TOYOTA BT OSE100 OSE100W MATERIAL HANDLER SERVICE REPAIR MANUAL

TOYOTA BT OSE100 OSE100W MATERIAL HANDLER SERVICE REPAIR MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 320
FILE SIZE: 10.3MB

MODEL COVERED:

OSE100

OSE100W

PART NO: 7538992-040

APPLICABLE SERIAL NO: 6195074

ISSUED:

DECEMBER, 2016
 

CONTENTS:

1 Contents 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

3 General safety rules 0

3 1 Work safety 0

3 2 Electrical system 0

3 3 Safe lifting 0

3 4 Truck modifications 0

4 Operation and connection sequences 0

Symbols on keypad and display 0

4 1 Battery is connected 0

4 2 Logging in 0

4 3 Basic conditions for driving 0

4 4 Driving in fork direction 0

4 5 Driving in the drive wheel direction 0

4 6 Braking in neutral 0

4 7 Reverse braking 0

4 8 Brake operation via controls 0

4 9 Steering 0

4 10 Initial fork lift up 0

4 11 Initial fork lift down 0

4 12 Platform up 0

4 13 Platform down 0

5 Parameters, menu navigation and calibration 0

5 1 General 0

Symbols on keypad and display 0

5 1 1 Menu navigation 0

5 1 2 Display hour counter values 0

5 1 3 Show part numbers for software/hardware 0

5 2 Parameter settings 0

5 2 1 Copying the truck’s configurations 0

5 2 2 Setting operator/service parameters without using PC/PDA 0

5 2 3 Operator parameters 0

Overview 0

Factory preset operator parameters 0

Description of operator parameters 0

5 2 4 Service parameters 0

Overview 0

Description of service parameters 0

Verifying parameter settings for freely ventilated batteries (lead-acid batteries) 0

5 2 5 Factory parameters 0

Factory parameters # 1003 to 1042 – configurable optional functions 0

5 3 Calibration 0

5 3 1 Steering servo calibration 0

5 3 2 Hydraulic calibration 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 Battery installation 0

