TOYOTA 6BPU15 ORDERPICKER Service Repair Manual SN70001 to 79999

Service Manual

TOYOTA ORDERPICKER

Model6BPU15

Serial No. 70001-79999

00700-CL221

Issued: 9/10/98

Toyota Orderpicker Service Manual

How to Use This Manual

How to Use This Manual

00700-CL221 Issued: 9/10/98

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How to Use This Manual

Toyota Orderpicker Service Manual

Map of the Manual

Map of the Manual

HowtoUse I This Manual I

Manu~ Design

ITable of Contents

Start Page

Component Location Photos

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Scheduled I Maintenance I

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00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

How to Use This Manual Manual Design

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

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How to Use This Manual

Toyota Orderpicker Service 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:

1-4

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Frequency of attention Physical attachment (e.g., brake must be removed before drive motor)

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Functional relation (e.g., carriage and mast components are grouped together)

00700-CL221 Issued: 9/10/98

How to Use This manual

Toyota Orderpicker Service 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.

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.00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual

How tc;> Use This manual

Page Revision Record

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.

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00700-CL221 Revised: 2/1.5/00

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Toyota Orderpicker Service Manual

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Toyota Orderpicker Service Manual

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00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

How To Use This Manual Table of Contents

Table of Contents Ho\V to Use This Manual. . . . . . . .

Map of the Manual

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1-1 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. . 路 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . . . . . . . . . . 3-4 Electric Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Chassis 路 . . 路 路 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Operator's Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Operator Compartment Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Steering and Controls

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Toyota Orderpicker Service Manual

How To Use This Manual Table of Contents

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

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Miscellaneous Circuits

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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

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Charging Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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5-2

Electrical Troubleshooting Guidelines

5-2

Electrical Connector wcator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Shorts to Frame Test. · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Electric Motor Tests

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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

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Toyota Orderpicker Service Manual

Table of Contents

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

6-1 73

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

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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

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Toyota Orderpicker Service Manual

Table of Contents

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1-14

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How to Use This Manual

Toyota Orderpicker Service 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

Toyota Orderpicker Service Manual

List of Figures

Figure 6-9: Location of Wire Guidance Coils and Related Tests Figure 7-1: Component Locations (Sheet 1 of 5) Figure 7-2: Correct Jacking Locations Figure 7-3: Proper/Improper Method of Holding Circuit Card Figure 7-4: Integrated Circuit Tool Figure 7-5: Preparing Integrated Circuit for Insertion Figure 7-6: Installation of Integrated Circuit Figure 7-7: Removing Drive Unit Figure 7-8: Drive Unit Service Tools ~ Figure 7-9: Drive Unit Cross Section Figure 7-10: Drive Unit Components - Lower End Figure 7-11: Removing Axle Bearing Figure 7-12: Pressing Bearing Cone onto Axle Figure 7-13: Assembly of Axle into Housing Figure 7-14: Preparing Axle Seal for Assembly into Housing Figure 7-15: Install/Torque Clamp Nut on Axle Figure 7-16: Securing Clamp Nut by Tightening Retaining Screw Figure 7-1 7: Installing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-18: Drive, Unit Assembly Figure 7-19: Checking Skidpads : Figure 7-20: Deadman Pedal/Master Cylinder Figure 7-21: Brake Bleeding Set-Up Figure 7-22: Exploded View of Brake Assembly Figure 7-23: Deadman Switch (S2) Adjustment (Not to Scale) Figure 7-24: 2 Stage Lift Cylinder (Top End) Figure 7-25: 2 Stage Lift Cylinder (Bottom End) Figure 7-26: Center Lift Cylinder, 3 Stage (Top End) Figure 7-27: Center Lift Cylinder, 3 Stage (Bottom End) Figure 7-28: Lift/Lower Manifolds Figure 7-29: Proper Installation of Proportional Valve Figure 7-30: Access for Lift Cylinder Bleed Screws . . . . . . . . . . . .

Figure 7-31: Directional/Speed Control - Exploded View Figure 7-32: Lift/Lower Return Spring Replacement Figure 7-33: Lift/Lower Control Assembly, Potentiometer Wiring Figure 7-34: Elevating Section Figure 7-35: Elevating Section (cont.)

Figure 7-36: Elevating Section (cant.)

Figure 7-37: Elevating Section (cant.)

