Toyota 7BNCU18 Forklift Service Repair Manual SN50001 and up

SERVICE MANUAL Stand-Up End-Control Lift Truck Models: 7BNCU15 7BNCU18 7BNCU20 7BNCU25 Serial No. 50,001 and up

00700-CL1SM-3 Issued: 6/1/04

Š 2004 by Toyota Industrial Equipment All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher.

Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 1 SIB MA06-001 - 7FBCU Option Menu Changes 2 SIB CC06-001 - A5 Error Code Additional Information 3 SIB RA06-002 - Tie Rod Change 4 SIB FA06-003 - Front Axle Hub Change 5 SIB FA06-002 - Changes to Reamer Bolt Torque Specification 6 SIB RA04-001 - New Tie Rod End Design 7 SIB MA05-009 7FBEU Option Set Menu Changes 8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload) 9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion 10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks 11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust 12 SIB DU05-004 - Reduction Gear Change 13 SIB ST99-001R - Recommended Special Service Tools 14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting 15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting 16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32) 17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55) 18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32) 19 SIB FA05-001 - Gear Case Change (7FBCU35-55) 20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20) 21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20 22 SIB CE05-001 Key Switch Change (All Models) 23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20) 24 SIB CE05-008 7FBEU Voltage Conversion 25 SIB CC05-011 Low Battery Voltage / Performance Reduction 26 SIB CC05-007 MB Contactor Cover (7FBEU15-20) 27 SIB ST06-001 - Recommended Special Service Tools 28 SIB CE05-006 Pump Motor Cooling Fan 29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit 30 SIB MA07-005 - Maintenance Indicator Changes 31 SIB RA07-001 Rear Axle Flange Change 32 SIB HS07-001 Addition of Back-Tilt Lock Valve 33 SIB CE06-005R - Display Battery Replacement 34 SIB CE06-005R Display Battery Replacement 35 SIB FA07-001R Front Axle Shaft Change 36 SIB CC07-004 - Tuning No. 14 Information 37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section

ma06-001.pdf cc06-001.pdf ra06-002.pdf fa06-003.pdf fa06-002.pdf ra04-001.pdf ma05-009.pdf ma05-008.pdf ce02-002r.pdf cy04-001.pdf bf04-003.pdf du05-004.pdf st99-001r.pdf st03-001.pdf st00-001.pdf cc05-002.pdf cc05-008.pdf cc05-006.pdf fa05-001.pdf hs05-003.pdf ms03-001.pdf ce05-001.pdf cc05-003.pdf ce05-008.pdf cc05-011.pdf cc05-007.pdf st06-001.pdf ce05-006.pdf ce05-002.pdf ma07-005.pdf ra07-001.pdf hs07-001.pdf ce06-005-r1.pdf ce06-005-r1.pdf fa07-001r.pdf cc07-004.pdf dm07-001.pdf

REV: 1/31/08 69 KB 2/20/2006 119 KB 2/20/2006 343 KB 3/7/2006 129 KB 3/7/2006 44 KB 3/7/2006 963 KB 6/7/2006 124 KB 6/7/2006 742 KB 6/7/2006 52 KB 6/8/2006 83 KB 6/8/2006 271 KB 6/8/2006 222 KB 6/8/2006 59 KB 6/8/2006 93 KB 6/8/2006 57 KB 6/8/2006 50 KB 6/8/2006 89 KB 6/8/2006 191 KB 6/8/2006 107 KB 6/8/2006 929 KB 6/8/2006 1810 KB 6/8/2006 103 KB 6/8/2006 98 KB 6/8/2006 51 KB 6/8/2006 63 KB 6/8/2006 184 KB 6/8/2006 90 KB 6/13/2006 229 KB 6/16/2006 5801 KB 9/6/2006 102 KB 5/10/2007 100 KB 5/10/2007 1246 KB 5/10/2007 876 KB 7/12/2007 876 KB 7/12/2007 281 KB 9/25/2007 190 KB 10/26/2007 557 KB 10/26/2007

Technical New Briefs affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal Option, Over Heating Diagnosis, and 7FBCU Voltage Specs 2 TNB - 2004-07 - Hydraulic oil change 3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange 4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump 5 TNB - 2006-05 - Plate to Prevent Chain Rollback 6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates 7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure 8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage 9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display 10 TNB - 2006-09 - 7-Series Electric ROM Write 11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention 12 TNB-2006-03 - 7FBEU Counterweight Squeaking 13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure

tnb-2001-01.pdf tnb-2004-07.pdf tnb-2006-02.pdf tnb-2006-04.pdf tnb-2006-05.pdf tnb-2006-10.pdf tnb-2006-12.pdf tnb-2006-13.pdf tnb-2006-01r.pdf tnb-2006-09.pdf tnb-2003-07.pdf tnb-2006-03.pdf tnb-2003-04.pdf

REV: 1/31/08 113 KB 11/29/2005 79 KB 11/29/2005 375 KB 2/20/2006 125 KB 4/25/2006 86 KB 4/25/2006 140 KB 9/6/2006 82 KB 11/1/2006 159 KB 12/22/2006 517 KB 4/9/2007 339 KB 4/9/2007 118 KB 1/31/2008 805 KB 1/31/2008 110 KB 1/31/2008

Hotline Tech Tips affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels 7FBCU hotline tech tips-2004-11.pdf 2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU gradeability; 7FBCU CB1 and CB2 hotline tech tips-2004-12.pdf 3 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on 7FBEU and 7FBCU hotline tech tips-2005-01.pdf 4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential Oil Level hotline tech tips-2005-03.pdf 5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing hotline tech tips-2005-05.pdf 6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction hotline tech tips-2005-06.pdf 7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement hotline tech tips-2005-07.pdf 8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2 hotline tech tips-2005-08.pdf 9 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers hotline tech tips-2005-09.pdf 10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon hotline tech tips-2005-10.pdf 11 HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel hotline tech tips-2005-11.pdf 12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures; 7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse R hotline tech tips-2005-12.pdf 13 HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers hotline tech tips-2006-01.pdf 14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes hotline tech tips-2006-02.pdf 15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3 hotline tech tips-2006-03.pdf 16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement hotline tech tips-2006-04.pdf 17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm hotline tech tips-2006-05.pdf 18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption hotline tech tips-2006-06.pdf 19 HTT-2006-07 - 7FBEU Slow Motor Speed hotline tech tips-2006-07.pdf 20 HTT-2006-08 - 7FBEU E2-1 Error Code hotline tech tips-2006-08.pdf 21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N hotline tech tips-2006-09.pdf 22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes hotline tech tips-2006-10.pdf 23 HTT-2006-11 - 7FBCU Drive Transistors hotline tech tips-2006-11.pdf 24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor hotline tech tips-2006-12.pdf 25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install hotline tech tips-2007-01.pdf 26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added hotline tech tips-2007-02.pdf 27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU hotline tech tips-2007-03.pdf 28 HTT-2007-04 - Class 1 gear case oil hotline tech tips-2007-04.pdf 29 HTT-2007-05 - 7FBCU Gear Case Sealing hotline tech tips-2007-05.pdf 30 HTT-2007-06 - Steer Cylinder change hotline tech tips-2007-06.pdf 31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil hotline tech tips-2007-07.pdf 32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting hotline tech tips-2007-08.pdf 33 HTT-2007-09 - Repair Manual 322 hotline tech tips-2007-09.pdf 34 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors hotline tech tips-2007-10.pdf 35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-3 hotline tech tips-2007-11.pdf 36 HTT-2007-12 - Class 1 Alarm with OPSS hotline tech tips-2007-12.pdf 37 HTT-2008-01 - Class I Gear Noise hotline tech tips-2008-01.pdf

REV: 1/31/08 114 KB 2/6/2006 130 KB 2/6/2006 119 KB 7/5/2006 121 KB 2/6/2006 168 KB 7/5/2006 326 KB 2/6/2006 118 KB 3/13/2006 112 KB 3/13/2006 323 KB 2/6/2006 97 KB 2/2/2006 74 KB 2/6/2006 278 KB 4/9/2007 71 KB 2/2/2006 185 KB 3/2/2006 249 KB 4/3/2006 84 KB 4/27/2006 279 KB 6/20/2006 344 KB 7/11/2006 131 KB 4/9/2007 268 KB 9/6/2006 134 KB 10/3/2006 257 KB 4/9/2007 99 KB 11/27/2006 308 KB 4/9/2007 136 KB 4/9/2007 519 KB 4/9/2007 154 KB 4/9/2007 381 KB 5/10/2007 216 KB 9/24/2007 162 KB 9/24/2007 600 KB 9/24/2007 148 KB 9/24/2007 502 KB 9/24/2007 303 KB 10/30/2007 155 KB 11/19/2007 479 KB 12/12/2007 363 KB 1/28/2008

Toyota Stand-Up End Control Service Manual

i: How To Use This Manual

How To Use This Manual

Table of Contents

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Abbreviations & Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jacking Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Lift Truck Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Configure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Software Configuration/PC Loader Program . . . . . . . . . . . . . . . . . . . . . 3-15

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Troubleshooting Wiring Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Messages, Codes, and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 List of Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Message and Code Summary Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-121

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Covers and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Drive and Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81 Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-125 Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-147

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34 Sense Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

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How To Use This Manual

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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How to Use This Manual

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How to Use This Manual

Toyota Stand-Up End Control Service Manual

Map of the Manual

Map of the Manual How To Use This Manual

Map of the Manual

Safety

Systems Overview

Manual Design

Abbreviations & Symbols Vehicle Specifications

Table of Contents Planned Maintenance

Troubleshooting

Messages, Codes And Tests

1-2

Component Procedures

Alphabetical List of Component Procedures

Go to Chart MAP2

Component Location Photos

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How to Use This Manual Map of the Manual

MAP2: Map of the Manual (Continued)

Theory of Operation

Appendix

Lubrication Equivalency Chart

Torque Charts

Index

Decimal Equivalent Chart

Standard/Metric Conversions

Electrical and Hydraulic Schematics

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Toyota Stand-Up End Control Service Manual

Manual Design

Manual Design This 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: • Name of the manual (Toyota Stand-Up End Control Service Manual) • Current Chapter Title (for example; How to Use This Manual) • Current topic (for example; Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual.

