TOYOTA 6BPU15 ORDERPICKER Service Repair Manual SN70001 to 79999

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Service Manual TOYOTA ORDERPICKER Model6BPU15 00700-CL221 Serial No. 70001-79999 Issued: 9/10/98 Toyota Orderpicker Service Manual How to Use This Manual How to Use This Manual 00700-CL221 Issued: 9/10/98 1-1 How to Use This Manual Toyota Orderpicker Service Manual Map of the Manual Map of the Manual HowtoUse I This Manual I ITable of Contents Manu~Design Start Page Component Location Photos ~ I Scheduled I Maintenance I 1-2 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Manual Design The Toyota Orderpicker Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise. Anticipate your needs and reduce your decisions regarding maintenance. Reduce page flipping through a "one-stop shopping" approach. The two-line running page header at the top of each page tells you: the name of the manual (Toyota Orderpicker Service Manual) the current Chapter Title (e.g., this page How to Use This Manual) the current topic . (e.g., this page Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual. 00700-CL221 Issued: 9/1 0/98 How to Use This Manual Manual Design 1-3 How to Use This Manual Manual Design The START page asks a few simple questions to gUide you to the proper chapter. How to Use This Manual explains the manual format and design and contains the Table of Contents and START page. Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding. Systems Overview includes truck specifications and functional overview of the major systems. Planned Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently. Troubleshooting is a set of "decision-tree" charts designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component. The GENERAL TROUBLESHOOTING chart (see List of Troubleshooting Charts on page 5-25) ,will gUide you to the individual troubleshooting symptom chart you need. Once you're familiar with the symptoms listed, you may instead simply find the symptom chart from the List of Troubleshooting Charts on page 5-27. When you complete a troubleshooting procedure, be sure to follow the steps in End of Troubleshooting Chart END-I. Electrical Codes and Tests contains information about electrical fault codes and diagnostic tests under the control of the system firmware. Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order which considers: Frequency of attention Physical attachment (e.g., brake must be removed before drive motor) Functional relation (e.g., carriage and mast components are grouped together) 1-4 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 How to Use This manual To fmd a component procedure, you may use one of three methods: Look up the component name in the Alphabetical List of Components. Find the component in the Component Locators. Look up the component name in the maintenance manual Index. Theory of Operation gives detailed theory of operation information for all major systems. Appendix: contains reference information such as torque values and lubricants. Index lists subjects alphabetically. 1-5 Toyota Orderpicker Service Manual .00700-CL221 Revised: 2/15/00 Toyota Orderpicker Service Manual Page Revision Record How tc;> Use This manual Page Revision Record This page is a record of the latest revised pages in this manual. Whenever a page is revised, we update this section and include it in the revision. This lets you keep track of the latest revised pages for this manual. If no date appears in the "revised" column, it means that the page has never been revised since the manual was fIrst issued. Cover . 1-1 . 1-2 . 1-3 . 1-4 . 1-5 . 1-6 9/23/98, 2/15/00 1-7 ... 9/23/98, 2/15/00 1-8 . 1-9 . 1-10 . 1-11 . 1-12 . 1-13 . 1-14 . 1-15 . 1-16 . 1-17 . 1-18 . 1-19 . 1-20 . 2-1 . 2-2 . 2-3 . 2-4 . 2-5 : . 2-6 . 2-7 . 2-8 . 2-9 . 2-10 . 2-11 . 2-12 . 2-13 . 2-14 . 2-15 . 2-16 . 3-1 . 3-2 . 3-3 . 3-4 . 3-5 . 3-6 . 3-7 . 3-8 . 3-9 . 3-10 , . 3-11 . 3-12 . 3-13 . 3-14 . 3-15 . 3-16 . 3-17 . 3-18 . 3-19 . 3-20 . 3-21 . 3-22 . 3-23 . 3-24 . 3-25 . 3-26 . 3-27 . 3-28 . 3-29; . 3-30 . 3-31 . 3-32 ~ . 3-33 . 3-34 . 3-35 . 3-36 . 3-37 . 3-38 . 3-39 . 3-40 . 3-41 . 3-42 . 4-1 . 4-2 . 4-3 . 4-4 . 4-5 . 4-6 . 4-7 . 4-8 . 4-9 . 4-10 . 4-11 . 4-12 . 4-13 . 4-14 . 4-15 . 4-16 . 4-17 . 4-18 . 5-1 . 5-2 . 5-3 . 5-4 . 5-5 . 5-6 . 5-7 . 5-8 . 5-9 . 5-10 . 5-11 . 5-12 . 5-13 . 5-14 . 5-15 . 5-16 . 5-17 . 5-18 . 5-19 . 5-20 . 5-21 . 5-22 . 5-23 . 5-24 . 5-25 . 5-26, . 5-27 . 5-28 . 5-29 . 5-30 . 5-31 . 5-32 . 5-33 . 5-34 . 5-35 . 5-36 . 5-37 . 5-38 . 5-39 . 5-40 . 5-41 . 5-42 . 5-43 . 5-44 . 5-45 . 5-46 . 5-47 . 5-48 . 5-49 . 5-50 . 5-51 . 5-52 . 5-53 . 5-54 . 5-55 . 5-56 . 5-57 . 5-58 . 6-1 . 6-2 . 6-3 . 6-4 . 6-5 . 6-6 . 6-7 . 6-8 . 6-9 . 6-10 . 6-11 . 6-12 . 00700-CL221 Revised: 2/15/00 1-6 How to Use This manual Page Revision Record Toyota Orderpicker S~rvice Manual 6-13 . 6-14 . 6-15 2/15/00 6-16 2/15/00 6-17 2/15/00 6-18 2/15/00 6-19 2/15/00 6-20 2/15/00 6-21 . 6-22 . 6-23 2/15/00 6-24 2/15/00 6-25 . 6-26 . 6-27 . 6-28 . 6-29 . 6-30 . 6-31 . 6-32 . 6-33 2/15/00 6-34 2/15/00 6-35 . 6-36 . 6-37 . 6-38 . 6-39 . 6-40 . 6-41 . 6-42 . 6-43 . 6-44 . 6-45 . 6-46 . 6-47 . 6-48 . 6-49 . 6-50 . 6-51 . 6-52 . 6-53 2/15/00 6-54 2/15/00 6-55 . 6-56 . 6-57 . 6-58 . 6-59 . 6-60 . 6-61 2/15/00 6-62 2/15/00 6-63 . 6-64 . 6-65 . 6-66 . 6-67 . 6-68 . 6-69 . 6-70 . 6-71 . 