Figure 7-38: Three Stage Elevating Section Figure 7-39: End Cap Pulley Assembly (3 Stage mast only) Figure 7-40: Staging of Mast Prior to Shimming Bearings . . . . . . .

Figure 7-41: End Cap Assembly, 3 Stage Mast . . . . . . . . . . . . .

Figure 7-42: Steering Control Assembly . . . . . . . . . . . . . . . . . . ., Figure 8-1: Steering Encoder Output - Left Turn , Figure 8-2: Steering Encoder Output - Right Turn

1-16

6-163 7-2 7-9 7-12 7-15 7-15 7-16 7-19 '7-20 7-20 7-21 7-21 7-22 7-23 7-23 7-24 7-25 . . 7-25 7-28 7-29 7-32 7-34 7-35 7-36 7-38 7-39 7-41 7-42 7-44 7-45 . . 7-47 7-48 7-52 7-53 7-56 7-57 7-58 7-59 7-60 7-61 . . 7-62 7-63 7-66 8-12 8-13

Issued: 9/10/98

Toyota Orderpicker Service .Manual

How to Use This Manual List of Figures

Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure

8-3: 8-4: 8-5: 9-1: 9-2: 9-3: 9-4: 9-5: 9-6: 9-7: 9-8: 9-9:

Wire Guidance Functional Block Diagram Location of Wire Guidance Coils and Related Tests Wire Guidance LEDs on the Operator's Display Lubrication Equivalency Chart Torque Chart - Standard Torque Chart - Standard Brass Torque Chart - Ferrous Metric Torque Chart - Brass Metric Decimal Equivalent Chart .. ,. ' Electrical Schematic Electrical Schematic Hydraulic Schematic

00700-CL221 Issued: 9/10/98

8-18 8-19 8-21 9-2 9-4 9-5 9-6 9-6 9- 7 9-12 9-14 9-18

1- 17

Toyota Orderpicker Service Manual

How to Use This Manual List of Figures

This page intentionally left blank

1- 18

Issued: 9/10/98

Toyota Orderpicker Service Manual

How To Use This Manual

Start Page START

Go to Chapter 2

To review safety precautions?

>----yes---+!

"Safety"

No I

To examine specifications?

>----yes---+I

Go to Chapter 3 "Systems Overview"

No

To do scheduled maintenance?

Go to Chapter 4 >----yes---+I "Planned Maintenance"

No

To troubleshoot a problem?

>----yes---+I

No

Go to Chapter 5 'Troubleshooting"

I--------~.: Troubleshooting Guidelines _I

'---------.1.

I

List of Troubleshooting Charts

1 '---------------'

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1- 19

Toyota Orderpicker Service Manual

How To Use This Manual Start Page

START-2

r---yes---+I

Go to Chapter 6 "Electrical Codes and Tests"

No

To test.

Go to Chapter 7 inspect. adjust. >----yes---+I "Component Procedures" remove/install a component':!

No

Go to Chapter 8 >----yes---+I

'Theory of Operation"

No

Tofmd general reference >----yes---+I information?

Go to Chapter 9 "Appendix"

No

To locate an object or procedure by name?

r----yes---+I

Go to the Index

No

1-20

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Safety

Safety

00700-CL221 Issued: 9/10/98

2-1

Toyota Orderpicker Service Manual

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

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Safety General Safety

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.

•

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

Toyota Orderpicker Service Manual

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).

..

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

Safety General Safety

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

2-5

Toyota Orderpicker Service Manual

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

00700-CL221 Issued: 9/10/98

Safety

Toyota Orderpicker Service Manual

Battery Safety Make sure a shower and eyewash station are nearby in case there is an accident.

..

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

Toyota Orderpicker Service Manual

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

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Safety Battery Safety

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

2-9

Safety

Toyota Orderpicker Service Manual

Battery Safety Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual.

2-10

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Safety Static Safety

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 staticsensitive 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

2- 11

Safety

Toyota Orderpicker Service Manual

Static Safety

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 0059004849-71. 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

Safety

Toyota Orderpicker Service Manual

Jacking Safety

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 Only jack in this area, no more tban 112" (13 mm) off the floor.

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).