The START page asks a few simple questions to guide you to the proper chapter.

• Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are grouped by truck system.

To find a component procedure, you may use one of three methods: •

Look up the component name in the List of Component Procedures.

•

Find the component in the Component Locator Photos.

•

Look up the component name in the Index.

• Theory of Operation explains signal flow within the hydraulic and electrical schematics for various conditions of lift truck operation.

• Appendix contains reference information such as torque values, lubricants, standard/metric conversions, and electrical and hydraulic schematics.

• Index lists subjects alphabetically.

• How to Use This Manual explains the format and design of the manual as well as abbreviations and symbols used within the manual.

• Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.

• Systems Overview includes lift truck specifications and theory of operation information.

• Planned Maintenance outlines the recommended schedule of preventive services to keep your lift truck working most efficiently.

• Troubleshooting is designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.

• Messages, Codes, and Tests lists the electrical fault codes and procedures for running firmware electrical tests.

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How to Use This Manual Abbreviations & Symbols

Abbreviations & Symbols These abbreviations, acronyms, and symbols are used in this manual.

Term/Symbol

Definition

A approx amp aux AWG

ampere approximately ampere or amplifier auxiliary American Wire Gauge

BDI BSOC BWI

Battery Discharge Indicator battery state-of-charge Brush Wear Indicator

CAN cm COP

Controller Area Network centimeter Computer Operating Program

dia.

DGND DVM

diameter Digital Ground Digital Volt Meter

EE

UL Electric Truck Type Certification Rating where

electrical equipment is completely enclosed

EPO ESD

Emergency Power Off Electrostatic Discharge

ft.

foot

gal. gm Gnd

gallon or gallons gram ground

HD Ht. in.

hours on deadman height inch, inches

kg km/h kPa

kilogram(s) kilometers per hour kilo Pascal

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Term/Symbol

Definition

lb.

LED LPC

pound, pounds Light Emitting Diode Lift Power Control

mA max min mm mph

milliampere maximum minute or minimum millimeter miles per hour

NV Nm

non-volatile newton meter

OACH ODI OSHA oz.

Overall Collapsed Height Operator Display Interface Occupational Safety and Health Association ounce

PC psi PWM P/N

personal computer pounds per square inch pulse width modulation part number

RAM ROM Regen

random access memory read only memory regenerative braking

SAE SG SOL spec STR

Society of Automotive Engineers Specific Gravity solenoid specification Steer Contactor

TPC

Traction Power Control

UL

Underwriter’s Laboratories

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How to Use This Manual

Toyota Stand-Up End Control Service Manual

Abbreviations & Symbols Term/Symbol

Definition

V VDC

volt volts direct current

wrt w/ w/o

with respect to with without

@ ™ © ® + – ± ° °F °C < > % =

at trademark copyright registered plus or positive minus or negative plus or minus degrees degrees Fahrenheit degrees Celsius less than greater than percent equals

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Safety

Safety

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Safety

Toyota Stand-Up End Control Service Manual

Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

! WARNING Warning means a potentially hazardous situation exists which, if not avoided, could result in death or serious injury.

! CAUTION Caution means a potentially hazardous situation exists which, if not avoided, could result in minor or moderate injury or in damage to the truck or nearby objects.

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Safety General Safety

General Safety

Do not operate or work on this truck unless you have reviewed the Operator’s Manual (Publication No. 00700-AUCL1-2) and are trained, qualified, and authorized to do so.

8B15004D.EPS

Know the truck’s controls and what they do.

?

7J27009S.EPS

Do not operate this truck if it is in need of repair or if it is in any way unsafe.

7J27010S.EPS

Operate this truck only from the operator’s compartment.

7J27011S.EPS

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Safety

Toyota Stand-Up End Control Service Manual

General Safety

Before working on this truck, always turn the key switch to OFF and disconnect the truck’s battery connector (unless this manual tells you otherwise).

7J27012S.EPS

Do not wear watches, rings, or jewelry when working on the truck.

JEWELRY.EPS

Follow the scheduled lubrication, maintenance, and inspection steps.

SCHEDMNT.EPS

Follow exactly the safety and repair instructions in this manual. Do not take “shortcuts.”

8B15008D.EPS

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Toyota Stand-Up End Control Service Manual

Safety General Safety

Do not use an open flame near the truck.

7J27013S.EPS

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.

SPILLS.EPS

.

Use and park this truck indoors. Do not operate outdoors (except for dock or ramp operation, if permitted).

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2-5

Safety

Toyota Stand-Up End Control Service Manual

General Safety

Do not wash this truck with a hose. Do not steam clean inside compartments.

Do not add to or modify this truck without written approval from Toyota. Refer to the Standards Compliance section of the Operatorâ&#x20AC;&#x2122;s Manual (Publication No. 00700-AUCL1-2).

7J27015S.EPS

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Toyota Stand-Up End Control Service Manual

Safety Battery Safety

Battery Safety Before working on or near a battery, review the general safety rules. Always follow these safety rules.

See the battery manufacturer’s instruction manual for specific instructions on battery maintenance. The instructions found there take precedence over the instructions found in this truck manual.

Size and Type When you install a battery in this truck, make sure that it is the correct size and voltage.

! WARNING Do not install a battery that weighs less than the recommended minimum weight. This could affect the truck’s stability.

The truck’s specification plate gives you important information about the battery used in this truck. See Figure 2-1.

1

2

3

4

The following list explains the numbered items in the figure: 1. Truck weight without battery (pounds/kilograms) 2. Truck voltage 3. Minimum/maximum allowable weight of battery (pounds/kilograms) 4. Maximum rating of battery (amp-hours)

412-645.eps

Figure 2-1:

00700-CL1SM-3 Issued: 6/1/04

Truck Specification Plate

2-7

Safety

Toyota Stand-Up End Control Service Manual

Battery Safety

! WARNING 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.

! CAUTION 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.

25L6S016.EPS

Make sure a shower and eyewash station are nearby in case of an accident.

04G6S059.EPS

2-8

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Toyota Stand-Up End Control Service Manual

Safety Battery Safety

A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.

23L6S012.EPS

Keep the charging area well-ventilated to avoid hydrogen gas concentration.

04G6S058.EPS

Disconnect the battery from the truck at the battery connector, after turning the key switch OFF. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

7J27012S.EPS

Do not lay tools or metal objects on top of the battery. A short circuit or explosion could result.

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Safety

Toyota Stand-Up End Control Service Manual

Battery Safety

Keep batteries clean. Corrosion causes shorts to the frame.

Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks.

8D14127S.TIF

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 certain that the vent holes in the filler plugs are open to allow the gas to escape from the cells.

09G6S047.TIF

Do not allow cleaning solution, dirt, or any foreign matter to enter the cells.

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Toyota Stand-Up End Control Service Manual

Safety Battery Safety

Make sure that the battery you are installing in this truck is the correct size. A smaller or lighter weight battery could seriously affect truck stability. See the truckâ&#x20AC;&#x2122;s specification plate for more information.

7J27016S.EPS

Never plug a battery charger into the truckâ&#x20AC;&#x2122;s battery connector. Plug the battery charger only into the battery connector from the battery.

7J27017S.EPS

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

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Safety

Toyota Stand-Up End Control Service Manual

Static Precautions

Static Precautions Electronic circuit boards and devices used on this Toyota lift truck can be damaged by the discharge of static electricity, called electrostatic discharge (ESD).

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).

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 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 your wrist. Connect the ground lead to the wrist strap connector. The wrist strap should be equipped with a 1 megohm resistor to protect against shock hazard.

8D14130S.TIF

Figure 2-2:

Anti-Static Ground Jack

2. Connect the ground plug to the ESD ground jack on the lift truck. The ESD ground jack is located on the tractor frame near the steer tiller. If you cannot use the ground jack, connect the ground clamp to an unpainted, grounded surface on the lift truck frame.