6-72 . 6-73 . 6-74 . 6-75 2/15/00 6-76 2/15/00 6-77 . 6-78 . 6-79 . 6-80 . 6-81 . 6-82 . 6-83 . 6-84 . 6-85 . 6-86 . 6-87 2/15/00 6-88 2/15/00 6-89 . 6-90 . 6-91 . 6-92 . 6-93 . 6-94 . 6-95 . 6-96 9/23/98 6-97 . 6-98 . 6-99 . 6-100 . 6-101 . 6-102 . 6-103 . 6-104 . 6-105 . 6-106 . 6-107 2/15/00 6-108 2/15/00 6-108.1 2/15/00 6-108.2 2/15/00 6-108.3 2/15/00 6-108.4 2/15/00 6-108.5 2/15/00 6-108.6 2/15/00 6-108.7 2/15/00 6-108.8 2/15/00 6-109 2/15/00 6-110 2/15/00 6-111 2/15/00 6-112 2/15/00 6-113 2/15/00 6-114 2/15/00 6-115 . 6-116 . 6-117 . 6-118 . 6-119 . 6-120 . 6-121 . 6-122 . 6-123 . 6-124 . 6-125 . 6-126 . 6-127 . 6-128 . 6-129 . 6-130 . 6-131 . 6-132 . 6-133 . 6-134 . 6-135 . 6-136 . 6-137 . 6-138 . 6-139 . 6-140 . 6-141 . 6-142 . 6-143 . 6-144 . 6-145 . 6-146 . 6-147 . 6-148 . 6-149 . 6-150 . 6-151 . 6-152 . 6-153 . 6-154 . 6-155 . 6-156 . 6-157 ~ .. 6-158 . 6-159 . 6-160 . 6-161 2/15/00 6~162 2/15/00 6-163 . 6-164 . 6-165 . 6-166 . 6-167 . 6-168 . 6-169 . 6-170 . 6-171 . 6-172 . 6-173 . 6-174 . 6-175 . 6-176 . 6-177 2/15/00 6-178 . 6-179 . 6-180 . 6-181 . 6-182 . 7-1 . 7-2 . 7-3 . 7-4 . 7-5 . 7-6 . 7-7 . 7-8 . 7-9 . 7-10 . 7-11 . 7-12 . 7-13 . 7-14 . 7-15 . 7-16 . 7-17 . 7-18 . 7-19 . 7-20 . 7-21 . 7.:.22 . 1-7 00700-CL221 Revised: 2/1.5/00 Toyota Orderpicker Service Manual How to Use This manual Page Revision Record 7-23 . 7-24 . 7~25 . 7-26 . 7-27 . 7-28 . 7-29 . 7-30 . 7-31 . 7-32 . 7-33 . 7-34 . 7-35 . 7-36 . 7-37 . 7-38 . 7-39 . 7-40 . 7-41 . 7-42 . 7-43 . 7-44 . 7-45 . 7-46 . 7-47 . 7-48 . 7-49 . 7-50 . 7-51 ~ . 7-52 . 7-53 . 7-54 . 7-55 . 7-56 . 7-57 . 7-58 . 7-59 . 7-60 . 7-61 . 7-62 . 7-63 . 7-64 . 7-65 . 7-66 . 7-67 . 7-68 . 7-69 . 7-70 . 7-71 . 7-72 . 8-1 . 8-2 . 8-3 . 8-4 . 8-5 . 8-6 . 8-7 . 8-8 . 8-9 . 8-10 . 8-11 . 8-12 . 8-13 . 8-14 . 8-15 . 8-16 . 8-17 . 8-18 . 8-19 . 8-20 . 8-21 . 8-22 . 8-23 . 8-24 . 9-1 . 9-2 . 9-3 . 9-4 . 9-5 . 9-6 . 9-7 . 9-8 . 9-9 . 9-10 . 9-11 2/15/00 9-12 2/15/00 9-13 2/15/00 9-14 2/15/00 9-15 2/15/00 9-16 2/15/00 9-17 . 9-18 . 10-1 . 10-2 . 10-3 . 00700-CL221 Revised: 2/15/00 1-8 Toyota Orderpicker Service Manual How to Use This manual Page Revision Record 6-14 . 6-15 . 6-16 . 6-17 . 6-18 . 6-19 9/23/98 6-20 . 6-21 . 6-22 . 6-23 . 6-24 . 6-25 . 6-26 . 6-27 . 6-28 . 6-29 . 6-30 . 6-31 . 6-32 . 6-33 . 6-34 . 6-35 . 6-36 . 6-37 . 6-38 . 6-39 . 6-40 . 6-41 . 6-42 . 6-43 . 6-44 . 6-45 . 6-46 . 6-47 . 6-48 . 6-49 . 6-50 . 6-51 . 6-52 . 6-53 . 6-54 . 6-55 . 6-56 . 6-57 . 6-58 . 6-59 . 6-60 . 6-61 . 6-62 . 6-63 . 6-64 . 6-65 . 6-66 . 6-67 ~ . 6-68 . 6-69 . 6-70 . 6-71 . 6-72 . 6-73 . 6-74 . 6-75 . 6-76 . 6-77 . 6-78 . 6-79 . 6-80 . 6-81 . 6-82 . 6-83 . 6-84 . 6-85 . 6-86 . 6-87 . 6-88 . 6-89 . 6-90 . 6-91 . 6-92 . 6-93 . 6-94 . 6-95 . 6-96 9/23/98 6-97 . 6-98 . 6-99 . 6-100 . 6-101 . 6-102 . 6-103 . 6-104 . 6-105 . 6-106 . 6-107 . 6-108 . 6-109 . 6-110 . 6-111 . 6-112 . 6-113 . 6-114 . 6-115 . 6~116 . 6-117 . 6-118 . 6-119 . 6-120 . 6-121 . 6-122 . 6-123 . 6-124 . 6-125 . 6-126 . 6-127 . 6-128 . 6-129 . 6-130 . 6-131 . 6-132 . 6-133 . 6-134 . 6-135 . 6-136 . 6-137 . 6-138 . 6-139 . 6-140 . 6-141 . 6-142 . 6-143 . 6-144 . 6-145 . 6-146 . 6-147 . 6-148 . 6-149 . 6-150 . 6-151 . 6-152 . 6-153 . 6-154 . 6-155 . 6-156 . 6-157 . 6-158 . 6-159 . 6-160 . 6-161 . 6-162 . 6-163 . 6-164 . 6-165 . 6-166 . 6-167 . 6-168 . 6-169 . 6-170 . 6-171 . 6-172 . 6-173 . 6-174 . 6-175 . 6-176 . 6-177 . 6-178 . 6-179 . 6-180 . 6-181 . 6-182 . 7-1 . 7-2 . 7-3 . 7-4 . 7-5 . 7-6 . 7-7 . 7-8 . 7-9 . 7-10 . 7-11 . 7-12 . 7-13 . 7-14 . 7-15 . 7-16 . 7-17 . 7-18 . 7-19 . 7-20 . 7-21 . 7-22 . 7-23 . 7-24 . 7-25 . 7-26 . 7-27 . 7-28 . 7-29 . 7-30 . 7-31 : . 00700-CL221 Revised: 9/23/98 1-7 How to Use This manual Page Revision Record Toyota Orderpicker Service Manual 7-32 . 7-33 . 7-34 . 7-35 . 7-36 . 7-37 . 7-38 . 7-39 . 7-40 . 7-41 . 7-42 . 7-43 . 7-44 . 7-45 . 7-46 . 7-47 . 7-48 . 7-49 . 7-50 . 7-51 . 7-52 . 7-53 . 7-54 . 7-55 . 7-56 . 7-57 . 7-58 . 7-59 . 7-60 . 7-61 . 7-62 . 7-63 . 7-64 . 7-65 . 7-66 . 7-67 . 7-~8 . 7-69 . 7-70 . 7-71 . 7-72 . 8-1 . 8-2 . 8-3 . 8-4 . 8-5 . 8-6 . 8-7 . 8-8 . 8-9 . 8-10 . 8-11 . 8-12 . 8-13 . 8-14 . 8-15 . 8-16 . 8-17 . 8-18 . 8-19 . 8-20 . 8-21 . 8-22 . 8-23 . 8-24 . 9-1 . 9-2 . 9-3 . 9-4 . 9-5 . 9-6 . 9-7 . 9-8 . 9-9 . 9-10 . 9-11 . 9-12 . 9-13 . 9-14 . 9-15 . 9-16 . 9-17 . 9-18 . 10-1 . 10-2 . 10-3 . 1-8 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Table of Contents Ho\V to Use This Manual. . . . . . . . . How To Use This Manual Table of Contents 1-1 Map of the Manual 1-2 Manual Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Start Page 1-19 Safety'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1 Definitions. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safe'ty 2-3 Battery Safe'ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Static Safe'ty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Jacking Safety 2-13 Tie-down for Transport 2-14 Towing 2-14 Welding Safe'ty 2-15 Systellls Overvie\V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-1 Systems Ovenriew 3-2 1'ype 3-3 Power 3-3 Capaci'ty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Mast 3-3 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3'-3 Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . . . . . . . . . . 3-4 Electric Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator's Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator Compartment Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Steering and Controls 3-13 00700-CL221 Issued: 9/10/98 1-9 How To Use This Manual Table of Contents Toyota Orderpicker Service Manual Steer Controller Guidance System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 7 Drive Unit 3-17 Brake 3-17 Mast 3-19 Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Hydraulic Components 3-21 Lift/wwer System 3-21 Electrical Components and Systems 3-24 General 3-24 Miscellaneous Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Fuses 3-40 Sidegate Switches (S60, S61) 3-40 Tie-Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Over-the-Mast Cables 3-41 Planned Maintenance . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. 4-1 Planned Maintenance 4-2 General Maintenance Instructions 4-2 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Battery Maintenance 4-13 Battery Safety 4-13 Battery Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Battery Cleaning Procedure 0 4-15 Charging Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-1 How to Use This Chapter 5-2 Electrical Troubleshooting Guidelines 5-2 Electrical Connector wcator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Shorts to Frame Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Electric Motor Tests ' 5-12 1-10 Issued: 9/10/98 Toyota Orderpicker Service Manual How To Use This Manual Table of Contents Motor 1)rpes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Open Circuit Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Grounded Motor Test 5-13 Short Circuited Armature or Field Winding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Hydraulic L,eakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 List of Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Electrical Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' . . . . . . . . . . . . . . . . . . 6-3 Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Disable the Brush Wear Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Start the Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Self-diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Maneuvering within Self-diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Analyzer (AnL) Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Entering Analyzer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Maneuvering within Analyzer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Tuning (Tuning) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Entering the Secondary Password 6-13 Maneuvering within Tuning Mode. . . . . . ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Exiting Tuning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Calibrate (Calibrte) Mode 6-16 Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Entering Calibrate Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Maneuvering within Calibrate Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Configure (Configur) Mode 6-20 Entering the Secondary Password 6-20 Code Summary Tables . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 00700-CL221 Issued: 9/10/98 1-11 How To Use This Manual Table of Contents Toyota Orderpicker Service Manual Analog Inputs 6-25 Category 1 Class 2: 6-25 Tests 6-29 Steer Controller Guidance Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99 Steer Controller Guidance System 6-149 Analog Input Tests: (Category 1, Class 2: 12) 6-149 12-20: Steer Controller Power Supply Voltage 6-149 Steer Controller Guidance System 6-173 Digital Input Tests '0 6-1 73 Component Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-1 Component Locator Photos 7-2 General Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Maintenance Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Adjustment and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7 Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-1 Electrical Functions ' 8-2 Operating Description Overview. . . . . . . . . . . . . . . . . . . . . . . . . ..' . . . . . . . . . . . . .8-2 Lift/Lower System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Unique System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lift 8-4 Lower 8-4 Braking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Proportional Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-1 Lubrication Equivalency Chart 9-2 Torque Chart - Standard (Ferrous) 9-4 Torque Chart - Standard (Brass) 9-5 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Decimal EqUivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 1-12 Issued: 9/10/98 Toyota Orderpicker Service Manual How To Use This Manual Table of Contents Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 9-11 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 7 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 10-1 00700-CL221 Issued: 9/1 0/98 1- 13 How To Use This Manual Table of Contents 1-14 This page intentionally left blank Toyota Orderpicker Service Manual Issued: 9/10/98 Toyota Orderpicker Service Manual How to Use This Manual List of Figures List of Figures Figure 2-1: Anti-Static Kit with Wrist Strap and Mat 2-12 Figure 2-2: Correct Jacking Locations 2-13 Figure 3-1: Toyota Orderpicker 3-2 Figure 3-2: Component Identification 3-8 Figure 3-3: Operator's Console 3-12 Figure 3-4: Hydraulic Compartment Components (Sheet 1 of 2) 3-26 Figure 3-5: Electrical Compartment Components 3-28 Figure 3-6: Platform Components (Electric Steering, Cover Removed) 3-29 Figure 3-7: Carriage Interface Card 3-30 Figure 3-8: Tractor Interface Card . . . . . . . . . . . . . . . . . 