Figure 2-2:

Correct Jacking Locations

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

2-13

Toyota Orderpicker Service Manual

Safety Tie-down for Transport

Tie-down for Transport To transport your Toyota lift truck in an overthe-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

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Safety Welding Safety

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

2-15

Toyota Orderpicker Service Manual

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

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Toyota Orderpicker Service Manual

Systems Overview

Systems Overview

00700-CL221 Issued: 9/10/98

3-1

Systems Overview

Toyota Orderpicker Service Manual

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:

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Toyota Orderpicker

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Toyota Orderpicker Service Manual

Systems Overview Use

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.

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Systems Overview

Toyota Orderpicker Service Manual

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.

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Systems Overview Specifications

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 (Minimum)

Approximate weight of the lift truck without battery installed, minus operator and load.

TRUCK WEIGHT (Maximum)

Approximate weight of the lift truck with maximum size battery installed, minus operator and load.

BATTERY WEIGHT (Maximum)

Maximum weight of battery designed for this lift truck.

BATTERY WEIGHT (Minimum)

Minimum weight of battery required for this lift truck.

BATTERY MAX. RATED (Maximum Ampere Hour Capacity)

Power rating of the battery.

CAPACITY CHART

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Maximum load capacity of the lift truck.

Exceeding niaximum load weight may damage the lift truck or affect stability.

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Toyota Orderpicker Service Manual

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):

24 Volt Battery Width 14.50" (370 mm)

Width 13.25" (335 mm)

Height 32.25" (820 mm)

Height 32.25" (820 mm)

Length 36.75" (935 mm)

Length 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.

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Systems Overview Chassis

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.

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Systems Overview

Toyota Orderpicker Service Manual

Chassis

Chains and Pulleys

Most Guard Control Panel Key Switch

Sidegat~ Steering Wheel

Pollet Clomp

Figure 3-2:

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Component Identification

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Toyota Orderpicker Service Manual

Systems Overview Operator's Compartment

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.

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Systems Overview

Toyota Orderpicker Service Manual

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

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Toyota Orderpicker Service Manual

Systems Overview Operator Compartment Options

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

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Toyota Orderpicker Service Manual

Systems Overview Operator Compartment Options

Steering Indicator Lights (electric steering)

Operator's Display

Emergency Power Disconnect Button

Locked On Wire Lights

Steering Wheel

Figure 3-3:

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Auto/Manual On/Off Switch

Operator's Console

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Toyota Orderpicker Service Manual

Systems Overview Steering and Controls

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 changing the oil, and a filler level plug to determine the quantity of lubricant in the unit. The output shaft turns a gear that powers a gear on the drive unit.

Directional/Speed Control Assembly The main components of the Directional/Speed Controller are the: • Control Handle • Housing • Throttle Potentiometer (VRl) • Lift Potentiometer (VR2) • Horn Switch (S3) • Auto/Manual Switch (S45)(mounted on bezel) Control Handle

The Control Handle is constructed of formed plastic. It has provisions for a horn button (S3), and lift/lower potentiometer (VR2).

Housing

The Housing provides support and protection for the throttle potentiometer (VRl). The control handle is also attached to the housing by a rotating shaft. The housing is constructed of molded black polycarbonate and is mounted

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Systems Overview

Toyota Orderpicker Service Manual

Steer Controller Guidance System

under the right-hand side of the operator's control console.

ThroHle Potentiometer (VR1)

The Throttle Potentiometer is mounted within the housing. The potentiometer is turned by two nylon gears; one gear is mounted on the potentiometer shaft and the other gear is on the control handle shaft. Potentiometer specifications include the following: • Mechanical Rotation - 3120 • Resistance - 2,000 ohms (2K) As the throttle potentiometer is rotated by the

operator, a voltage proportional to the position of the control is sent to the Carriage Interface Card. VRI voltage is sensed by the carriage interface and passed to the Display Card, which determines the direction and magnitude of the speed request.

Lift/Lower Potentiometer (VR2).

The lift/lower potentiometer is directly connected to the thumb lever; potentiometer specifications include the following: • Mechanical Rotation - 312 0 • Resistance - 2,000 ohms (2K) As the lift/lower potentiometer is rotated by the

operator, a voltage proportional to the position of the control is sent to the Carriage Interface Card. When the lift/lower control is moved to lift, voltage from VR2 increases; when moved to lower, the voltage from VR2 decreases. VR2 voltage is sensed by the carriage interface card and passed to the Display Card which determines whether to lift or lower. This is accomplished by comparing the actual voltage to the learned voltage values. Neutral for VR2 is learned and stored.