3. Handle circuit boards by edges only. Avoid touching edge connectors.

4. If you will be removing or installing static-sensitive components, place them on a properly grounded static mat.

5. 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 non-functional static discharge wrist band will not alert you that it is bad.

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Toyota Stand-Up End Control Service Manual

Safety Static Precautions

MAT2.TIF

Figure 2-3:

Anti-Static Kit (P/N 00590-04849-71) with Wrist Strap and Mat

Figure 2-3 shows the components of the Toyota antistatic field service kit, Part Number (P/N) 00590-04849-71. The kit includes a wrist strap, ground cord, and static-dissipative work surface (mat). Follow the instructions packaged with the kit.

Wrist straps are available in quantities of 25, as P/N 00590-04848-71.

A wrist strap tester is available as P/N 00590-04850-71.

Contact your local Toyota dealer for information.

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Safety

Toyota Stand-Up End Control Service Manual

Jacking Safety

Jacking Safety Sometimes you may need to jack the truck off the floor to perform maintenance procedures.

When doing so, observe the proper safety precautions: 1. Lower the carriage and forks completely to the floor. Remove any load.

2. Place all controls in neutral.

3. Block the wheels to reduce the risk of movement of the vehicle.

4. Disconnect battery connector.

5. Place the jack under the designated jacking points. See Figures 2-4 and 2-5.

! WARNING Use extreme care whenever the truck is jacked up. Never block the truck between the telescopic and the floor.

Keep hands and feet clear from vehicle while jacking the truck. After the truck is jacked, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck.

8D14044S.TIF

Figure 2-4:

Jacking Drive Wheel

Figure 2-5:

Jacking Tractor

6. To jack the drive wheel: Place the jack in the designated jacking position. See Figure 2-4. Jack the truck up just high enough to raise the drive wheel off the floor.

Place a block under the frame as shown.

7. To jack the tractor: Place the jack in the designated jacking position near the steerable wheel. See Figure 2-5. Jack the truck so that the steerable wheel is off the floor no more than 1 in. (25.4 mm). Block under the frame as shown.

NOTE: After working on vehicle, test all controls and functions to verify correct operation.

8D14047S.TIF

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Toyota Stand-Up End Control Service Manual

Safety Towing

Towing To safely tow this lift truck: 1. Lower the carriage and remove any load from the forks.

2. Turn the key switch OFF and disconnect the battery connector.

3. Install the brake release bolts.

4. Using a suitable towing vehicle, lift the truck until the steer tire is no more than 1 in. (25.4 mm) off the floor.

5. Tow the truck slowly in the tractor-first direction.

! WARNING When towing is complete, make sure to remove the brake release bolts. Failure to do so could cause serious injury.

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Safety

Toyota Stand-Up End Control Service Manual

Welding Safety

Welding Safety ! CAUTION 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. Perform flame cutting and/or welding operations in well ventilated areas. Use local exhaust if necessary.

Before working on this truck, make sure that: • Fire protection equipment is nearby.

• You know where the nearest eyewash station is.

! CAUTION Disconnect the battery before you attempt to inspect, service, or repair the lift truck.

04G6S059.EPS

• Check for shorts to frame as described on page 5-15. If any shorts are detected, remove them before you proceed with the welding operation.

• Clean the area to be welded.

• Remove Interface Card, Translator Card, and power amplifiers from the lift truck.

• Protect all truck components from heat, weld spatter, and debris.

• Attach the ground cable as close to the weld area as possible.

7j27012.eps

• Do not perform any welding operations near the electrical components.

• Remove battery from truck if welding must be done near the battery compartment.

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Toyota Stand-Up End Control Service Manual

Systems Overview

Systems Overview

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3:

3-1

Systems Overview

Toyota Stand-Up End Control Service Manual

Lift Truck Dimensions and Specifications

Lift Truck Dimensions and Specifications This lift truck is rated for performance by load center and load weight.

Review the specification plate located in the battery compartment for detailed load capacity and load center information.

Toyota model designation

Nominal battery voltage

Serial Number

Maximum battery weight for this lift truck

Approximate weight of lift truck minus battery, load, and operator

Minimum battery weight for this lift truck

Maximum load capacity for this lift truck

Battery weight must be between the minimum and maximum weight 412-645.wmf

Figure 3-1:

Lift Truck Specification Plate

For basic dimensions, see Table 3-1, Lift Truck Dimensions and Specifications on page 3-3.

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Toyota Stand-Up End Control Service Manual

Systems Overview Lift Truck Dimensions and Specifications

Table 3-1: Lift Truck Dimensions and Specifications

Category

Max Load @ 24 in.

(610 mm) Load Center

Model 7BNCU15

7BNCU18

7BNCU20

7BNCU25

3000 lb.

(1361 kg)

3500 lb.

(1588 kg)

4000 lb.

(1814 kg)

5000 lb.

(2268 kg)

Overall Collapsed Height* (OACH)

83 - 107 in.

(2108 - 2716 mm)

Elevated Height*

127 to 258 in.

(3226 to 6553 mm)

123 to 251 in.

(3124 to 6375 mm)

Extended Height w/Load Backrest*

175 to 306 in.

(4445 to 7772 mm)

175 to 299 in.

(4445 to 7594 mm)

Truck Wheelbase

50.3 in.

(1280 mm)

53.1 in.

(1349 mm)

55.6 in.

(1412 mm)

Truck Head Length w/o Sideshift*

68.5 in.

(1740 mm)

71.2 in.

(1808 mm)

73.7 in.

(1872 mm)

Truck Head Length w/Sideshift

70.9 in.

(1801 mm)

73.6 in.

(1869 mm)

76.1 in.

(1933 mm)

39.6 x 18.5 x 32.3 in.

(1007 x 470 x 820 mm)

39.6 x 21.25 x 32.3 in.

(1007 x 540 x 820 mm)

39.6 x 23.75 x 32.3 in.

(1007 x 603 x 820 mm)

Battery Compartment Battery Voltage Minimum Battery Weight

36V 2300 lb.

(1044 kg)

2600 lb.

(1180 kg)

2700 lb.

(1226 kg)

*Specifications will vary according to mast type

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3-3

Systems Overview

Toyota Stand-Up End Control Service Manual

General System Data

General System Data Modes of Operation

Maintenance Mode

There are four different modes of operation for this lift truck:

This mode lets you test a circuit in the lift truck while the lift truck is stationary.

• Performance Selection Mode • Configure Mode

You cannot operate the lift truck while it is in Maintenance Mode.

• Maintenance Mode

! WARNING

• Learn Mode To select a mode, enter the correct password (see page 3-5 for instructions on entering a password).

Before placing the lift truck in Maintenance Mode:

Performance Selection Mode

1. Jack the lift truck so that the drive tires are off the floor.

Entering Performance Selection Mode will allow the operator or supervisor to choose between four different performance modes. Each performance mode can be configured and stored for use in different types of applications.

Use the MODE button on the operator display to view the mode being used. Pressing the MODE button will cycle through all four performance modes.

Configurable settings in Performance Selection Mode include maximum forward and reverse speeds, acceleration strength and coast distances. To configure each mode individually, use the operator display to enter Configure Mode and select Mode #1, Mode #2, Mode #3, or Mode #4.

Configure Mode Entering the Configuration Password lets you access the lift truck’s Configure Mode.

This mode lets you enter the lift truck’s software and change the lift truck’s performance limits.

Use the Configure Mode Chart on page 3-6 to see which items you can change and the selections that are available.

2. Make sure the controls are in neutral.

3. Make sure the lift truck is blocked to keep it from moving.

4. Lower the forks all the way to the floor.

See Maintenance Mode on page 3-11.

Learn Mode You can select Learn Mode after entering Maintenance Mode.

Learn Mode lets you re-calibrate the lift truck’s control handle. You would enter Learn Mode and perform the instructions that are shown on the operator display if you replace any of these components: • Interface Card • Control Handle • Firmware NOTE: The lift truck automatically asks the technician to perform Learn on initial power-up. It does not need to be run again.

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Systems Overview General System Data

Passwords There are two levels of passwords that you might use on this lift truck.

The Configuration Password allows you to enter most of the items in Configure Mode.

NOTE: If you push and hold the button, you will scroll very quickly.

10. Stop pressing the button when the letter or number you want appears in the space.

11. Move to the next space you want to change by:

The Maintenance Password lets you enter Maintenance Mode.

•

pressing the ENTER button to move the active space to the right.

Entering a Password

•

holding down the ENTER button and pressing the DOWN button to move the active space to the left.

1. The operator display will show 7BNCU15 or similar message depending on the truck model.

NOTE: If you are trying to access Maintenance Mode or Configure Mode after the lift truck has shown an error code on its operator display, simply press the ENTER button.

2. Press the ENTER button.

12. Repeat steps 8, 9, and 10 to change the letter or number in this space. Repeat steps 7, 8, 9, and 10 to enter the rest of the password.