3-31 Figure 3-9: Steer Controller Card 3-34 Figure 3-10: Display Controller Card . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Figure 3-11: Filter Card (with wire guidance only) . . . . . . . . . . . . . . 3-39 Figure 4-1: Lubrication/Inspection Points 4-12 Figure 5-1: Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Figure 5-2: Motor Circuits 5-12 Figure 5-3: GENl: General Troubleshooting 5-26 Figure 5-4: ENDl: End of Troubleshooting Procedure 5-27 Figure 5-5: W-l: Truck Functions Partially 5-28 Figure 5-6: H-l: Hydraulic Lift/Lower Problem 5-29 Figure 5-7: H-2: No Lift; Lift Motor/Pump Won't TUITl 5-30 Figure 5-8: H-3: No Lift; Lift Pump/Motor Rotate 5-34 Figure 5-9: H-4: Load Drifts Down while Forks are Elevated 5-36 Figure 5-10: H-5: Cannot Pick Up a Load 5-38 Figure 5-11: T-l: Travel Problem " 5-41 Figure 5-12: T-2: No Travel in Either Direction 5-42 Figure 5-13: T-3: Travel in One Direction Only 5-43 Figure 5-14: T-4: Problem with Slow Travel 5-44 Figure 5-15: T-5: Truck Does Not Accelerate Properly 5-45 Figure 5-16: T-6: Truck Does Not Travel 5-47 Figure 5-17: T-7: No Slow travel When Mast Elevated Above S 11 Mast Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52 Figure 5-18: T-8: Slow travel Speed Occurs All the Time 5-54 Figure 6-1: Menu Structure for the Different Modes 6-4 Figure 6-2: Steer Controller Card - Code 52 6-101 Figure 6-3: Steer Controller Card - Code 53 6-102 Figure 6-4: Location of Wire Guidance Coils and Related Tests 6-153 Figure 6-5: Location of Wire Guidance Coils and Related Tests 6-155 Figure 6-6: Location of Wire Guidance Coils and Related Tests 6-157 Figure 6-7: Location of Wire Guidance Coils and Related Tests 6-159 Figure 6-8: Location of Wire Guidance Coils and Related Tests' 6-161 00700-CL221 Issued: 9/10/98 1-15 How to Use This Manual List of Figures Toyota Orderpicker Service Manual Figure 6-9: Location of Wire Guidance Coils and Related Tests 6-163 Figure 7-1: Component Locations (Sheet 1 of 5) 7-2 Figure 7-2: Correct Jacking Locations 7-9 Figure 7-3: Proper/Improper Method of Holding Circuit Card 7-12 Figure 7-4: Integrated Circuit Tool 7-15 Figure 7-5: Preparing Integrated Circuit for Insertion 7-15 Figure 7-6: Installation of Integrated Circuit 7-16 Figure 7-7: Removing Drive Unit 7-19 Figure 7-8: Drive Unit Service Tools ~ '7-20 Figure 7-9: Drive Unit Cross Section 7-20 Figure 7-10: Drive Unit Components - Lower End 7-21 Figure 7-11: Removing Axle Bearing 7-21 Figure 7-12: Pressing Bearing Cone onto Axle 7-22 Figure 7-13: Assembly of Axle into Housing 7-23 Figure 7-14: Preparing Axle Seal for Assembly into Housing 7-23 Figure 7-15: Install/Torque Clamp Nut on Axle 7-24 Figure 7-16: Securing Clamp Nut by Tightening Retaining Screw 7-25 Figure 7-1 7: Installing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Figure 7-18: Drive, Unit Assembly 7-28 Figure 7-19: Checking Skidpads : 7-29 Figure 7-20: Deadman Pedal/Master Cylinder 7-32 Figure 7-21: Brake Bleeding Set-Up 7-34 Figure 7-22: Exploded View of Brake Assembly 7-35 Figure 7-23: Deadman Switch (S2) Adjustment (Not to Scale) 7-36 Figure 7-24: 2 Stage Lift Cylinder (Top End) 7-38 Figure 7-25: 2 Stage Lift Cylinder (Bottom End) 7-39 Figure 7-26: Center Lift Cylinder, 3 Stage (Top End) 7-41 Figure 7-27: Center Lift Cylinder, 3 Stage (Bottom End) 7-42 Figure 7-28: Lift/Lower Manifolds 7-44 Figure 7-29: Proper Installation of Proportional Valve 7-45 Figure 7-30: Access for Lift Cylinder Bleed Screws . . . . . . . . . . . . . . 7-47 Figure 7-31: Directional/Speed Control - Exploded View 7-48 Figure 7-32: Lift/Lower Return Spring Replacement 7-52 Figure 7-33: Lift/Lower Control Assembly, Potentiometer Wiring 7-53 Figure 7-34: Elevating Section 7-56 Figure 7-35: Elevating Section (cont.) 7-57 Figure 7-36: Elevating Section (cant.) 7-58 Figure 7-37: Elevating Section (cant.) 7-59 Figure 7-38: Three Stage Elevating Section 7-60 Figure 7-39: End Cap Pulley Assembly (3 Stage mast only) 7-61 Figure 7-40: Staging of Mast Prior to Shimming Bearings . . . . . . . . . 7-62 Figure 7-41: End Cap Assembly, 3 Stage Mast . . . . . . . . . . . . . 7-63 Figure 7-42: Steering Control Assembly . . . . . . . . . . . . . . . . . . ., 7-66 Figure 8-1: Steering Encoder Output - Left Turn , 8-12 Figure 8-2: Steering Encoder Output - Right Turn 8-13 1-16 Issued: 9/10/98 Toyota Orderpicker Service .Manual How to Use This Manual List of Figures Figure 8-3: Wire Guidance Functional Block Diagram 8-18 Figure 8-4: Location of Wire Guidance Coils and Related Tests 8-19 Figure 8-5: Wire Guidance LEDs on the Operator's Display 8-21 Figure 9-1: Lubrication Equivalency Chart 9-2 Figure 9-2: Torque Chart - Standard 9-4 Figure 9-3: Torque Chart - Standard Brass 9-5 Figure 9-4: Torque Chart - Ferrous Metric 9-6 Figure 9-5: Torque Chart - Brass Metric 9-6 Figure 9-6: Decimal Equivalent Chart .. ,. ' 9-7 Figure 9-7: Electrical Schematic 9-12 Figure 9-8: Electrical Schematic 9-14 Figure 9-9: Hydraulic Schematic 9-18 00700-CL221 Issued: 9/10/98 1-17 How to Use This Manual List of Figures 1-18 This page intentionally left blank Toyota Orderpicker Service Manual Issued: 9/10/98 Toyota Orderpicker Service Manual Start Page START How To Use This Manual To review safety precautions? No I To examine specifications? No >----yes---+! >----yes---+I Go to Chapter 2 "Safety" Go to Chapter 3 "Systems Overview" To do scheduled maintenance? No Go to Chapter 4 >----yes---+I "Planned Maintenance" To troubleshoot a problem? No >----yes---+I Go to Chapter 5 'Troubleshooting" I--------~. : Troubleshooting Guidelines I 00700-CL221 Issued: 9/10/98 _I List of Troubleshooting '---------.1. 