Dokumen - Tips - Toyota BT Lpe200 Electric Pallet Truck Service Repair Manual

Repair manual 7572514 en
LPE200
LPE220
LPE250
LPE340BE
Translation of the original instruction
List of models:
Model T-Code Valid from serial number

LPE200 1010 6304531-
LPE220 1010 6304531-
LPE250 1010 6304531-
LPE340BE 1010 6593220
Change history:
Date Change Change description

2017-11-01 Various updates
2018-01-01 Periodic maintenance, page 6 - 5 Updated maintenance list.
2018-03-01 General, page 13 - 23 Changed to block 1 as standard.
List of error codes, page 7 - 11 Clarified truck behaviour, 3:587 updated
Emergency release of the parking brake, Updated the transport screws.
page 11 - 6
Overview, page 11 - 2 New dust seal
Programming PIN codes, page 13 - 24
PIN code defaults, page 13 - 26
PIN code at delivery, page 13 - 25 [New information]
PreOpCheck, page 17 - 4 [New information]
Parameter list, page 4 - 2 1142 added, 311/ 329 new value
Weighing system, page 13 - 28 New setting
2018-05-25 Parameter list, page 4 - 2 Added configurable optional functions
Overview steering servo, page 12 - 45 New bracket
Technical data, page 8 - 43 Suspension/PT cylinder
Truck data Added LPE340BE
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 7572514 en

1 General introduction
Images and other information
1
General introduction
1.1 Images and other information 1

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
Component replacement.
connections.
Cleaning Measurement
Check that screws, nuts, etc. are tightened to

Checks for leaks.
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 7572514 en

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 Explanation

ation
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 7572514 en 1-2

Abbreviations
Abbrevi- Meaning Explanation

ation
SCU Secondary Control Unit Secondary control unit
1
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 Repair manual 7572514 en

10 Transmission/Drive gear C2000
Drive unit, final gear C2500

10
Transmission/Drive gear C2000
10.1 Drive unit, final gear C2500

10.1
10.1.1 Drive unit/gear C2550

10.1.1
Drive unit/gear C2550
10.1.1.1 Overview
10.1.1.1
Overview
Part number: 7540136 7525837 7530286

b
10
a e
Pos. Designation
a Transmission housing
b Motor bearing and packing box
c Steering bearings
d Seal and cover ring
e Stud M12X1.5
10 - 1 Repair manual 7572514 en

10.1.1.2 Overview
10.1.1.2
Overview
Part number: 7525839 7540133

c
b e
Pos. Designation
a Seal and cover ring
b Transmission housing
c Motor bearing and packing box
d Steering bearings
e Stud M14X1.5
10.1.1.3 Description
10.1.1.3
Description
10.1.1.3.1 Design
10.1.1.3.1
Design
The drive gear is a two-stage angle gear that is integrated with the motor and brake assembly in a complete drive unit.
The drive gear is bolted to the chassis. At the top edge of the gear, the steering bearing and a gear ring for the steering
motor (option) are fitted.
A complete reconditioning of the drive gear must be performed in the workshop by trained technicians.
10.1.1.3.2 Technical data

10.1.1.3.2
Technical data
Part number: 7525839 7540133
Description Value
Type Two-stage angle gear
Gear ratio 16.96
Oil quality 1.05 litres
Drive wheel Ø 250
Repair manual 7572514 en 10 - 2

Description Value
Oil type See Lubricants specification, page
22 - 2
10.1.1.3.3 Technical data

10.1.1.3.3
Technical data
Part number: 7540136 7525837 7530286
Description Value
Type Two-stage angle gear
Gear ratio 18.39
Oil quality 0.9 litres
Drive wheel Ø 230
Oil type See Lubricants specification, page 10
22 - 2
10.1.1.4 Check the drive gear's attachment

10.1.1.4
Check the drive gear's attachment
1. Check the drive gear's attachment. Tighten the screws if ne-

cessary. 23 N·m
10.1.1.5 Checking for leaks in the drive gear

10.1.1.5
Checking for leaks in the drive gear
1. Check the drive gear for leaks. If there are any leaks, change
the oil seal, see Replacing the wheel hub seal , page 10 - 7.