13. When the operator display shows the correct password, press the ENTER button.

14. If the password was correct, you are now in the lift truck’s Maintenance Mode.

3. The operator display will show 8 blank spaces.

4. Enter the password as follows: NOTE: The default Maintenance Password is “TOY2----”. The default Configuration Password is “TOY1----”.

5. To illustrate this procedure, assume you will be entering the default Maintenance Password (“TOY2----").

6. Look at the operator display. The blinking space is the active space.

7. To move the active space to the right, press the ENTER button.

To move the active space to the left, hold down the ENTER button and press the DOWN button.

8. When the space you want to change is active, stop pressing the button.

9. Press the UP button. You will scroll up through the numbers (0, 1, 2, 3 — 7, 8, 9) and letters (a, b, c, — x, y, z).

If you press the DOWN button, you will scroll down through the letters (z, y, x, — c, b, a) and numbers (9, 8, 7 — 2, 1, 0).

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3-5

Systems Overview

Toyota Stand-Up End Control Service Manual

Configure Mode

Configure Mode Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values

Description

Save? Yes Save? No

Exit Configuration Mode Save changes and leave Configuration Mode Abandon changes and leave Configuration Mode

Yes No

Restore Factory Defaults Restore to Factory Defaults Do not restore Factory Defaults

@ Operator Super.

Select Mode Access Mode Selection Accessible by Operator Mode Selection Accessible Only by Supervisor

Quit

Default

Modes

Mode #1

Configure Performance Mode #1.

See Mode #1 Menu on page 3-9.

Mode #2

Configure Performance Mode #2.

See Mode #2 Menu on page 3-9.

Mode #3

Configure Performance Mode #3.

See Mode #3 Menu on page 3-10.

Mode #4

Configure Performance Mode #4.

See Mode #4 Menu on page 3-10.

BDI 20%)

@ 20%

TOY2_____

Enter new Maintenance Password Default Maintenance Password = "TOY2----"

TOY1_____

Enter New Configuration Password Default Configure Password = â&#x20AC;&#x153;TOY1----â&#x20AC;&#x153; Quit @ English French Spanish

Select Language for Messages Quit Language Selection Menu Select English Select French Select Spanish

Quit @ English Metric

Units of Measurement (For Display Messages) Quit Selection Menu English Metric

English

English

3-6

Set BDI Lift Cutout Point 0% to 50% (1% increments)

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Toyota Stand-Up End Control Service Manual

Systems Overview Configure Mode

Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Clock

Set Date and Time Quit

Quit

24 Hour? Y 24 Hour? N

Select 12 or 24 Hour Clock

DayLtS? Y DayLtS? N

Daylight Savings Time?

Set Time

Set Time: 10:41PM = 10:41 PM or 2241 = 10:41 PM (24 Hour Clock)

08/20/98

Set Date: Month/Day/Year

SchMaint Quit Reset @ Brake Drive 200 Hours FS

MSG Only L Cutout Enable Disable BWI-Trac Half Speed @ Icon BWI-Lift No Lift @ Icon Sideshift*

Description

On Off

00700-CL1SM-3 Issued: 6/1/04

Select Hourmeter for Scheduled Maintenance Quit Scheduled Maintenance Menu Reset Clock Select Deadman Brake Hourmeter Select Drive System Hourmeter Select Interval For Service Reminder 20 to 500 Hours in 20 Hour Increments Defaults (hours) = Hourmeter E Label EE Label Brake 200 200 Drive 350 150 Message reminder only Lift cutout with reminder Turn ON maintenance reminder feature Turn OFF maintenance reminder feature Brush Wear Indicator Action Mode Half Top Travel Speed After 200 Additional Traction Miles or Illuminated Icon ONLY Brush Wear Indicator Action Mode Lift Motor Inoperative After 10 Additional Lift Hours or Illuminated Icon ONLY Select Sideshift (Low Speed Attachment) Turn Sideshift On Turn Sideshift Off

3-7

Systems Overview

Toyota Stand-Up End Control Service Manual

Configure Mode Configuration Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item Travel Alarm*

SpdLimit*

Values

Description

Forks Tractor @ Both None

Select Alarm To Sound For Travel Forks-First Direction Of Travel Tractor-First Direction Of Travel Both Directions Of Travel Neither Direction of Travel Set the Height Limit Switch Speed

@ 3.0 MPH 2.0 to 6.0 MPH 3.0 to 10.0 KPH

LftLimit*

Weight*

Attch#1*

Attch#2*

3-8

0.2 MPH Increments 0.2 KPH Increments (metric)

@ On Off

Set the Lift Limit with Bypass Switch Turn On Switch Function Turn Off Switch Function

On Off Learn

Select Weight Sensor Turn On Weight Sensor Turn Off Weight Sensor Learn Weight Sensor

Type?

Clamp Other None Quit

Select Optional Hydraulic Attachment #1 Select Attachment Type Clamp Attachment Another Type of Attachment No Attachment Quit

On Off

Select Optional Hydraulic Attachment #2 Turn Attachment #2 On Turn Attachment #2 Off

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Toyota Stand-Up End Control Service Manual

Systems Overview Configure Mode

Configuring Modes 1-4 Mode #1 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #1

@ 7.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 7.0 MPH

Set Acceleration Strength

Medium Soft Medium @ Hard

Set Coast Distance

Long Short @ Medium Long

Mode #2 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #2

@ 7.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 7.0 MPH

Set Acceleration Strength

Medium Soft @ Medium Hard

Set Coast Distance

Long Short Medium @ Long

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3-9

Systems Overview

Toyota Stand-Up End Control Service Manual

Configure Mode

Mode #3 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #3

@ 6.5 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 6.5 MPH

Set Acceleration Strength

Medium Soft @ Medium Hard

Set Coast Distance

Long Short Medium @ Long

Mode #4 Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values Quit

Description Quit Mode #4

@ 6.0 MPH 2.0 to 7.0 3.0 to 11.0

Set Maximum Forward Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

2.0 to 7.0 3.0 to 11.0

Set Maximum Reverse Speed 0.2 MPH Increments 0.2 KPH Increments (metric)

@ 6.0 MPH

Set Acceleration Strength

Medium @ Soft Medium Hard

Set Coast Distance

Long Short Medium @ Long

3-10

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Toyota Stand-Up End Control Service Manual

Systems Overview Maintenance Mode

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Item

Values

Quit

Description Exit Maintenance Mode

Learn Quit Controls Weight D Input

Learn the Control Handle Quit Learn Mode Learn Controls: Return Control to Neutral, Press Enter Learn the Weight Sensor Digital Inputs

Quit DI

Quit Digital Inputs

I00

Deadman Switch

I01

EPO Switch

I02*

High Speed Limit Switch

I03

Tilt Up Switch

I04

Tilt Down Switch

I05

Sideshift Right Switch

I06

Sideshift Left Switch

I07*

Lift Limit Mast Switch

I08

Steer Position Sensor

I09*

Attachment Spool Valve Switch

I10

Horn Switch

I11

FU1 Steering Fuse

I12

FU3 Lift Fuse

I13

Traction Motor #1 (Left) Brush Wear Indicator (Both)

I14

Traction Motor #2 (Right) Brush Wear Indicator (upper)

I15

Traction Motor #2 (Right) Brush Wear Indicator (lower)

I16

Lift Motor Brush Wear Indicator (upper)

I17

Lift Motor Brush Wear Indicator (lower)

I18

Traction Motor #1 (left) Speed Sensor

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Systems Overview

Toyota Stand-Up End Control Service Manual

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item

3-12

I19

Traction Motor #2 (right) Speed Sensor

I20

Traction Motor #1 (left) Thermostat

I21

Traction Motor #2 (right) Thermostat

I22

Lift Motor Thermostat

I23

Lift Switch

I24

Lower Switch

I25*

Tilt Limit Switch

I26*

Tilt Limit Switch

I27

TPC_L Signal

I28

TPC_R Signal

I29

Left Power Amp Switch Inputs

I30

Right Power Amp Switch Inputs

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Toyota Stand-Up End Control Service Manual

Systems Overview Maintenance Mode

Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item Output

Digital Outputs Ready?