1 Charts '---------------' 1-19 How To Use This Manual Start Page START-2 No To test. inspect. adjust. remove/install a component':! No r---yes---+I >----yes---+I Toyota Orderpicker Service Manual Go to Chapter 6 "Electrical Codes and Tests" Go to Chapter 7 "Component Procedures" >----yes---+I Go to Chapter 8 'Theory of Operation" No Tofmd general reference information? No To locate an object or procedure by name? No 1-20 >----yes---+I r----yes---+I Go to Chapter 9 "Appendix" Go to the Index 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Safety Safety 2-1 Safety Definitions Definitions Throughout this manual, you will see two kinds of safety reminders: ~ Warning means a potentially hazardous situation exists which, if not avoided, could result in death or serious iniury. A CAUTION Caution means a potentially hazardous situation exists which, if not ~voided, could result in minor or moderate iniury or in damage to the lift truck or nearby obiects. 2-2 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual General Safety Do not operate or work on this lift truck unless you are trained, qualified, authorized to do so, and have read the operator's manual. Safety General Safety Know the lift truck's controls and what they do. Do NOT operate this lift truck if it needs repair or if it is in any way unsafe. Operate this lift truck only from the operator's position. 00700-CL221 Issued: 9/10/98 2-3 Safety General Safety Before working on this lift tIuck, always turn the key switch to OFF and disconnect the lift tIuck's battery connector (unless this manual tells you otherwise). .. Toyota Orderpicker Service Manual Do NOT wear watches, rings, or jewelry when working on this lift truck. Follow the scheduled lubrication, maintenance and inspection steps. Follow exactly the safety and repair instIuctions in this manual. Don't take "shortcuts". 2-4 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Do NOT use an open flame near the lift truck. Do NOT use gasoline or other flammable liquids for cleaning parts. Clean up any hydraulic fluid. oil or grease that has leaked or spilled on the floor. Always park this lift truck indoors. Do NOT wash this lift truck with a hose. Do NOT add to or modify this lift truck until you contact your local Dealer to receive written manufacturer approval. Do NOT park this lift truck in a cold storage area overnight. 00700-CL221 Issued: 9/10/98 Safety General Safety 2-5 Safety Battery Safety Battery Safety ~ As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury. ~ Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with your clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in your eyes, flush the area with cold water and get medical help immediately. Wear personal protective equipment to protect eyes. face and skin when checking. handling or filling batteries. This equipment includes goggles or face shield. rubber gloves (with or without arm shields) and a rubber apron. 2-6 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Make sure a shower and eyewash station are nearby in case there is an accident. Safety Battery Safety .. ~ W .... ' "'Jr! ~ A battery gives off explosive gases. NEVER smoke. use an open flame. or use anything that gives off sparks near a battery. Keep the charging area well-ventilated to avoid hydrogen gas concentration. Turn the key switch off before disconnecting the battery from the lift truck at the battery connector. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken. 00700-CL221 Issued: 9/10/98 2-7 Safety Battery Safety Do not lay tools or metal objects on top of the battery. A short circuit or explosion could result. Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks. Keep plugs, terminals, cables and receptacles in good condition to avoid shorts and sparks. 2-8 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Keep filler plugs firmly in place at all times except when the electrolyte level is checked. when water is added to the cells or when the specific gravity is checked. Make sure the vent holes in the filler plugs are open to allow the gas to escape from the cells. Do not allow cleaning solution, dirt or any foreign matter to enter the cells. Make sure you install the correct size battery. A smaller or lighter weight battery could seriously affect lift truck stability. See the lift truck's specification plate for more information. Never plug a battery charger into the lift truck's battery connector. Plug the battery charger only into the battery connector from the battery. 00700-CL221 Issued: 9/10/98 Safety Battery Safety 2-9 Safety Battery Safety Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual. 2-10 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Static Safety Electronic circuit boards and devices used on the Toyota lift truck can be damaged by the discharge of static electricity, called electrostatic discharge. Static charges can accumulate from normal operation of the lift truck as well as movement or contact between non-conductive materials (plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups, etc.) Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without your seeing or feeling it. Whenever working on or near static-sensitive electronics, always use static discharge precautions. 1. Place a static discharge wrist strap around YO.ur wrist. Connect the ground lead to the wrist strap connector. 2. Connect the ground clamp to an unpainted, grounded surface on the lift truck frame. 3. If you will be removing or installing static- sensitive components, place them on a properly grounded static mat. 4. To transport static-sensitive components, including failed components being returned, place the components in an antistatic bag or box (available from your dealer). The wrist strap and associated accessories should be tested monthly to verify they are working properly. A defective static discharge wrist band will not alert you that it is bad. 00700-CL221 Issued: 9/10/98 Safety Static Safety 2- 11 Safety Static Safety Toyota Orderpicker Service Manual Figure 2-1: Anti-Static Kit with Wrist Strap and Mat Figure 2-1 shows the components of the Toyota antistatic field service kit, part number 00590- 04849-71. The kit includes a wrist strap, ground cord and static-dissipative work surface (mat). Follow the instructions packaged with this kit. Wrist straps are available in quantities of 25, as part number 00590-04848-71. A wrist strap tester is available as part number 00590-04850-71. Contact your local Dealer for further information. 2-12 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Jacking Safety Sometimes you may need to jack up the lift truck off the floor to perform maintenance procedures. When doing so, observe the proper safety precautions: 1. Lower the forks completely. Remove any load. 2. Place all controls in neutral. 3. Block the wheels to prevent movement of the vehicle. 4. Disconnect battery connector. 5. Place the jack under the designated jacking points. See Figure 2-2. ~ Use extreme care whenever the lift truck is jacked up. Keep hands and feet clear from vehicle while jacking the lift truck. After the lift truck is jacked, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the lift truck. Tractor 1. Place the jack in the designated jacking position. See Figure 2-2. 2. Jack the rear of the lift truck so that the drive tire is off the floor no more than 2" (51 mm). 3. Block the lift truck in place. Mast 1. Place the jack in the designated jacking position. See Figure 2-2. 2. Jack the side of the truck so that the load wheel is off the floor no more than 1/2" (13 mm). 3. Block the lift truck in place. NOTE: Mter working on a vehicle, test all controls and functions to assure proper operation. 00700-CL221 Issued: 9/10/98 Safety Jacking Safety Only jack in this area, no more tban 112" (13 mm) off the floor. Figure 2-2: Correct Jacking Locations 2-13 Safety Tie-down for Transport Tie-down for Transport To transport your Toyota lift truck in an over- the-road vehicle or rail car, follow these steps: 1. Lower the forks and locate the lift truck in the center of the transport vehicle. 2. Using suitable lifting device, remove the battery. See "Battery Safety" on page 2-6. 3. Position the adjustable chain over and through the battery compartment. 4. Position an additional adjustable chain over and through the battery compartment. 5. Position the chain ends of one chain toward the front of the vehicle bed and the chain ends of the other chain to the back of the vehicle bed and draw taut. This will secure the lift truck to the vehicle bed and prevent tip-over and forward or backward movement. 6. Secure the battery according to the battery manufacturer's instructions. Towing To safely tow a Toyota lift truck: 1. Lower the carriage arid remove any load from the forks. 2. Turn the key s~tch OFF and disconnect the battery connector. 3. Using a suitable towing vehicle, lift the tractor end of the lift truck until the drive tire is no more than 1" off the floor. 4. Tow the lift truck slowly in the tractor-first direction. A CAUTION Use care to avoid damage to the wire guidance sensor located beneath the truck. 2-14 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Welding Safety ~ Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors. Prior to performing flame cutting or welding operations, it is recommended that the coating be removed in the vicinity where the operation(s) will be performed. Coating removal may be by mechanical methods, chemical methods or a combination of methods. Flame cutting and/or welding operations should be carried out only in well ventilated areas using local exhaust if necessary. Before working on this lift truck, make sure that: Fire protection equipment is nearby. You know where the nearest eyewash station is. 00700-CL221 Issued: 9/10/98 Safety Welding Safety 2-15 Safety Welding Safety A CAUTION Disconnect the battery before you attempt to inspect, service or repair the lift truck. Check for shorts to frame as described in "Shorts to Frame Test" on page 5-6. If any shorts are detected, remove them before you proceed with the welding operation. Clean the area to be welded. Protect all lift truck components from heat, weld spatter and debris. Attach the ground cable as close to the weld area as possible. Do not perform any welding operations near the electrical components. Disconnect the following connectors: HD 1 on Display Card JPC 1- on Carriage Interface Card JPR1, JPR3 on Tractor Interface Card JP4, JP5 on Steer Controller Card JT1, JT2 on Traction Power Amplifier JL1, JL2 on Lift Power Amplifier A CAUTION If welding must be done near the battery compartment, remove the battery from the lift truck. When you are finished welding, perform all ground tests and electrical inspections before the vehicle is operated. 