
			Degreasing agents........................................................0
			Cleaning the truck exterior..............................................0
			Cleaning the chain.......................................................0
			Cleaning the motor compartment...........................................0
			Cleaning electrical components...........................................0
	7.4 Checks for cracks............................................................0
		7.4.1 Visual inspection......................................................0
		7.4.2 Crack detection........................................................0
			Crack detection with liquid penetrant....................................0
			Crack detection with magnetic yoke.......................................0
	7.5 Periodic maintenance.........................................................0
		7.5.1 Every 500 operating hours/6 m..........................................0
		7.5.2 Every 1000 operating hours/12 m........................................0
		7.5.3 Every 3000 operating hours/36 m........................................0
		7.5.4 Lubrication chart......................................................0
8. Troubleshooting methods...........................................................0
	8.1 Initial troubleshooting......................................................0
	8.2 Concluding troubleshooting...................................................0
	8.3 Troubleshooting using error codes............................................0
		8.3.1 Error code log.........................................................0
		8.3.2 Warning codes..........................................................0
		8.3.3 Error codes............................................................0
		8.3.4 Transistor regulator error codes.......................................0
			Resetting errors.........................................................0
			Safety...................................................................0
	8.4 Auxiliary functions..........................................................0
		8.4.1 Built-in test function.................................................0
			Test mode 2: digital inputs/outputs......................................0
		8.4.2 Display test mode......................................................0
	8.5 Troubleshooting chart........................................................0
		8.5.1 The truck cannot be driven.............................................0
		8.5.2 The truck can be driven but only at reduced speed......................0
		8.5.3 The truck can be driven but behaves abnormally.........................0
		8.5.4 Hydraulic system blocked or becomes blocked by a specific operation....0
		8.5.5 Hydraulic system operates but behaves abnormally.......................0
		8.5.6 Steering servo error...................................................0
9. Frame/Chassis C0000...............................................................0
	9.1 Inspection covers C0340......................................................0
		9.1.1 Opening the motor compartment..........................................0
		9.1.2 Close the motor compartment............................................0
	9.2 Motor suspension C0450.......................................................0
		9.2.1 Components.............................................................0
		9.2.2 Removing the motor suspension..........................................0
		9.2.3 Spring replacement.....................................................0
	9.3 Operator platform C0560......................................................0
		9.3.1 Components.............................................................0
		9.3.2 Removing the platform..................................................0
		9.3.3 Fitting the operator platform..........................................0
10. Motors C1000 – Action............................................................0
	10.1 Pump motor C1710............................................................0
		10.1.1 Replacing the pump motor..............................................0
	10.2 Drive motor, C1760..........................................................0
		10.2.1 Overview..............................................................0
		10.2.2 Removing the drive motor..............................................0
		10.2.3 Fastening the drive motor.............................................0
		10.2.4 Disassembling the drive motor.........................................0
		10.2.5 Assembling the drive motor............................................0
		10.2.6 Cleaning..............................................................0
11. Drive gear C2000.................................................................0
	11.1 Drive gear C2000............................................................0
	11.2 Overview....................................................................0
	11.3 Removing the drive gear from the truck......................................0
	11.4 Installing the drive gear in the truck......................................0
	11.5 Oil check or change.........................................................0
		11.5.1 Checking/refilling the oil............................................0
		11.5.2 Oil change............................................................0
	11.6 Replacing the drive shaft seal..............................................0
		11.6.1 Dismantling...........................................................0
		11.6.2 Installation..........................................................0
	11.7 Leakage from top cover......................................................0
12. Brakes and wheels C3000..........................................................0
	12.1 Parking brake C3370.........................................................0
		12.1.1 Overview..............................................................0
		12.1.2 Maintenance...........................................................0
			Basic adjustment of the clearance........................................0
			Replacing the brake disc.................................................0
	12.2 Drive wheel C3530...........................................................0
		12.2.1 Replacing the drive wheel.............................................0
	12.3 Support/castor wheels - 3540................................................0
		12.3.1 Components............................................................0
		12.3.2 Replacing the castor wheel............................................0
	12.4 Support arm wheel - 3550....................................................0
		12.4.1 Component overview....................................................0
		12.4.2 Replacing the wheel...................................................0
13. Steering system C4000............................................................0
	13.1 Tiller arm handle C4110.....................................................0
		13.1.1 Tiller arm handle components..........................................0
		13.1.2 Disassembling/assembling the steering unit handle.....................0
			Disassembly..............................................................0