Jack Drive Wheels Off Floor

Quit DO

Quit Digital Outputs

O01

Toggle the Load Hold (SOL1) Solenoid

O02*

Toggle the Sideshift (SOL2) Solenoid

O04

Toggle the Tilt (SOL4) Solenoid

O05*

Toggle the Aux PSI Select (SOL 5) Solenoid

O06

Toggle the Auxiliary Direction A (SOL 6) Solenoid

O07

Toggle the Equalization (SOL 7) Solenoid

O08

Toggle the Auxiliary Direction B (SOL 8) Solenoid

O09*

Toggle the High Flow Auxiliary (SOL 9) Solenoid

O10*

Toggle the High Flow Attachment 1 (SOL 10) Solenoid

O11*

Toggle the High Flow Attachment 2 (SOL 11) Solenoid

O12

Toggle the TPC Contactor

O13

Toggle the LPC Contactor

O14

Toggle the STR Contactor

O15

Toggle the AUX Contactor

O16

Ramp Command to Traction Power Amplifier #1 (left)

O17

Ramp Command to Traction Power Amplifier #2 (right)

O18

Toggle Traction Motor Brake #1 (left)

O19

Toggle Traction Motor Brake #2 (right)

O20

Ramp the Frequency to the Operator Display Alarm

O21

Toggle the Horn

O22*

Toggle the Travel Alarm

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3-13

Systems Overview

Toyota Stand-Up End Control Service Manual

Maintenance Mode Maintenance Mode Menu NOTE: @ Indicates Factory Default; * Indicates Optional Item A Input

# of Errors Logged

TT:Versn

3-14

Analog Inputs Quit AI

Quit Analog Inputs

A05

Throttle Potentiometer Voltage

A06

Battery Discharge Indicator Voltage

A07

Power Supply +12VDC

A08

FU3 Lift Fuse Voltage

A09*

Weight Sensor Voltage

0-16 Quit Enter Clear TT:XX.X

Error Codes Logged System Will Store Up To 16 Error Codes Exit Error Log Menu Press to Scroll Through Logged Error Codes Firmware Version Number

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Toyota Stand-Up End Control Service Manual

Systems Overview Software Configuration/PC Loader Program

Software Configuration/PC Loader Program Overview The PC Loader Program allows you to update software, set factory defaults, and configure options on your Toyota lift truck.

• Flash Memory Program • Blank Primary Memory • Set Factory Defaults • Options

Requirements PC Loader can be installed on an IBM-compatible PC. The PC communicates with the truck through a 9-pin serial cable (P/N 00590-43591-71).

! WARNING We recommend using the surge protector (P/N 00590-43592-71) to protect your PC from possible electrostatic discharge or voltage surges.

Install PC Loader

To Install from Windows95: 1. Use your mouse to click on the START button located in the lower left corner of your screen. Then, use your arrow to click on RUN. 2. At the prompt, type a:\install and use your mouse to click on the OK button. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place.

3. The program will automatically install onto your PC’s hard drive.

To Install from Windows version 3.1: 1. Locate the Program Manager icon on the main desktop screen and open it by double-clicking on it with your mouse.

2. Locate the menu bar at the top of the screen. Click on FILE. 3. From the FILE menu screen, select RUN by double-clicking on it with your mouse button.

4. At the prompt, type a:\install and use your mouse to click on the OK button. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place.

5. The program will automatically install onto your PC’s hard drive.

NOTE: This program can be installed and accessed using either DOS or Windows application.

To Install from DOS: 1. Place the disk in your floppy drive.

2. Type a:\install at the DOS prompt. If your 3.5 in. disk drive has not been designated as “a”, you will need to substitute the proper drive letter in its place.

3. The program will automatically install onto your PC’s hard drive.

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Systems Overview

Toyota Stand-Up End Control Service Manual

Software Configuration/PC Loader Program

Connect PC To Lift Truck 1. Turn truck key switch OFF. 2. Connect the surge protector to the COMM 1 or COMM 2 port of your computer.

NOTE: On most PC’s and laptop PC’s, the COMM 1 or COMM 2 port is located on the rear of the unit and is a 9-pin “male” connection.

3. Connect the 9-pin serial cable to the surge protector.

4. Connect the cable to JC1 on the Interface Card mounted on the left side of the tractor frame.

Starting PC Loader

To Start PC Loader from Windows version 3.1: 1. Locate the Program Manager icon on the main desktop screen and open it by double-clicking on it with your mouse.

2. Locate the menu bar at the top of the screen. Click on FILE. 3. From the FILE menu screen, select RUN by double-clicking on it with your mouse button.

4. At the prompt, type C:\toyota\loadlite\loadlite.bat and use your mouse to click on the OK button.

5. The Main Menu screen should appear on your PC screen. See Figure 3-2.

NOTE: PC Loader can be started from either DOS or a Windows application.

To Start PC Loader from DOS: 1. Make sure you are in the main directory on your hard drive. Your DOS prompt should be C:\> If you are not in the main directory, type cd\ at the prompt and press ENTER. This should return you to the main directory.

2. Type C:\toyota\loadlite\loadlite.bat at the DOS prompt.

3. The Main Menu screen should appear on your PC’s screen. Select the feature you want to use from the Main Menu. See Figure 3-2.

To Start PC Loader from Windows95: 1. After starting Windows, use your mouse to click on the START button located in the lower left corner of your screen. Then, use your arrow to click on RUN. 2. At the prompt, type C:\toyota\loadlite\loadlite.bat and use your mouse to click on the OK button.

3. The main menu screen should appear on your PC screen. See Figure 3-2.

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Systems Overview Software Configuration/PC Loader Program

Figure 3-2:

opening.tif

Main Menu Screen In PC Loader

Troubleshooting At Start-Up If PC Loader cannot read the truck software when you start PC Loader, you will see the communication error screen in Figure 3-3.

Figure 3-3:

comm.tif

Communication Error Screen, At Start-Up

1. Check the following: •

Cable connection between the truck and the PC

•

Correct communication port selected (1 or 2)

•

Truck key switch is ON

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2. Cycle key switch OFF and ON. 3. Restart PC Loader.

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Systems Overview

Toyota Stand-Up End Control Service Manual

Software Configuration/PC Loader Program

During Regular Use If you see the screen in Figure 3-4 while you are using PC Loader, communication with the truck software was lost.

Figure 3-4:

Communication Error Screen, During Regular Use

Check the following: • Cable connection between the truck and the PC • Truck key switch is ON NOTE: If you see the message in Figure 3-5, the truck’s firmware must be updated.

Figure 3-5:

Dealer Mismatch Screen

To clear the screen, perform the following: 1. Close and restart PC Loader.

2. Update the truck software. See Flash Memory Program on page 3-19.

3. If you see the message in Figure 3-5 at any time after you update the software, call your authorized Toyota Dealer.

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Systems Overview Software Configuration/PC Loader Program

Flash Memory Program The flash memory program allows you to: â&#x20AC;˘ Identify current version of software on your truck â&#x20AC;˘ Update current version of software with a newer version 1. Type F at the main menu prompt. See Figure 3-6.

Figure 3-6:

Main Menu Screen

Opening.tif

2. Type the number of the software version you want to load on the truck at the flash programming prompt. See Figure 3-7.

NOTE: To exit this menu, select A to abort. This will return you to the main menu.

3. After the Flash Memory Program has been installed, select X to terminate PC Loader.

Turn the key switch OFF and wait 5 seconds. Then, turn the key switch back ON to complete the software loading process.

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Systems Overview

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Software Configuration/PC Loader Program

Figure 3-7:

Flash Programming Screen

Flash.tif

Blank Primary Memory The Blank Primary Memory feature allows you to clear the memory in a truck so the Operator Display can be used in another truck.

NOTE: The primary memory of this truck is located on the Operator Display.

1. Type B at main menu prompt. See Figure 3-8.

Figure 3-8:

3-20

Main Menu Screen

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Systems Overview Software Configuration/PC Loader Program

2. After selecting this feature, the Blank Primary Memory screen appears. See Figure 3-9.

Figure 3-9:

Clear Primary Memory Caution Screen

clearcau.tif

3. If you type N, the action is cancelled. If you type Y, the memory is cleared. The truck will then automatically restart and a new prompt appears on your screen. See Figure 3-10.

! CAUTION Before removing the Operator Display, be sure you do not cycle the power OFF/ON. Doing so will rewrite the memory of the truck.

Figure 3-10: Blank Primary Memory Screen

clear2.tif

4. Turn the truck OFF. It is now safe to remove the Operator Display from the lift truck.

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Systems Overview

Toyota Stand-Up End Control Service Manual

Software Configuration/PC Loader Program

Set Factory Defaults The â&#x20AC;&#x153;Set Factory Defaultsâ&#x20AC;? feature allows you to configure the truck to the original factory settings.

1. Type S at the Main Menu prompt. See Figure 3-11.

Figure 3-11: Main Menu Screen

2. The program will ask you to verify your decision to restore the factory defaults.

Enter Y if you want to restore the settings.

Enter N if you want to exit to the Main Menu screen. See Figure 3-12.

Figure 3-12: Factory Default Settings Screen

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Systems Overview Software Configuration/PC Loader Program

Options The Options feature allows you to: • Enable and disable options on the truck like sideshift, attachments, electric key, etc.

• Check the software version on the truck • Check the serial number of the truck • Check the manufacture date of the truck • Check the model type of the truck 1. Type O at the Main Menu prompt. See Figure 3-13.

Figure 3-13: Main Menu Screen

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opening.tif

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Systems Overview

Toyota Stand-Up End Control Service Manual

Software Configuration/PC Loader Program 2. The Options Menu screen shows you the available options which can be enabled/disabled on the truck. See Figure 3-14.

Figure 3-14: Options Menu Screen

options.tif

3. Use the UP or DOWN arrows to move through the options items. See Figure 3-14.

4. To change an option setting: a. Type Y or N to change the highlighted option. See Figure 3-14. b. When you finish changing the options, type X to exit.