2-16 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Systems Overview 00700-CL221 Issued: 9/10/98 Systems Overview 3-1 Systems Overview Systems Overview Systems Overview Figure 3-1 provides an overview of the Toyota Orderpicker. Detailed descriptions of major components, supported by photographs and drawings, are contained herein. Figure 3-1: Toyota Orderpicker Toyota Orderpicker Service Manual 3-2 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Use The Orderpicker is designed for indoor warehouse use only. Type Stand-up, rider type, designed for narrow aisle installations where the operator must orderpick items from storage racks. The lift truck is operated with electric steering and may be wire or rail gUided. Povver 24-volt industrial battery. Capacity Refer to specification plate. Mast Two\three stage, hydraulic lift with a variety of overall lowered heights (OALH) and elevated heights (EH). Controls Lockable key switch, emergency power off switch, emergency lower valve, steering wheel, electric steering, wire/rail gUidance, traction/ lift/lower amplifiers, brake, and horn button. Selector switches are available for options such as working lights, fan, or other customer selected options. Indicators Operator's display, wire/rail gUidance acquisition light, and an audible alarm which sounds to alert the operator of certain system conditions and when acquiring the gUide wire/ rail. A strobe light helps to alert others of the orderpicker's presence. 00700-CL221 Issued: 9/10/98 Systems Overview Use 3-3 Systems Overview Electronics Electronics The traction and lift control systems use separate Pulse Width Modulated (PWM), solid state, programmable power amplifiers to monitor and control current flow through the traction and lift motors. The amplifiers are located on the right side of the power section. Both amplifiers feature fail safe operation and the traction power amplifier has regenerative braking capability. Electric Steering System The electric steering system controls all the lift truck steering and wire/rail gUidance functions. The system has stand-alone programming and test capabilities. It communicates with the Display Card through the CAN bus. 3-4 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Specifications Systems Overview Specifications Category Description MODEL Toyota Model Designation SER.NO. Serial number assigned by the factory for this particular lift truck dUring manufacture. VOLTS Nominal battery voltage. TRUCK WEIGHT Approximate weight of the lift truck without (Minimum) battery installed, minus operator and load. TRUCK WEIGHT Approximate weight of the lift truck with (Maximum) maximum size battery installed, minus operator and load. BATTERY WEIGHT Maximum weight of battery designed for (Maximum) this lift truck. BATTERY WEIGHT Minimum weight of battery required for (Minimum) this lift truck. BATTERY MAX. RATED (Maximum Ampere Hour Power rating of the battery. Capacity) CAPACITY CHART Maximum load capacity of the lift truck. Exceeding niaximum load weight may damage the lift truck or affect stability. 00700-CL221 Issued: 9/10/98 3-5 Systems Overview Description Description Chassis The Chassis is constructed of the following parts: Power Section Frame The Power Section Frame is constructed of formed sheet and plate steel welded together to form a strong integral unit. The Power Section is bolted to the baselegs and mast. Battery Compartment The Battery Compartment will accept a battery with the following dimensions (all dimensions are maximum): Toyota Orderpicker Service Manual 24 Volt Battery Width Width 14.50" (370 mm) 13.25" (335 mm) Height Height 32.25" (820 mm) 32.25" (820 mm) Length Length 36.75" (935 mm) 31.50" (800 mm) Battery gates located on each side of the lift truck lift out to allow the battery to be removed or installed from either side. Steel rollers support the battery and allow easy removal and installation. The battery gates contain adjustment screws to limit battery movement. Baselegs The Baseleg frame is constructed of square structural tubing and steel plate. Each baseleg has one or two load wheels, depending on lift truck configuration. 3-6 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Forks The Forks are constructed of 2-inch (50 nun) by 4-inch (100 mm) rectangular steel (the length of the forks is an option specified by the customer). The forks are attached to the bottom of the operator's compartment. The overall width of the forks is adjustable from 24 to 28 inches (610 to 710 mm). Covers Two Covers constructed of formed plastic enclose components on the power section. Button assemblies allow both covers to be removed from the lift truck. 