			Assembly.................................................................0
		13.1.3 Replacing the signal button/switch....................................0
		13.1.4 Replacement of lift/lower button......................................0
		13.1.5 Replacing the lift control for simultaneous lift......................0
	13.2 Electric steering servo C4300...............................................0
		13.2.1 General...............................................................0
		13.2.2 Component parts, steering servo.......................................0
	13.3 Adjustment..................................................................0
		13.3.1 Reference sensor......................................................0
		13.3.2 Calibration...........................................................0
			Parameter 36.............................................................0
			Parameter 37.............................................................0
	13.4 Replacing the steering angle potentiometer..................................0
14. Electrical system C5000..........................................................0
	14.1 General.....................................................................0
		14.1.1 Terminology...........................................................0
		14.1.2 Version numbers.......................................................0
		14.1.3 Description of steering system........................................0
		14.1.4 Spider expansion unit (SEU)...........................................0
		14.1.5 Speed limitation......................................................0
		14.1.6 Hour meter and battery charge level...................................0
		14.1.7 Reset voltage for BDI.................................................0
		14.1.8 TLS - Truck log system (optional).....................................0
			General..................................................................0
			Registration.............................................................0
			Logging in/out SD16......................................................0
			Logging in/out S16.......................................................0
			Collision sensor.........................................................0
			Settings.................................................................0
		14.1.9 ID unit (optional)....................................................0
		14.1.10 Warning lamp.........................................................0
	14.2 Transistor regulator........................................................0
		14.2.1 General...............................................................0
		14.2.2 Technical specifications – Curtis 1243................................0
	14.3 Sending units and sensors C5800.............................................0
		14.3.1 Inductive sensors.....................................................0
	14.4 Electrical system C5000.....................................................0
	14.5 Battery C5110...............................................................0
		14.5.1 Battery recommendations...............................................0
		14.5.2 Changing the battery..................................................0
			Battery installation/replacement using a battery changing table..........0
			Battery installation/replacement using a lifting device..................0
	14.6 Senders and sensors C5380...................................................0
		14.6.1 Replacing the position sensor with 1.8 m XR/XRD.......................0
		14.6.2 Replacing the position sensor for the secondary lift..................0
		14.6.3 Adjusting the sensor for the secondary lift...........................0
		14.6.4 Replacing the reference sensor for the steering servo.................0
			Calibration..............................................................0
15. Hydraulic system C6000...........................................................0
	15.1 System description..........................................................0
		Simultaneous lift (main lift and secondary lift).............................0
		Main lift....................................................................0
		Working pressure.............................................................0
		PowerTrak system.............................................................0
	15.2 Hydraulic unit C6100........................................................0
		15.2.1 Overview SPE120 XRD...................................................0
		15.2.2 Tightening torque for hydraulic unit..................................0
	15.3 Installation instructions, hydraulic hoses SPE120 XRD.......................0
		15.3.1 Overview SPE120 XR....................................................0
	15.4 Main valve C6210............................................................0
		15.4.1 Pressure limiting valve...............................................0
		15.4.2 Pressure sensor.......................................................0
	15.5 Hose rupture valve..........................................................0
	15.6 Hydraulic system C6000......................................................0
	15.7 Hydraulic hygiene...........................................................0
		15.7.1 Washing...............................................................0
		15.7.2 Packaging.............................................................0
		15.7.3 Handling..............................................................0
		15.7.4 Storage...............................................................0
		15.7.5 Work procedures.......................................................0
		15.7.6 Emptying the tank.....................................................0
		15.7.7 Filling the tank......................................................0
		15.7.8 Removing/installing the hydraulic unit................................0
		15.7.9 Replacing the tank....................................................0
			SPE120 XRD...............................................................0
			SPE 120XR................................................................0
		15.7.10 Replacing the oil pump...............................................0
		15.7.11 Bleeding the hydraulic system........................................0
	15.8 Main valve C6210............................................................0
		15.8.1 Replacing the main valve..............................................0
		15.8.2 Replacing the valve...................................................0
			Valve calibration........................................................0
		15.8.3 Replacing the valve solenoid..........................................0
		15.8.4 Replacing pressure filter [PF] SPE120XRD..............................0
		15.8.5 Quick change connector................................................0
			Overview.................................................................0
			Assembling the quick change connector....................................0
			Dismantling the quick change connector...................................0
	15.9 Main lift C6610.............................................................0
		15.9.1 Removing lift cylinder from the mast..................................0