10.1.1.6 Checking for noise in the drive gear

10.1.1.6
Checking for noise in the drive gear
1. Listen for any abnormal noise in the drive gear bearings

In case of noise:
Check if the oil level is up to the bottom edge of the filler hole,
see Lubricants specification, page 22 - 2.
Replace the steering bearing. Replacing the drive gear steering
bearing , page 10 - 13
10.1.1.7 Replacing the drive gear

10.1.1.7
Replacing the drive gear
10.1.1.7.1 Removing the drive gear

10.1.1.7.1
Removing the drive gear
Preparations
Removing the platform, page 8 - 78
Removing the platform [Fixed side guards], page 8 - 81
1. Turn the drive wheel as much as possible in one direction.
2. Switch off the truck and disconnect the battery connector.
WARNING Risk of personal injury and material and prop-

erty damage
For trucks with power steering, the truck battery must be dis-
connected when working on the drive gear/drive wheel.
► The drive wheel will automatically return to the original
position when the truck is started.
Removing the drive motor [M1], page 9 - 19, Removing the drive
motor [M1], page 9 - 21, Removing the drive motor [M1], page
9 - 23

3. Undo and remove the screws to the drive gear.
10
4. Lift the truck 100 mm and support it on trestles.
WARNING Risk of crushing under the truck

Risk of crushing since a poorly supported truck could fall
down.
► Secure the truck in a safe manner.
5. Remove the gear from the truck.
6. Mark the position of the steering bearing.

10.1.1.7.2 Installing the drive gear

10.1.1.7.2
Installing the drive gear
1. Lift the drive gear in place.

Turn the wheel towards you (rearwards) to facilitate the lift.
2. Rotate the steering bearing to the right position; see marking.
3. Lower the truck and position the gear in place.
4. Fit the drive gear.

Remember to tighten the screws crosswise

Resetting
Installing the drive motor [M1], page 9 - 25
Installing the platform, page 8 - 81
Fitting the platform [Fixed side guards], page 8 - 83
10.1.1.8 Replacing the wheel hub seal

10.1.1.8
Replacing the wheel hub seal
10.1.1.8.1 Removing the wheel hub seal

10.1.1.8.1
Removing the wheel hub seal
Disassembling the drive wheel, page 11 - 17
1. Remove the cover ring using a screwdriver or similar to remove

the seal.
10

2. Remove the seal using a screwdriver or similar to remove the

seal.
10.1.1.8.2 Installing the wheel hub seal

10.1.1.8.2
Installing the wheel hub seal
1. Fit the seal. Tap lightly to get it into the right position.

2. Fit the cover ring. Tap it lightly into place.
Installing a drive wheel, page 11 - 18
10
10.1.1.9 Drive gear oil change
10.1.1.9
Drive gear oil change
1. Empty the oil from the drive gear. Empty the drive gear oil, page
10 - 10, Empty the drive gear oil, page 10 - 11
2. Fill oil into the drive gear. Filling oil in the drive gear, page
10 - 12, Filling oil in the drive gear, page 10 - 13

10.1.1.9.1 Empty the drive gear oil

10.1.1.9.1
Empty the drive gear oil
1. Undo and remove the oil plug on the lower part of the gear
housing.
2. Drain all old oil into a suitable receptacle.
3. Clean away dirt and metal shavings from the oil plug.
4. Install the oil plug, tighten to 20 N·m.

10.1.1.9.2 Empty the drive gear oil

10.1.1.9.2
Empty the drive gear oil
1. Undo and remove the oil plug on the lower part of the gear
housing.
10
2. Drain all old oil into a suitable receptacle.
3. Clean the oil plug of any dirt and shavings. Refit the oil plug,
tighten to 20 N·m.

10.1.1.9.3 Filling oil in the drive gear

10.1.1.9.3
Filling oil in the drive gear
1. Remove the oil filler plug on the upper part of the gear housing.
2. Top up with oil up to the lower edge of the hole to reach the
correct level, Lubricants specification, page 22 - 2.
3. Screw in the plug.