NOTE: The option settings for “EE Truck,” “French” and “Spanish” are for information only. They cannot be configured and appear as grey letters. c. The program will then ask you to verify the settings which you have chosen. A message, “Write This Data to the Vehicle?”, will appear at the bottom of your screen. Type Y to configure the truck or N to exit. d. After changing the option settings, the Main Menu appears.

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Toyota Stand-Up End Control Service Manual

Planned Maintenance

Planned Maintenance

4:

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4-1

Planned Maintenance

Toyota Stand-Up End Control Service Manual

Maintenance Guidelines

Maintenance Guidelines A planned maintenance program is recommended to enable: • Maximum truck performance • Maximum truck life • Reduction of costly down time • Avoidance of unnecessary repairs Planned maintenance includes: • Lubrication • Cleaning • Inspection • Service The planned maintenance guidelines fall into two categories: • Moderate usage • Severe usage: •

More than 1500 hours of operation per year

•

Extreme environment conditions, such as a bumpy or abrasive floor, constant exposure to air saturated with dirt or metallic particles, or an “EE” label

Perform all of the scheduled checks and maintenance during the suggested intervals.

The time intervals given in this guide are based on normal operating conditions. When operating under abnormal or severe conditions, perform these services more often as required to keep the unit in good operating condition.

See “Lubrication Equivalency Chart” on page A-2. This provides information on lubrication specifications. Refer to the manufacturer’s supplements for components not listed on the following pages.

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Planned Maintenance Maintenance Guidelines

Operatorâ&#x20AC;&#x2122;s Daily Checklist 7BNCU15/18/20/25 Operatorâ&#x20AC;&#x2122;s Daily Checklist Visual Inspection/Key Turned OFF Component

What to Check

Mark

BATTERY Battery Battery Gates

Fully charged/correct water level/correct voltage, no leakage, proper installation Proper installation

BRAKE Deadman Pedal

Pedal moves freely, no binding Deadman brake functions properly (travel circuit disabled)

CONTROLS Function Controls Emergency Power Off

Move smoothly without binding, return to neutral when released Emergency disconnect functions properly

GENERAL Guards/Covers Decals Leakage

Guards and covers installed and secure Replace warning decals that are illegible or damaged.

Check floor under truck for any accumulation of fluid indicating a possible leak

LIFT/LOWER SYSTEM Cables/Hoses Hydraulic Reservoir

No damage to chains or hoses Check hydraulic fluid level in hydraulic reservoir

TIRES Tires

No gouges, chunking, or flat spots No bond failures Adequate tread (if applicable)

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Planned Maintenance

Toyota Stand-Up End Control Service Manual

Maintenance Guidelines

7BNCU15/18/20/25 Operatorâ&#x20AC;&#x2122;s Daily Checklist Operational Inspection/Key Turned ON Component

What to Check

Mark

HORN Sounds when button is depressed STEERING Smooth steering, without binding or excess play DIRECTIONAL/SPEED CONTROL Moves smoothly without binding Returns to neutral when released Controls speed and direction properly Plugging functions properly Speed limits function properly LIFT/LOWER SYSTEM Lift/lower controls move smoothly and return to neutral when released All controls perform their functions as indicated OPERATOR DISPLAY Displays correct information and is easily readable BRAKES Pedal moves freely without binding Lift truck stops in specified distance Deadman brake functions properly (travel circuits disabled) EMERGENCY POWER OFF BUTTON Shuts down travel and lift functions when depressed SAFETY All flashing and working lights (optional) are functional All limit switches function properly Travel alarm (optional) functions Check condition of static straps (beneath tractor)

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Toyota Stand-Up End Control Service Manual

Planned Maintenance Maintenance Guidelines

Moderate and Severe Usage: 90-Day Inspection Component

What To Do

Refer to

Drive Unit

Change the fluid in the drive unit.

Refer to the â&#x20AC;&#x153;Recommended Oils by Temperature Chartâ&#x20AC;? to assure the proper type of fluid for your application.

page 7-46

Mounting Hardware

Check torque of mounting hardware for major truck components (lift motor and pump, aux. motor and pump, brake assembly, drive motor and drive unit, hydraulic manifolds, and mast-to-drive unit mounting bolts). Tighten or replace any loose, broken, or missing hardware.

Check the torque of the overhead guard mounting bolts.

page A-4

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Planned Maintenance

Toyota Stand-Up End Control Service Manual

Maintenance Guidelines

Moderate Usage: Every 6 Months or 500 hours; Severe Usage: Every 3 Months or 250 Hours (whichever comes first) Component Battery

Battery Connector

What To Do

Refer to

Check the weight stamped on the battery in the truck against the minimum and maximum allowable weights on the specification tag for the truck. Report any trucks that are running with batteries under the minimum, or over the maximum allowable weight.

Make sure the battery has no more than 0.5 in. (13 mm) free play in any direction.

page 3-2

page 7-91

Inspect all battery connectors and leads for damage and cuts in protective coatings.

Check for voltage and shorts to frame.

page 7-91

Battery Gates

Make sure the battery gates are in place and not damaged.

page 7-93

Brakes/Brake Pads

In the tractor-first direction, check brakes for proper operation.

Visually inspect the friction disc and plates with the brakes released. Minimum thickness of the friction disc is 0.207 in.

(5.3 mm).

The air gap between the armature disc and the brake coil must be 0.012 to 0.018 in. (0.305 to 0.457 mm). Failure to keep the brake shimmed will cause premature wear on the friction disc and plates and excessive motor heat.

page 7-76

Electrical Cables

Inspect all cables for nicks or cuts. Replace any cable that is damaged or shows signs of excessive heat.

Inspect over-the-mast cables for proper tension.

Make sure over-the-mast pulleys spin freely and show no signs or wear.

Control Handle Functions

Operate the lift/lower function. Verify the response is smooth and controllable.

Operate the travel function. Verify that the full range of acceleration is smooth and responsive. Make sure that plugging/Regen is functioning properly.

Look for any play in the center position of the lift or travel.

Operate the Tilt, Sideshift and Optional attachment switches.

Verify they operate the function smoothly and do not stick.

Enter the maintenance mode and test the travel potentiometer, Test A05. Make sure the potentiometer voltage is stable with no voltage fluctuations in the neutral position. If the voltage fluctuates by more than 0.2V in 10 seconds, replace the potentiometer to avoid unscheduled down time. Run the potentiometer all the way up and down the scale to verify smooth voltage changes.

4-6

page 5-15

page 7-37

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Toyota Stand-Up End Control Service Manual

Planned Maintenance Maintenance Guidelines

Component

What To Do

Refer to

Deadman Pedal

The Deadman Pedal must operate smoothly with no binding.

Check proper activation and deactivation of the deadman switch under the pedal.

page 7-43

Horn

Make sure the horn sounds loudly when activated.

page 7-101

Hydraulic Hoses

Inspect all hydraulic hoses for leaks, nicks, cuts, chafing and bulges. Replace bad hoses as soon as possible.

Inspect all fittings for leaks. Repair any leaks immediately.

Inspect over-the-mast hoses for proper tension.

Make sure over-the-mast pulleys spin freely and show no signs of wear.

Hydraulic Reservoir

Check for proper fluid level and the proper fluid for the working environment.

Optional Lights

Make sure all lights function and mountings are secure.

Overhead Guard

Look for any physical damage to the guard. If the overhead guard is structurally damaged, replace the guard.

page 7-20

Switches

Check mast and optional switches for proper operation (if used).

page 7-122

Chassis and Mast

Inspect the mast pivot and telescopic bearings and rollers for damage or wear.

Inspect the outside of the main frame for wear, especially if the truck is used in drive-in racks.

page 7-148

Contactors

Inspect contact tips for burnt or pitted surfaces. Failure to replace the tips may cause surfaces to weld together, causing unscheduled down time.

Check the plunger for smooth operation with no binding. If binding occurs, the truck may exhibit intermittent fault codes.

page 7-84

Drain Holes

Make sure the drain holes are not blocked by any debris.

page 7-126

(beneath deadman pedal and in battery compartment)

Drive Unit

Check for proper fluid level in the drive unit. If the fluid level is low, investigate for leaks and determine causes.

Forks

Inspect forks for modifications, bends, cracks or wear. Check for welding arcs and signs of excessive heat.

page 7-46

NOTE: If any of the imperfections above are found, replace the fork immediately.

Hardware (bolts, nuts, and screws)

Check the tightness of wire and cable connections. This can be done by physically trying to move the connection with your hand.

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page A-4

4-7

Planned Maintenance

Toyota Stand-Up End Control Service Manual

Maintenance Guidelines Component

What To Do

Refer to

Lift Chains

Check for proper adjustment of the chains. Lubricate as required.

Inspect the chains for excessive stretch or wear.

page 7-153

Motors

Visually inspect brushes for excessive heat (discoloration of the pigtails). If excessive heat is evident, inspect the armature circuit for loose connections.