6 4 1 Safety for battery handling 0

6 4 2 Installing the battery 0

Battery indicator 0

6 5 Using PIN codes 0

6 5 1 General 0

6 5 2 Programming PIN codes 0

6 5 3 PIN code defaults 0

6 6 Setting parameters 0

6 6 1 Setting collision sensor parameters (option) 0

Collision sensor parameters 105 and 106 0

PIN code programming for truck reset 0

6 6 2 Setting battery parameters 0

6 7 Function check 0

7 Maintenance 0

7 1 Introduction 0

7 2 Maintenance instructions 0

7 2 1 Cleaning and washing 0

7 2 2 High-pressure washers 0

7 2 3 Degreasing agents 0

7 2 4 Cleaning the exterior 0

7 2 5 Cleaning the chain 0

7 2 6 Cleaning the motor compartment 0

7 2 7 Electric components 0

7 3 Checking normal truck function 0

7 4 Safety check 0

7 5 First service 0

7 6 Maintenance schedule 0

7 6 1 Maintenance service every 500 operating hours/6 months 0

7 6 2 Maintenance service every 1000 operating hours/12 months 0

7 6 3 Maintenance service every 3000 operating hours/36 months 0

8 Troubleshooting 0

8 1 Towing a defective truck 0

Tow using a tow truck and tow wagon: 0

8 2 Auxiliary functions 0

8 2 1 Emergency driving mode 0

8 2 2 Error code history 0

8 3 Error code system 0

8 4 Error codes 0

8 5 Built-in test function for the tiller arm 0

8 5 1 Display test 0

8 5 2 Speed control 0

8 5 3 Controls for lifting/lowering 0

8 5 4 Sensilift 0

8 5 5 Keypad 0

8 6 Built-in test function 0

8 7 Digital input/output status 0

8 7 1 Test mode “2” – 0

8 7 2 Test mode “8” – Expansion unit SEU (option) 0

9 Chassis – C0000 0

9 1 Signs, warnings, labels – C0850 0

Identification plate 0

10 Motors – C1700 0

10 1 Pump motor – C1710 0

10 1 1 General 0

10 1 2 Replacing the pump motor 0

10 2 Steering motor – C1730 (steering servo assembly) 0

10 2 1 General 0

10 2 2 Replacing the steering servo assembly 0

10 2 3 Gear replacement 0

10 3 Drive motor – C1760 0

10 3 1 General 0

10 3 2 Tightening torque – Drive motor 0

10 3 3 Component overview – Drive motor 0

10 3 4 Removing the drive motor 0

10 3 5 Fitting the drive motor 0

10 3 6 Replacing the temperature sensor 0

10 3 7 Replacing the RPM sensor 0

10 3 8 Replacing the speed sensor toothed wheel 0

10 3 9 Disassembly 0

10 3 10 Cleaning 0

10 3 11 Replacing the upper bearing 0

10 3 12 Replacing the lower bearing 0

10 3 13 Assembly 0

11 Drive gear – C2000 0

11 1 General 0

11 2 Component overview – drive gear 0

11 3 Service and repairs with the drive gear in the truck 0

11 3 1 Checking and changing the oil 0

11 3 2 Replacing studs 0

11 4 Repairs with transmission removed 0

11 4 1 Removing/fitting the drive gear 0

11 4 2 Replacing the drive shaft seal 0

11 4 3 Sealing the upper cover 0

11 4 4 Replacing the primary gear 0

12 Brake system/Wheels – C3000 0

12 1 General 0

12 2 Parking brake – C3370 0

12 2 1 Checking the parking brake air gap 0

12 2 2 Removing/fitting the parking brake 0

12 2 3 Cleaning the parking brake 0

12 2 4 Releasing the parking brake 0

12 3 Drive wheel – C3530 0

12 3 1 Component overview 0

12 3 2 Replacing the drive wheel 0

12 4 Support arm wheels – C3550 0

12 4 1 Main components 0

12 4 2 Replacing the wheel 0

Dismantling 0

Assembly 0

12 4 3 Replacing the wheel bearing 0

12 5 Wheel wear 0

13 Steering system – C4000 0

13 1 General 0

13 2 Component overview 0

13 3 Steering unit – C4110 0

13 3 1 Calibration 0

13 3 2 Disassembly/assembly of the steering unit handle 0

Disassembly 0

Assembly 0

13 3 3 Replacing the potentiometer [R2] 0

13 3 4 Replacing the inductive brake sensor [S10] 0

13 3 5 Replacing the damper 0

13 3 6 Checking and replacing the lateral movement line (Ergo version) 0

13 3 7 Replacing buttons in the tiller arm handle 0

Signal button/switch 0

Lift/lower button 0

Push button 0

13 4 Reference sensor – C4350 0

13 4 1 Replacing steering reference sensor [S65] 0

13 5 Steering bearing – C4380 0

13 5 1 Replacing the steering bearing 0

14 Electrical system – C5000 0

14 1 Battery C5110 0

14 1 1 Replacing the battery 0

Battery installation/replacement using a battery changing table 0

Battery installation/replacement using a lifting device 0

14 1 2 Charging the battery 0

14 1 3 Performance limitations due to battery status 0

14 2 Contactor C5190 0

14 2 1 Replacing the contactor [Q10] 0

14 3 ACT/ACC regulators C5460 0

14 3 1 General 0

14 3 2 Replacing the transistor regulator 0

14 3 3 Replacing the transistor regulator cooling fan 0

15 Hydraulic system – C6000 0

15 1 General 0

15 2 Hydraulic cleanliness 0

15 2 1 Washing 0

15 2 2 Packaging 0

15 2 3 Handling 0

15 2 4 Storage 0

15 2 5 Work procedures 0

15 3 Component overview – Hydraulic system 0

15 3 1 Overview OSE100W 0

15 3 2 Overview OSE100 0

15 4 Operating pressure 0

15 5 Pressure limiting valve 0

15 6 Hose rupture valve 0

15 7 Pressure sensor 0

15 8 Hydraulic unit – C6100 0

15 8 1 Overview 0

15 8 2 Tightening torque for hydraulic unit 0

15 8 3 Emptying the hydraulic tank 0

15 8 4 Filling the tank 0

15 9 Removing/installing the hydraulic unit 0

15 9 1 Replacing valves 0

15 10 Adjusting the pressure limiting valve 0

15 11 Hydraulic calibration 0

15 12 Hydraulic system, bleeding 0

15 13 Hydraulic couplings C6230 0

15 13 1 Tightening torques for hydraulic connections 0

Tapered coupling with O-ring 0

Tredo seal 0

Pipe coupling 0

Coupling set in aluminium 0

Coupling set in steel 0

15 13 2 Quick change connector 0

Overview 0

Assembling the quick change connector 0

Dismantling the quick change connector 0

16 Mast/Lift system – C7000 0

16 1 Main lifting chain system C7120 0

16 1 1 Checking the chain setting 0

16 1 2 Adjustment 0

16 1 3 Checking the chain 0

Noise 0

Surface rust 0

Rusty links 0

Stiff links 0

Bolt rotation 0

Loose bolts 0

Outline wear 0

Stretching 0

Damage 0

Damaged plates 0

Damaged bolts 0

Dirty chain 0

16 1 4 Cleaning 0

16 1 5 Lubrication 0

16 2 Fork carriage – 7420 0

16 2 1 General – Fork carriage 0

Inspection 0

Fork height OSE100 0

16 3 Fork carriage – 7420 0

16 3 1 Component parts 0

16 3 2 Removing the fork carriage OSE100W 0

16 3 3 Replacing the mast rollers 0

16 3 4 Adjusting fork carriage lateral play 0

Adjusting fork carriage lateral play without a stop screw 0

Adjusting fork carriage lateral play with a stop screw 0

16 3 5 Removing the initial lift fork carriage OSE100 0

16 4 Forks C7410 0

16 4 1 Overview 0

General 0

Checking 0

Inspection intervals 0

Surface cracks 0

Difference in height between the fork tips 0

Position lock 0

Readability of the markings 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

17 Option – C9000 0

17 1 Spider expansion unit 0

17 2 T W I S Toyota Wireless Information System 0

17 2 1 Overview OSE100/ 100W 0

17 2 2 Component list 0

17 2 3 Drilling instructions 0

17 2 4 Method 0

17 3 E-bar 0

17 4 Overview 0

17 4 1 Component list E-bar 0

17 4 2 Method 0

17 4 3 E-bar accessories 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 struts 0

18 4 Sorting categories 0

19 Electrical components and electrical diagram 0

19 1 Electric components 0

19 1 1 Electric component overview 0

19 2 Electrical wiring diagrams 0

19 2 1 List of symbols 0

19 2 2 Wiring diagram 100/100W – Overview 0

19 2 3 Wiring diagram 100/100W 0

20 Hydraulics schematics 0

20 1 OSE100 0

20 2 OSE100W 0

21 Tools 0

21 1 Super Seal connectors 0

21 2 AMP connectors 0

21 3 AMP connectors, Multilock series 040 0

21 4 Molex connectors 0

21 5 CPC contacts 0

21 6 MQS contacts 0

21 7 Grease guns 0

21 8 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 Lubrication chart 0

22 3 Oil and grease specification 0

23 Technical data 0

23 1 Basic data 0

23 2 Speed limitation 0