Horn (Hl)

During the self diagnosis (power up) mode, the horn (HI) can be sounded whenever the key switch is ON. The horn assembly is mounted on the front lower section of the power section.

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Systems Overview Steer Controller Guidance System

Horn Switch (S3)

The Horn Switch is located on the front-side of the directional/speed control handle. .

Auto/Manual Switch (S45)

Switch position selects steering mode, i.e., direct operator control or auto steer. Wire gUidance (and rail gUidance) allows the lift truck to follow a predetermined path automatically, without steering assistance of the operator. The switch is located on the operator's console, beneath the control handle.

Drive Unit Position Encoder (ENC2)

The Drive Unit Position Encoder is located near the gear reducer assembly. This encoder is turned as the drive unit is steered. The signal from the encoder is sent to the steer controller.

The steer controller uses this signal, in addition to the signal from the Home Switch Proximity Sensor, to determine the position of the drive unit.

Home Switch Proximity Sensor (PROX)

The Home Switch Proximity Sensor is located on the drive unit next to the Steering Position Encoder. The switch opens or closes depending upon its proximity to a metal surface. The open/close signal is sent to the steer controller.When the lift truck is initially turned on, and deadman depressed, the steer controller will steer the drive unit towards the straight ahead position until the home switch proximity sensor changes state. The switch changes state when a metal surface passes beneath it (when the drive unit is at the straig:qt ahead position).

Steering Encoder (ENC1)

The Steering Encoder is located on the operator's carriage, behind the steering wheel.

As the steering wheel is turned, the encoder generates a quadrature phase signal and sends it to the display card. The display card processes the signal to determine the direction and amount of steering request. The resulting steering request is sent via the ~us+/BusController Area Network (CAN) to the Steer

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Systems Overview

Toyota Orderpicker Service Manual

Steer Controller Guidance System

Controller Card. The Steer Controller Card then powers the steer motor to steer the drive unit.

Speed Feedback Proximity Sensors (SPl and SP2)

The Speed Feedback Proximity Sensors determine the speed and direction of rotation of the drive motor. They are used in conjunction with the holes in the brake drum to produce a quadrature signal that is sent to the steer controller. The characteristic pulses of the quadrature signal are produced as the proximity sensors read either the metal or void of the rotating brake drum.

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Toyota Orderpicker Service Manual

Systems Overview Drive and Brake

Drive and Brake Drive Unit The Drive Unit is a compact, self-contained assembly. It consists of a pivot bearing, gear housing, gear reduction assembly, drive motor, brake, and drive wheel.

Pivot Bearing The Pivot Bearing is the part of the drive unit assembly that provides support for the drive motor, wheel, and gear housing.

Gear Housing The Gear Housing is a precision machined casting into which the gear reduction system is assembled.

Gear ¡Reduction Assembly The Gear Reduction Assembly is comprised of a motor pinion, drive gear, drive pinion, compound gear, and splined shaft. The gears are continuously bathed in gear oil. The splined axle shaft turns on two ball bearings.

Drive Wheel The Drive Wheel consists of a polyurethane tire mounted on an inner hub. The design of the wheel permits replacement of the tire material.

Brake The Brake Assembly is mounted on top of the drive motor. The brake is hydraulically-applied and electrically released under control of the deadman pedal.

Deadman Pedal A Deadman Pedal is located on the compartment floor. The deadman pedal is spring loaded to the power off/brake engaged position. The deadman pedal disables the travel and lift/lower circuits and applies the brake whenever the pedal is released.

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Systems Overview

Toyota Orderpicker Service Manual

Brake Deadman Switch (52)

Switch S2 is located on the brake assembly, near the drive motor, in the power section.

When the deadman pedal is up, switch S2 is activated causing the circuit to open, preventing travel and lift/lower functions.

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Systems Overview Mast

Mast Mast Assembly The Mast Assembly is constructed of the following parts:

Mast Main Frame The Mast Main Frame has a ladder type construction. The mast uprights are made of structural I-sections. The uprights are tied together using structural steel crossties. The mast uprights are welded to the baseleg frame, forming a strong integral unit.