Find the shortest brush in the holder. Remove the brush and check the overall dimension. Inspect the brush for even wear over the full surface of the brush. If the brush is not contacting the complete surface, replace the brushes.

Inspect the brush rigging for damage or loose brush holders.

Ensure that the connections on the brush leads are tight.

Check brush spring tension.

Blow out the inside of the motor with compressed air.

Check the cable lugs to make sure they are tight to the terminal studs. Both the inside and outside nut should be torqued to the values listed on page A-4. Replace any cable that shows signs of excessive heat.

page 7-102

Wheel and Tires

Inspect all wheels and tires for chunking, bond failure, and excessive or uneven wear. Replace any tire exhibiting any of these symptoms.

Check caster wheel bearing for binding or excessive play.

Inspect drive and caster axle for excessive play.

page 7-27

Steerable Wheel Assembly

Inspect the caster wheel axle and bearings for excessive wear.

Inspect the steer chain for proper adjustment. Flex of the chain should be approximately 1/8 in. (3.175 mm).

page 7-31

Lift, Side Shift and Tilt Cylinders

Inspect the condition of the rams for leaking seals, scored pistons and secure mounting.

Check the lift cylinders for any load drift. Use the following specifications and observe the drift over a 10-minute period:

page 7-142

page 7-105 page 7-102

• 7BNCU15: 3.0 in. (76 mm) drift with 3000 lb. pressure • 7BNCU18: 3.5 in. (89 mm) drift with 3500 lb. pressure • 7BNCU20: 4 in. (102 mm) drift with 4000 lb. pressure • 7BNCU25: 5 in. (127 mm) drift with 5000 lb. pressure

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Planned Maintenance Maintenance Guidelines

Component

What To Do

Shorts and Voltage Leaks to Frame

Using a non-flammable cleaner, clean any dirt and oil buildup inside the tractor compartments. This will reduce the chance of intermittent error codes caused by shorts between maintenance intervals. It will also extend the life of cables and harnesses.

Refer to page 5-15

NOTE: Do not use any cleaners or solvents inside motors.

Unplug the battery and check for voltage leaks to frame. If voltage exists, the battery must be cleaned. If cleaning does not remove the voltage to frame, the battery must be serviced by an authorized battery technician.

Run the ground tests as outlined on page 5-15.

Sideshift Carriage

Ensure the cap screws that secure the lower mounting hooks to the carriage bar are tight.

Warning Decals

Replace any warning decals that have become unreadable or are damaged.

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Planned Maintenance

Toyota Stand-Up End Control Service Manual

Maintenance Guidelines

Moderate and Severe Usage: Annually or 1500 hours (whichever comes first) Component

What To Do

Refer to

Hydraulic Reservoir

Change the fluid in the main hydraulic reservoir and install a new fluid filter. Refer to Lubrication Equivalency Chart on page A-2 to assure proper type of fluid for your application.

Pump Couplings

Remove, clean, inspect and repack.

4-10

page 7-126

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Toyota Stand-Up End Control Service Manual

Planned Maintenance Battery Maintenance

Battery Maintenance Charging - General This section gives you only general battery information.

For exact battery charging and maintenance information, read the Battery Instruction Manual and the Battery Charger Instruction Manual.

Inspection Before installing the battery in the truck, inspect the battery for: • Cleanliness • Missing vent caps • Broken or damaged posts • A cracked or damaged case • Corrosion of metal parts • Wetness on the top or sides of the battery case

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Planned Maintenance

Toyota Stand-Up End Control Service Manual

Battery Maintenance

This page intentionally left blank.

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Troubleshooting

Troubleshooting

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5:

5-1

Troubleshooting

Toyota Stand-Up End Control Service Manual

How to Use This Chapter

How to Use This Chapter This chapter is designed to help you troubleshoot possible problems that may affect truck performance.

• When a particular component has been identified as or suspected to be bad, it is recommended that you troubleshoot the wiring from that component back to the Interface Card.

• Conduct any related tests in the truck’s Maintenance Mode to help you make any determinations.

• This truck features electronic devices that can help diagnose a situation. There is a bank of LEDs located on the Translator Card assembly that can be used to troubleshoot a condition.

• Always take note of any fault codes that appear on the Operator Display. Gather as much information as you can at the time of the Fault Code.

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Toyota Stand-Up End Control Service Manual

Troubleshooting Start-up

Start-up Waiting For Precharge Message What is Precharge?

Precharge is a method for powering up the traction power amplifiers in a controlled manner. The circuits for doing this are located within the amplifiers themselves.

The amplifiers have large banks of capacitors to prevent voltage spikes. When the truck key switch is turned OFF, these capacitors are discharged slowly to near 0V. If the contactor is immediately closed with these capacitors discharged, very high currents would result.

This could damage the amplifiers and/or the traction fuse and TPC Contactor.

The precharge circuits in the amplifiers will normally begin to charge up these capacitor banks as soon as the truck key switch is closed, and they are normally charged in just a few seconds.

You may encounter a “Waiting For Precharge” message during the start-up of this truck. If this occurs, it means that the voltage on the output side of the TPC contactor has not reached at least 31V. This is necessary before the power amplifiers can be started and the truck’s SelfTest can be completed.

The “Waiting For Precharge” message occurs for the following reasons: 1. The battery voltage is too low.

2. There is an internal short to ground in one or both of the power amplifiers.

3. There is an internal short to ground in the truck wiring.

4. The precharge circuits in one or both of the amplifiers are bad.

5. The sense line to the TPC is bad.

6. The Translator Card is bad.

7. The Interface Card is bad.

8. The key switch has been turned OFF and ON too frequently, resulting in overheating of the precharge circuits and causing precharge to be very slow.

00700-CL1SM-3 Issued: 6/1/04

Troubleshooting 1. Check to see if battery voltage is at least 32V when under no load.

2. Check for precharge with digital voltmeter by measuring the voltage at the output side of the TPC contactor with reference to TP4 (B-). When the key switch is turned ON, the voltage must climb higher than 31V and eventually reach within 1V of battery positive (B+).

NOTE: When the key switch is turned OFF, this voltage will slowly drop to 0V. Use Analog Test A08 in Maintenance Mode to view this voltage.

3. If the voltage at the output of the TPC contactor does not reach 31V: a. Verify that power is reaching the amplifiers by checking for B+ at the following points: • JPF5-1 or JPF5-2 on the Contactor Fuse Panel • JPX1-1 on the Translator Card • JPX2-1 on the Translator Card • JPX3-10 on the Translator Card • JPTL1-1 on the left power amplifier • JPTR1-1 on the right power amplifier 4. Use the following process of elimination to isolate the problem: a. Turn the key switch OFF and carefully disconnect the B+ power cable to one of the two amplifiers. Recheck to see if precharge will occur. If it will, the amplifier that has been disconnected is bad and must be replaced.

NOTE: Disconnect one of the power cables to the amplifiers at the TPC contactor and turn on the truck. Both amplifiers should precharge independently. If one does not, then that amplifier is bad. b. Reconnect the first amplifier and disconnect the B+ power cable to the remaining amplifier. If precharge will now occur, then the second amplifier is bad and must be replaced.

5-3

Troubleshooting

Toyota Stand-Up End Control Service Manual

Start-up c. Disconnect the B+ power cable from the TPC. Leave the sense lead connected at TPC1. Manually depress the TPC contactor tips. If the “Waiting For Precharge” message goes away and a Code 44 appears, the Interface Card is working correctly.

If the “Waiting For Precharge” message does not go away, check continuity of the wires between TPC1 and JPC8-8 (FU2_Sense on the Interface Card). d. Turn key switch OFF and disconnect battery. Reconnect the left amplifier power cable. Reconnect the battery and restart the truck. If the “Waiting For Precharge” message reappears, the left amplifier is bad. e. Turn key switch OFF and disconnect battery. Reconnect the right amplifier power cable. Reconnect the battery and restart the truck. If the “Waiting For Precharge” message reappears, the right amplifier is bad.

5. If the voltage at the output of the TPC does reach 31V: a. Perform a continuity check from the output side of the TPC contactor to JPC8-8 on the Interface Card and/or measure the voltage at JPC8-8 with respect to B-. If there is no continuity and/or voltage present, repair the truck’s wiring harness. b. Read the voltage at the output of the TPC contactor using the Analog input test A08 in Maintenance Mode. If the voltage read does not correspond with the voltage measured at JPC8-8, replace the Interface Card.

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Toyota Stand-Up End Control Service Manual

Troubleshooting Power Amplifier Fault Codes

Power Amplifier Fault Codes The truck will return a fault code to the operator display when an error has been detected in the lift truck. More specifically, the left and right traction power amplifiers may return error codes, 2M and HK, which could indicate a number of possible problems. Use the following procedures to help diagnose and troubleshoot these particular power amplifier codes.

What these error codes mean: Error code “2M” means that a problem has been detected with the Left Traction amplifier, and a code “HK” means that a problem has been detected with the Right Traction amplifier. The Left Traction amplifier is always checked first, so any error condition which affects both amplifiers will result in the display of the “2M” error code.