10.1.1.9.4 Filling oil in the drive gear

10.1.1.9.4
Filling oil in the drive gear
1. Remove the oil filler plug on the upper part of the gear housing.
10
2. Top up with oil up to the lower edge of the hole to reach the
correct level, Lubricants specification, page 22 - 2.
3. Screw in the plug.
10.1.1.10 Replacing the drive gear steering bearing

10.1.1.10
Replacing the drive gear steering bearing
10.1.1.10.1 Removing the drive gear steering bearing

10.1.1.10.1
Removing the drive gear steering bearing
Part number: 7525839 7540133
Removing the drive gear, page 10 - 4

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1. Undo and remove the screws to the steering bearing.
2. Lift away the steering bearing.
10.1.1.10.2 Removing the drive gear steering bearing

10.1.1.10.2
Removing the drive gear steering bearing
Part number: 7540136 7525837
Removing the drive gear, page 10 - 4
1. Undo and remove the screws to the steering bearing.

2. Lift away the steering bearing.
10
10.1.1.10.3 Installing the drive gear steering bearing

10.1.1.10.3
Installing the drive gear steering bearing
Part number: 7525839 7540133
1. Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.
Installing the drive gear, page 10 - 6

10.1.1.10.4 Installing the drive gear steering bearing

10.1.1.10.4
Installing the drive gear steering bearing
Part number: 7540136 7525837
1. Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.
Installing the drive gear, page 10 - 6
10.1.1.11 Stud replacement

10.1.1.11
Stud replacement
10.1.1.11.1 Removing a stud

10.1.1.11.1
Removing a stud
Disassembling the drive wheel, page 11 - 17

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Repair manual 7572514 en

Model T-Code Valid from serial number

Date Change Change description

General safety rules 2

Transmission/Drive gear C2000 10

Brake/wheel/track system C3000 11

Steering system C4000 12

Electrical system C5000 13

Work function - lifting masts C7000 15

Auxiliary equipment, installation equipment C8000 16

Optional equipment/Extra equipment C9000 17

Instructions for disposal 18

Service data and grease specifications 22

Repair manual 7572514 en

1.1 Images and other information 1

1.2 Warning levels and symbols

Used to attract attention and to give information about various actions.

Symbol Procedure Symbol Procedure

Check that screws, nuts, etc. are tightened to

Listening for noise. Lubrication, application.

Check of functions. Calibration

An example of another type of pictogram is “Cut cable ties”:

1-1 Repair manual 7572514 en

Abbrevi- Meaning Explanation

Repair manual 7572514 en 1-2

Abbrevi- Meaning Explanation

1-3 Repair manual 7572514 en

10 Transmission/Drive gear C2000

10.1 Drive unit, final gear C2500

10.1.1 Drive unit/gear C2550

Part number: 7540136 7525837 7530286

10 - 1 Repair manual 7572514 en

Part number: 7525839 7540133

10.1.1.3.2 Technical data

Part number: 7525839 7540133

Repair manual 7572514 en 10 - 2

10.1.1.3.3 Technical data

Part number: 7540136 7525837 7530286

10.1.1.4 Check the drive gear's attachment

1. Check the drive gear's attachment. Tighten the screws if ne-

10.1.1.5 Checking for leaks in the drive gear

10 - 3 Repair manual 7572514 en

10.1.1.6 Checking for noise in the drive gear

1. Listen for any abnormal noise in the drive gear bearings

10.1.1.7 Replacing the drive gear

10.1.1.7.1 Removing the drive gear

1. Turn the drive wheel as much as possible in one direction.

2. Switch off the truck and disconnect the battery connector.

WARNING Risk of personal injury and material and prop-

Repair manual 7572514 en 10 - 4

3. Undo and remove the screws to the drive gear.

WARNING Risk of crushing under the truck

5. Remove the gear from the truck.

6. Mark the position of the steering bearing.

10 - 5 Repair manual 7572514 en

10.1.1.7.2 Installing the drive gear

1. Lift the drive gear in place.

2. Rotate the steering bearing to the right position; see marking.

3. Lower the truck and position the gear in place.

4. Fit the drive gear.

Repair manual 7572514 en 10 - 6

10.1.1.8 Replacing the wheel hub seal

10.1.1.8.1 Removing the wheel hub seal