Telescopic Frame(s) The Telescopic Frame is also of ladder type construction. It is' constructed of structural 1sections and crossties.

Mast Bearings The Mast Bearings are roller type construction and lubricated for life.

24" Mast Switch (S 11 ) The 24" switch is physically located on the carriage, and is mounted so that it is activated whenever the carriage is below 24", and not activated whenever the carriage is above 24".

60" Mast Switch (S 12) The 60" Switch is mounted on the 'right-hand side of the mast, and is mounted so that it is activated whenever the carriage is below 60", and not activated whenever the carriage is above 60".

120" Mast Switch (S10) (with enhanced speed option) The 120" Switch is mounted on the right- hand side of the mast and is located about 3 feet high. It is mounted so that it is activated whenever the carriage is below 120", and not activated whenever the carriage is above 120".

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Systems Overview

Toyota Orderpicker Service Manual

Mast Assembly

150" Mast Switch (S26) (without Enhanced Speed option) The 150" Switch is mounted on the right-hand side of the mast and is located about 5 feet high. It is mounted so that it is activated whenever the carriage is below 150", and not activated whenever the carriage is above 150".

180" Mast Switch (S 100) (with Enhanced Speed option) The 180" Switch is mounted on the right-hand side of the mast and is located about 15 feet high. It is mounted so that it is activated whenever the carriage is below 180", and not activated whenever the carriage is above 180".

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Toyota Orderpicker Service Manual

Systems Overview Hydraulic Components

Hydraulic Components Lift/Lovver System The orderpicker variable speed Lift/Lower System is controlled manually by the operator using a thumb lever located on the directional/ speed controller in the operator's compartment.

The lift/lower system consists of: • Lift Pump/Motor Assembly • Lift Cylinders • Lift Chains • ReseIVoir • Return Line Filter • Flow Controls • Relief Valves • Hydraulic Manifold Assembly

Lift Pump A splined, fixed displacement gear pump is used on all models.

Lift Cylinder Assembly The Lift Cylinder is composed of the following: • Cylinder Housing • Piston • Flow Controls Cylinder Housing

The Cylinder Housing is constructed of welded steel tUbing. The cylinder housing is attached to the mast main frame.

Piston

The Piston is encased within the cylinder housing and lifts the telescopic section of the mast assembly. The piston is constructed from chrome plated tUbing.

Flow Controls

The Flow Control limits the rate fluid leaves the cylinder in the event of a br<?ken hose.

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Systems Overview

Toyota Orderpicker Service Manual

Lift/Lower System

Lift Chain The heavy duty Lift Chain is constructed of 3/4 inch pitch, 4x4 laced leaf chain. The lift chains comply with ANSI/ASME 829.8 requirements.

Reservoir The welded steel Reservoir has a capacity of approximately 5.5 gallons (20.8 L). The reservoir is located above the battery in the power section and is vented to the atmosphere through the filler cap.

Return Line Filter The Return Line Filter consists of a 10 micron filter element and bypass valve set at 15 psi (103.4 kPa) cracking pressure. The unit has a replaceable spin-on type canister.

Lift/Lower Hydraulic Manifold Assembly The Lift/Lower Hydraulic Manifold Assembly controls hydraulic flow rate and direction in the lift/lower system. The manifold assembly is controlled electrically by the lift truck Tractor Interface Card. The assembly is located in the lower, forward, left-hand side of the power section.

The Lift/Lower Hydraulic Manifold Assembly consists of: • Manifold Housing • Check Valves • High Pressure Relief Valve • Fixed Low Pressure Relief Valve • Manual Emergency Lowering Valve • Proportional Lower Solenoid (SOLI) • Load Holding Solenoid (SOL2) • Pressure Test Ports • Pressure Transducer (optional weight measurement) Manifold Housing

The Manifold Housing is machined from aluminum and contains the compon~nts identified in Figure 3-4 on page 3-26.

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Toyota Orderpicker Service Manual

Systems Overview Lift/Lower System

Lift Pump Check Valve (5 PSI) (34 kPa)

The Lift Pump Check Valve prevents hydraulic oil from flowing back through the lift pump.

High Pressure Relief Valve

The High Pressure Relief Valve is set to prevent lifting a load which exceeds the maximum load capacity of the lift truck.