How these codes are detected: NOTE: TPC_x is a reference to either the right or left power amplifier. Depending on which amplifier you are working on, substitute “L” or “R” for the “x”.

Detection of these error codes is centered around the TPC_x signal lines from each of the amplifiers to the Translator Card. These lines are used by the amplifiers to request that the TPC contactor be de-energized. The signal line to the left traction amplifier is named TPC_L and connects to the Translator Card at JPX2-13. The signal line to the right traction amplifier is named TPC_R and connects to the Translator Card at JPX1-13.

2. One or both amplifiers turn off its TPC_x output when the amplifier is supposed to be on.

3. One or both of the TPC_x lines stay on after the amplifiers are told to turn off.

What can cause these error codes: 1. The amplifier has an internal failure.

2. The TPC_x signal line from the amplifier to the Translator Card is open or shorted to battery minus.

NOTE: KEY_ON and EPO signals are generated by the Translator Card when the TPC contactor is energized and are not connected to the truck key switch or EPO switch in any way.

3. The KEY_ON signal line from the Translator to one or both of the amplifiers is open or shorted to battery minus.

4. The EPO output signal line from the Translator Card to one or both of the amplifiers is open or shorted to battery minus.

5. The Translator Card has failed and cannot read these inputs properly.

6. The power cables from the TPC contactor to one or both of the amplifiers is open.

7. JPC8-8 (FU2_Sense) is shorted to battery positive, resulting in the truck trying to start the amplifiers when the amplifier capacitor banks are not properly charged.

8. Battery power is not being provided to an amplifier at JPTL1-1 or JPTR1-1, preventing the amplifier from turning on.

A fault code will be detected when any of the following conditions occur: 1. An amplifier refuses to turn on its TPC_x output when the amplifier is told to turn on.

NOTE: The amplifiers are told to turn on when both the KEY and EPO signal outputs from the Translator Card are turned on.

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Troubleshooting

Toyota Stand-Up End Control Service Manual

Power Amplifier Fault Codes

Power Amplifier Start-up Procedure: The following is a description of the sequence of events which occurs regarding the power amplifiers when the truck key switch is first turned ON. 1. The truck must complete a series of internal checks before any tests of the power amplifiers are started.

2. Once the internal checks are complete, the voltage at the output side of the TPC contactor must reach at least 32V before the amplifiers can be turned on. This is referred to as “precharging” because the amplifiers have large capacitor banks which must be charged prior to closing the TPC contactor, or they may be damaged. This precharging is done by the amplifiers themselves and starts when the truck key switch is turned ON. If precharging does not happen within 5 seconds, a “Waiting For Precharge” message will be displayed.

Note that since both amplifiers are connected in parallel, one amplifier can precharge both amplifier's capacitor banks.

See Waiting For Precharge Message on page 5-3.

3. Once precharge occurs, the amplifiers will be run briefly with the TPC contactor open in order to verify that the TPC contactor is not welded: a. First, the amplifiers are activated by turning on the KEY and EPO outputs from the Translator card to the amplifiers. There are LED indicators on the Translator Card which illuminate when these lines are turned on. See Figure 5-2. The amplifiers must respond to this by turning on their respective TPC_x output (TPC_L for left amplifier, TPC_R for right amplifier).

NOTE: KEY_ON and EPO signals are generated by the Translator Card when the TPC contactor is energized and are not connected to the truck key switch or EPO switch in any way. If an amplifier fails to turn on its TPC_x output within 1 second, an error code “2M” and/or

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“HK” will be displayed on the operator display. b. Once both amplifiers have turned on their TPC_x outputs, the DM (deadman) output from the Translator Card will be turned on next. This signal also has an LED indicator. c. Next, one and only one direction command signal line will be turned on for each amplifier. These direction signals each have an LED indicator and are named as follows: • FWD_L - Forward command to the left power amplifier • REV_L - Reverse command to the left power amplifier • FWD_R - Forward command to the right power amplifier • REV_R - Reverse command to the right power amplifier The left forward direction line will always be turned on, but the right amplifier direction line will changed depending on how the steerable wheel is turned: If the wheel is close to straight, the right amplifier will be set to drive reverse. If the wheel is not close to straight, the right amplifier will be set to drive forward. This will cause the drive wheels to always drive against each other during SelfTest. d. Once the direction lines have been set, a small throttle command is sent to each amplifier. The amplifiers must then pull down the TPC contactor output voltage down sufficiently to verify that the TPC contactor is open. If this does not happen, a fault code “44” will be displayed on the operator display. e. The amplifiers are shut down when the TPC contactor output voltage drops down sufficiently or when 0.6 seconds elapses, whichever comes first.

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Toyota Stand-Up End Control Service Manual

Troubleshooting Power Amplifier Fault Codes

4. Once the TPC contactor welded test is complete, the truck must log on to each of the amplifiers using the communication lines TXD_L, RXD_L, TXD_R, and RXD_R. The TXD lines are transmit lines from the Translator Card, and the RXD lines are receive lines to the Translator Card.

Logging on involves sending several bytes of data to each amp on the TXD lines, followed by having each of these bytes echoed back to the Translator Card on the RXD lines. A failure during this procedure will produce a “5F” and/or “5G” error code to be displayed on the operator display.

The procedure for restarting the amplifiers after they have been shutdown is similar in that many of the same steps are taken (in the following sequence). When the Deadman pedal is depressed: 1. Precharge must have occurred or a “Waiting For Precharge” message will be displayed.

2. The KEY_ON and EPO outputs are turned on.

3. The power amplifiers must turn on their TPC_x outputs, 4. The DEADMAN output will be turned on, 5. When the control handle is moved, the appropriate direction lines will be turned on.

6. The throttle commands will be sent to the amplifiers.

NOTE: This sequence of events can be observed by viewing the LED indicators on the Translator Card, however the mounting bracket must be removed from under the Interface Card assembly to accomplish this. See Translator Card on page 7-90.

Troubleshooting Procedure: 1. Verify that the Translator Card can read the TPC_x inputs properly: a. Enter Maintenance Mode and select either Test I27 for the left amplifier or I28 for the right amplifier TPC_x input test. b. Disconnect the harness to the power amp at JPX1 for the left amplifier or JPX2 for the right amplifier. The TPC_x input test must indicate OFF. If not, replace the Translator Card. c. Carefully connect pin 13 of connector PX1 or PX2 on the Translator Card to battery negative using a jumper clip.

The TPC_x input test must now indicate ON. If not, replace the Translator Card.

Remove the jumper clip. d. Reconnect the harness to the power amp and verify that the TPC_x input test indicates OFF (Note that the KEY_ON and EPO outputs from the Translator should be off when in the TPC_x Maintenance Mode tests). If not, there is a problem in the harness to the amplifier and/or the amplifier itself.

2. Verify the harness to the power amp: a. Check for continuity of the TPC_x line to the affected amplifier per the truck schematic. b. Disconnect the connector JPTL1 for the left amplifier or JPTR1 for the right amplifier, and verify that the TPC_x input test indicates OFF. If not, the harness has a short to battery minus.

3. Test the amplifier TPC_x output driver: a. Disconnect the connector JPX1 for the left amplifier or JPX2 for the right amplifier. This will shut down the power amplifier. b. Measure the resistance from JX1-13 and/or JX2-13 to battery minus. This resistance must be greater than 20K ohms. If not, the amplifier has failed.

4. Monitor the operation of the TPC_x line:

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Troubleshooting

Toyota Stand-Up End Control Service Manual

Power Amplifier Fault Codes a. Measure the voltage on the TPC_x line to the affected amplifier using a Digital Volt Meter (DVM) referenced to battery minus: â&#x20AC;˘ When the KEY_ON and EPO signal lines are off, the TPC_x line must be at least 8V with respect to battery minus. If not, replace the amplifier. â&#x20AC;˘ When the KEY_ON and EPO signal lines are on, the TPC_x line must be no more than 2V with respect to battery minus. If not, replace the amplifier.

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00700-CL1SM-3 Issued: 6/1/04

Toyota Stand-Up End Control Service Manual

Troubleshooting Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines

• Whenever measuring resistance, turn the key switch OFF and disconnect the battery connector. Battery current can damage an ohmmeter.

Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. See Battery Exterior Cleaning on page 7-93.

! WARNING Jack and block the lift truck so that the drive tires are off the floor whenever a troubleshooting procedure requires turning key switch S1 ON.

! CAUTION Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter.

• Save time and trouble by looking for simple causes first.

• For information on electrical connector location and function, see Table 5-1, Electrical Connector Locator Chart on page 5-10.

• Use a DVM such as a Fluke meter for all measurements. Analog meters can give inaccurate readings and load down sensitive electronic circuits enough to cause failure. Make sure meter cables are connected to the proper meter jacks and that proper function and scale are selected.

• Printed circuit boards have been conformal coated. You may need to clean test points in order to obtain accurate readings.

• When measuring voltage, connect the positive meter lead to the connector or probe point marked (+) in the test. Connect the negative meter lead to the connector or probe point marked (-).

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