00700-CL221 Issued: 9/1 0/98 Systems Overview Chassis 3-7 Systems Overview Chassis Chains and Pulleys Toyota Orderpicker Service Manual Most Guard Key Switch Sidegat~ Steering Wheel Figure 3-2: Component Identification Pollet Clomp Control Panel 3-8 00700-Cl221 Issued: 9/10/98 Toyota Orderpicker Service Manual Operator's Compartment The Operator's Compartment has been designed for safety, efficiency, and operator comfort. Compartment Dimensions The operator's compartment is 28 inches (710 mm) long, 76 inches (1930 mrn) high, and 39 inches (990 mm) wide. The compartment floor width is expandable to 55 inches (1400 mm). Compartment Floor The center section of the floor is plate steel. It is covered by a rubber cushion. The extensions are constructed of non-slip steel. Overhead guard The Overhead Guard is constructed of steel tubing and bar stock. The overhead guard covers the floor area to protect the operator and complies with ANSI/ASME specification B56.1. A bar at the rear of the guard provides an attachment point for the tether. BeltITether The Belt/Tether is a safety device which is worn around the waist of the operator whenever the lift truck is operated. The tether prevents the operator from falling from the carriage. Sidegates The operator's compartment has one Sidegate on each side of the operator. The retractable sidegates are spring loaded to keep them in either the raised or lowered position. See "Sidegate Switches (S60, S61)" on page 3-40. Operator's Console The Operator's Console provides the operator with complete control of the lift truck. The controls have been designed for operator safety, efficiency, and comfort. The steering wheel and the key switch are located on the left side of the operator's console. 00700-CL221 Issued: 9/1 0/98 Systems Overview Operator's Compartment 3-9 Systems Overview Operator's Console The traction/lift/lower control, horn button, wire gUidance on/off switch, and emergency power off are located on the right side of the operator's console. . The lower portion of the operator's console has an accessory bin for storing pencils, pens, clipboards, picklist, etc. Operator's Display The Operator's Display is used to display: TOYOTA (turn on and system messages/ fault codes) Total hours the key has been turned on (Ks) Total hours on deadman (Bp) . Total hours drive (Dm) Total hours spent lifting (Lt) Clock/Calendar Status messages:. Informational: Performance Limiting: and Fault Codes. The operator display shows information on an eight character, alphanumeric digital display. Information will be displayed in either static or scrolling format. Scrolling messages move from right to left. Steering Indicator and Keypad All lift trucks are eqUipped with electric steering: five drive unit position lights are located above the steering wheel to indicate the approximate position of the drive unit. Additionally, all trucks have Guidance Status lights located next to the wheel position indicator: the status lights are not functional unless the lift truck has the rail/wire gUidance option installed. The keypad is used to access, enter, and change parameters on the information/status display. Emergency Power Disconnect Button The Emergency Power Disconnect Button is located on the operator's control console, to the left of the directional/speed control. The switch has two positions, UP allows the truck to travel, and DOWN which prevents travel and. lift/lower 3-10 Toyota Orderpicker Service Manual 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual functions from operating. The manual emergency lower function is not affected. Key Switch The lockable key switch is located near the steering wheel. The key switch has two (2) positions: OFF or ON. Battery Discharge Indicator (BDI) The Battery Discharge Indicator (BDI) shows the energy which remains in the battery, based on actual voltage readings. The value displayed is the percentage of usable energy. Voltage fluctuations occur dUring operation. Dependent upon the setting in Tuning mode, lift will be prevented until the battery is recharged or replaced. Brush Wear, Over temperature, Service Required, and Lift Limit Individual icons illuminate to inform the operator of the specific condition. Operator Compartment Options The following components are available per customer request (partial list): -Fan Dome Light Work Lights 00700-CL221 Issued: 9/10/98 Systems Overview Operator Compartment Options 3- 11 Systems Overview Operator Compartment Options Steering Indicator Lights (electric steering) Locked On Wire Lights Steering Wheel Figure 3-3: Operator's Console Operator's Display Toyota Orderpicker Service Manual Emergency Power Disconnect Button Auto/Manual On/Off Switch 3- 12 00700-CL221 Issued: 9/10/98 Toyota Orderpicker Service Manual Steering and Controls Steer Controller Guidance System The electric power steering system is a microprocessor-based control system using sophisticated software to manage the steering operation of the lift truck. It provides the electronic intelligence to govern lift truck steer functions under direct operator control or automated wire/rail gUidance systems. Steer Motor and Gear Reducer A permanent magnet steer motor connected to a gear reducer provides the mechanical force to steer the drive unit. The gear reducer has a drain plug for

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