Output Check Valve (100 PSI) (689 kPa)

The Output Check Valve provides for smooth stopping dUring lift. It is also used as the fixed low pressure relief valve.

Manual Emergency Lowering Valve

A Manual Emergency Lowering Valve provides ground level control allowing the operator's compartment to be lowered in the event the operator is unable to bring the carriage down.

This is a knurled knob located on the lift/lower hydraulic manifold assembly.

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Systems Overview

Toyota Orderpicker Service Manual

Electrical Components and Systems

Electrical Components and Systems General This section is an overview; for actual operation, see Theory of Operation or the Operating Instructions in this manual.

The 24-volt electrical systems description includes: • Traction/Lift System Components • Traction/Lift Power Amplifiers • Electric Steering • Miscellaneous Circuits

Traction/Lift Power Amplifiers The Traction and Lift Power Amplifiers (Figure 3-5 on page 3-28) monito~ and control current flow through the traction and lift motors, respectively, The traction amplifier is separately excited and controls traction motor speed and .torque. The lift motor amplifier controls the series-wound lift motor. The amplifiers are located on the right side of the power section.

The amplifiers feature: • Smooth, step-less operation • Current limiting • Under/over voltage and thermal protection • Fault protection • Plug braking (traction only) The amplifiers are low-maintenance sealed units, with no user-serviceable parts.

Battery Connector The Battery Connector is located on the left side of the truck and is mounted on the power section frame.

Solenoid 1 (SOL1) (Variable Lower) SOLI is the variable lower solenoid. Solenoid 1 proportionally controls hydraulic flow from the lift cylinders.

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Systems Overview General

Solenoid 2 (SOL2) SOL2 is the load holding solenoid. It prevents hydraulic fluid from leaving the lift cylinder when the carriage is elevated and the lift/lower control is in neutral.

Solenoid 12 (SOL12) SOL12 is the brake dump solenoid. When activated, it releases the brake; when deactivated, the solenoid allows hydraulic pressure to apply the brake.

Power Disconnect Contactor (MM) The Power Disconnect Contactor is a single unit with one contact actuate'd by a single coil.

NOTE:

Contactors used are magnetic type, designed for maximum interchangeability of parts. Contactor tips are silver alloy and are replaceable.

Drive Motor The Drive Motor is a s'hunt-wound direct current motor and uses sealed bearings for long service life. The drive motor transmits power to the reduction unit by a pinion gear on the motor armature shaft. A brake drum mounts on the other end of the armature shaft.

Drive Motor Temperature Sensor (DT)

A thermister provides a traction motor temperature input to the tractor interface card.

Lift Motor Power to drive the lift pump is a series wound, fan cooled, intermittent duty motor.

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General

Reservoir

ESD Jack

Return Line Filter

Lift Pump Motor (DMP)

Lift Pump

Steer Motor (DMS)

Figure 3-4:

3-26

Drive Motor (DMD)

Hydraulic Compartment Components (Sheet 1 of 2)

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Toyota Orderpicker Service Manual

General

Lift Pump Proportional Valve

SOL1

Emergency - - Lower Valve

Pressure Test Connection

Pressure Transducer (optional)

Figure 3-4:

Hydraulic Comportment Components (Sheet 2 of 2)

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General

, F3

F'uses F4-F8

Lift Motor

_ Traction Amplifier

Steer Motor

Drive Motor _~== Horn

Figure 3-5:

3-28

Electrical Compartment Components

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Systems Overview

Toyota Orderpicker Service Manual

General

Key Switch

Operator's Display

Steering Wheel

Travel, Lift!

Lower Control

Auto/Manual On/Off Switch

Carriage Interface Card

Brake Dump Solenoid (SOL12)

De,adnnan Pedal

Figure 3-6:

Pallet Clamp Release

Platform Components (Electric Steering, Cover Removed)

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General

CarriageITractor Interface Cards Virtually all lift truck inputs and outputs pass through and are monitored by the Carriage and Tractor Interface Cards. The Display Card and Steer Controller also have I/O functions. The tractor interface card controls the traction and lift/lower systems and "talks" to the Display card over the CAN bus. The carriage interface card accepts inputs from the control handle, and transfers data to the Display Card. The Carriage Card interfaces with the Display Card; of the two, only the Display Card has intelligence.