		15.9.2 Assembling the cylinder in the mast...................................0
	15.10 Lift cylinder secondary mast C6670.........................................0
16. Mast/Lift system C7000...........................................................0
	16.1 Main mast C7100.............................................................0
		16.1.1 Replacing/removing mast XRD...........................................0
		16.1.2 Replacement/installation of the mast..................................0
		16.1.3 Replacing/fitting the fork yoke.......................................0
		16.1.4 Adjusting the mast inclination........................................0
	16.2 Secondary mast C7200........................................................0
		16.2.1 Removing the secondary mast/cylinder..................................0
		16.2.2 Installing the secondary mast/cylinder................................0
		16.2.3 Adjusting and shimming the secondary mast.............................0
	16.3 Main lift chain system C1720................................................0
		16.3.1 Check.................................................................0
		16.3.2 Lubrication...........................................................0
		16.3.3 Adjustment............................................................0
		16.3.4 Replacing the chain...................................................0
	16.4 Forks C7410.................................................................0
		16.4.1 Overview..............................................................0
			General..................................................................0
			Inspection...............................................................0
			Inspection intervals.....................................................0
			Surface cracks...........................................................0
			Difference in height between the fork tips...............................0
			Position lock............................................................0
			Marking legibility.......................................................0
			Fork blades and back of fork carriage....................................0
			Mounting fixtures on the fork............................................0
		16.4.2 Forks, repairs and testing............................................0
			Repairs..................................................................0
			Testing the yield point..................................................0
			Forks-general............................................................0
17. Options – 9000...................................................................0
	17.1 Component overview, T.W.I.S. (Toyota Wireless Information System)...........0
	17.2 DC/DC converter.............................................................0
		17.2.1 Installation of the DC/DC converter and 12 V socket...................0
		17.2.2 Wiring diagram, DC/DC converter.......................................0
18. Instructions for disposal........................................................0
	18.1 General.....................................................................0
	18.2 Marking of plastics.........................................................0
		18.2.1 General marking of products and packaging.............................0
		18.2.2 Marking according to the manufacturer’s standards.....................0
			Abbreviations............................................................0
			Marking examples.........................................................0
	18.3 Pressure vessels............................................................0
		18.3.1 Gas dampers...........................................................0
	18.4 Sorting categories..........................................................0
19. Wiring diagram...................................................................0
	19.1 Overview of electrical equipment............................................0
		19.1.1 Component location....................................................0
		19.1.2 Component list........................................................0
	19.2 List of symbols.............................................................0
	19.3 Overview....................................................................0
	19.4 Wiring diagrams.............................................................0
20. Hydraulics schematics............................................................0
	20.1 SPE120XRD...................................................................0
		20.1.1 Hydraulic pump........................................................0
		20.1.2 Reach.................................................................0
	20.2 SPE120XR....................................................................0
	20.3 Hydraulic pump..............................................................0
		20.3.1 Reach.................................................................0
21. Tools............................................................................0
	21.1 AMP connectors..............................................................0
	21.2 AMP connectors, Multilock series 040........................................0
	21.3 Super Seal connectors.......................................................0
	21.4 Molex connectors............................................................0
	21.5 Other tools.................................................................0
22. Service data and grease specifications...........................................0
	22.1 General tightening torques..................................................0
		22.1.1 Galvanised, non-oiled screws..........................................0
		22.1.2 Untreated, oiled screws...............................................0
	22.2 Oil and grease specification................................................0
23. Technical data...................................................................0

DESCRIPTION:

BT TOYOTA SPE120XR, SPE120XRD REPAIR MANUAL 7550623-040 – PDF DOWNLOAD

The repair manual is divided into chapters containing the following information:
• Function – This chapter provides a basic description of the main functions of the truck.
• Parameters– This chapter provides a basic description of the truck and control system parameters.
• Installation – This chapter describes the preparatory work that is to be done before the truck is used for the first time
• Maintenance – the chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out
• Troubleshooting – The troubleshooting chapter describes the error codes that are displayed when the truck is partially or completely out of service. It also describes the cause of the problem together with suggested remedies.
• Remedies – This chapter describes the various truck systems, e.g. the hydraulic system and includes descriptions of system parts and the necessary service procedures. These descriptions are divided according to the C code system of the truck manufacturer.
• Appendices – The appendices include:
– Instructions for disposal
– Information about electrical components and wiring diagrams
– Hydraulics diagram
– List of required tools
– Information about general tightening torques
– Oil and grease specifications
– Technical data

S.S 05/01/2025