Carriage Interface Card The Carriage Interface Card (Figure 3-7) is an Input/Output (I/O) card that reads and passes the readings to the Display Card. Readings involve input/output from switches, the control handle, and the brake dump solenoid, including: • Control Handle Switches and Controls • EPO Switch • 24" Limit Switch • 60" Limit Switch

• Key Switch • Auto/Manual Switch (optional) • Left Sidegate Switch (optional) • Right Sidegate Switch (optional) • Control Handle

ODD PC7

PeS

PC8

PC4

PC9

PC3

DD 0 Figure 3-7:

3-30

Carriage Interface Card

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Systems Overview General

Tractor Interface Card The Tractor Interface Card (Figure 3-8) is an Input/Output (I/O) card that receives input/ output from switches. sensors. and solenoids. It is controlled by the Display Card.

Switch Inputs: • Lift Brush Wear Switch • Traction Brush Wear Switch • Brake Switch • 150"/180" Switch • 120" Switch • Lift Inhibit Switch (optional) Sensor Inputs: • Lift Sense • MM Contactor Sense Outputs are: • Proportional Solenoid • Load Holding Solenoid • MM Contactor • Hom PR2

[:]1 PR11

Figure 3-8:

PR10

I

PR1

DOD 0 D

PR9 PR8 PR7 PR6 PRS

Tractor Interface Card

Regulated Power Supply

A Regulated Power Supply is located on the Steer Controller Card. The power supply delivers clean. stabilized power throughout the

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General

network. Voltages generated by the power supply are: â&#x20AC;˘ +12 volts (for all cards) â&#x20AC;˘ +5 volts used by the Steer Controller Card NOTE:

3-32

This power supply should not be used to operate add-on accessories.

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Toyota Orderpicker Service Manual

Systems Overview Steer Controller Guidance System

Steer Controller Guidance System The electric steering control system interfaces with the Tractor Interface Card and the Display Card, and determines the truck steer direction.

The steering system is comprised of the following components: • • • •

Steer Controller Steer Motor (DMS) Display Card (see Note) Filter Card (optional wire gUidance)

• Steering Encoder • Home Switch Proximity Sensor • Antennas (Load and Tractor - wire gUidance) • Cables NOTE:

The Display Card is integrated with all systems.

Steer Controller The Steer Controller Card (Figure 3-9 on page 3-34) contains status LED's and a maintenance display. This section describes how the display works and what the LED's mean.

The individual items discussed are the: • Heartbeat LED • CAN LED • +12 Volt LED • +5 Volt LED • Seven Segment Display

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Systems Overview

Toyota Orderpicker Service Manual

Steer Controller Guidance System +5 Volt LED ~ +12 Volt LED Heartbeat LED - - . . . ~_______ CAN LED :¥--rA!lili!lii!l:i! '

~I:

A Ie

'I

~ i I

!LJ j

Seven Segment Display

JSl

~-i

i E1f1

~ Firmware Socket

-

I§EJPl ;~

Ip

i§i Itffi it$

!~ .~ JP2

!lE !LLW

i§

JP3

JS2 (reij

j;::q::q;ESE": I, !

'++'+'

'i:±:t:tt::

JP4

i~ JP5 !t:!:I:t1:j

, Fjgure 3-9:

Steer Controller Card

Heartbeat LED

The Heartbeat LED will turn On/Off at a rate of approximately 60 times per minute.

As long as the heartbeat LED is blinking. the processor on the card is working.

CAN CAN stands for Controller Area Network. A CAN is a communication protocol developed for "noisy" environments. A CAN uses two digital signal lines referred to as Bus+ and Bus-.

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Systems Overview Steer Controller Guidance System

CAN LED

The CAN LED indicates the status of communications on the CAN Bus between the Steer Controller Card and the Display Card. â&#x20AC;˘ When the CAN LED is Off, communications across the CAN Bus are being processed without error. â&#x20AC;˘ When the CAN LED is On, an error in communications across the CAN Bus has been detected. +12 Volt LED

The +12 Volt LED is lit as long as +12 volts is being generated by the power supply on the Steer Controller Card. The LED only indicates that +12 volts is being generated, not that the voltage is within specification. +5 Volt LED

The +5 Volt LED is lit as long as +5 volts is being generated by the power supply on the Steer Controller Card. The LED only indicates that +5 volts is being generated, not that the voltage is within specifications.

Seven Segment Display The Seven Segment Display is used to communicate the status of the steer controller gUidance system to the technician. When the system is operating normally at idle, each segment of the seven segment display will light one at a time. This process will repeat continuously until the steering/guidance system is activated.

Since this is a single segment display, a code having two digits must be displayed one digit at a time. Also, the display is not able to show all characters. An example of how some of the . codes are displayed follows:

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Systems Overview Steer Controller Guidance System

f

I

[3]--[2]

1--1

i fCl -- Ell LJ ~ II

3-36

I

I

Code 9K Is dIsplayed.

Code 53 Is dIsplayed

Code F2 Is dIsplayed.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Systems Overview Display Controller Card

Display Controller Card The Display Controller Card is located on the operator's console. The display controller serves as a communication device and as a feed through for signals from the steering encoder to the Steer Controller Card. It displays, in text, various messages about all the truck systems.

It also has a keypad and additional LED's to interface with the operator and technician.

Figure 3-10 on page 3-38 identifies the various parts of the display card. Individual items include: • ILl • LED Display ILl

ILl is the red LED located on the upper left corner of the card assembly. ILl will blink at a rate of approximately 60 times per minute and will start to blink when: • Successful communications with the steer controller is established.

Alpha-numeric Display

The Alpha-numeric Display is the portion of the card assembly that the operator/technician sees. This display shows operation and fault messages.

00700-CL221 Issued: 9/10/98

3-37

Systems Overview

Toyota Orderpicker Service Manual

Display Controller Card

~

Firmware Socket

:~ l;\

HDI

• :,

~HD5

::

HD2 (baL; - - - /

~/ ~\

HD3 JSI (backside)

HD4

Figure 3-10: Display Controller Card

Filter Card The Filter Card (Figure 3-11 on page 3-39) is used only when wire gUidance is installed. The filter card mounts on top of the Steer Controller Card. Individual items on the filter card include: • JSl • JWl • JW2 • ILl (+ 12 volts) • IL2 (+5 volts) JSl

This connector is located on the underside of the filter card. This connector mates with the Steer Controller Card.

JW1/JW2

The JWl connector connects the tractor-end sensors to the filter card. The JW2 connector connects the load-end antenna to the filter card.

3-38

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual

Systems Overview Display Controller Card

ILl (+12 volts)

The +12 Volt LED is lit as long as +12 volts are being generated by the power supply on the Steer Controller Card. The LED only indicates that + 12 volts are being generated. not that the voltage is within specification. +5 Volt LED

The +5 Volt LED is lit as long as +5 volts are being generated by the power supply on the Steer Controller Card. The LED only indicates that +5 volts are being generated. not that the voltage is within specification.

JS1 (far side)

II

I JW2

~

IL2 (+5 volts)

I

â&#x20AC;˘

-

ILl (+12 volts)

~------r.~

III III/ ~l i

Figure 3-11: Filter Card (with wire guidance only)

00700-CL221 Issued: 9/10/98

3-39

Toyota Orderpicker Service Manual

Systems Overview Miscellaneous Circuits

Miscellaneous Circuits Fuses Fuses on the Orderpicker include the following: Fuse Number

Used For .

Rating

FI

70 amps

Power Fuse for Steer Controller

F2

350 amps

Power Fuse for Traction Controller

F3

450 amps

Power Fuse for Lift Controller

F4

15 amps

Power Fuse for Tractor IIF, B+F

F5

15 amps

Power Fuse for Tractor IIF, B+PC

F6

15 amps

Ground Fuse for Tractor I1F, B-F, DGND

F7

6 amps

Power Fuse for Tractor IIF, Ext B+

F8

6 amps

Ground Fuse for Tractor IfF, Ext B-

F9

1.5 amps

Strobe Fuse

Sidegate S\ÂĽitches (560, S61) The Sidegate Switches prevent all travel and lift/lower functions when the sidegates are in the vertical position. The sidegate switches supply an input signal to the Carriage Interface Card which monitors their status.

Tie-Points Four (4) Tie-Points (TP) are located on the lift truck: TPI (Fl - B+); TP2 (F2 - Traction Motor); TP3 (F3 - Lift Motor) and TP4 (B-).

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00700-CL221 Issued: 9/10/98

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