DOWNLOAD PDF Toyota Forklift E Series 6BNCUE-18 Service Manual

TOYOTA Electric Stand Up “E” Series

Table of Contents

TABLE OF CONTENTS FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.i Battery Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Battery Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Rear Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Control Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Operator Compartment Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Floor Mat / Brake Pedal Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 High Back Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.i Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Changing Drive Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 V-Ring Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Drive Wheel Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Drive Unit Rebuild - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Drive Unit Rebuild - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Carrier Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.i Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Disc Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.i Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Pump and Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Steer Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Steer Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Steer Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Steer Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Steer Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Changing Steer Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Steer Position Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.i Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 10/01/00

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TOYOTA Electric Stand Up “E” Series

Table of Contents

Control Handle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Battery Disconnect Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Horn Button Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Lift & Travel Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Control Handle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Light and Auxiliary Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 LIFT AND AUXILIARY HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.i Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Lift Pump & Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Lift Pump Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Valve Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Relief Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 ELEVATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.i Mast Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Center (Free-Lift) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Outer Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.i Capacitor Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 System Controller / Operator Display Box . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Operator Display Board / Memory Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Traction Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Contactor Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Main Power Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Lift and Steer Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Amplifier Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 PROGRAMMING AND DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS.1

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TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Battery Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Battery Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Overhead Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Rear Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Control Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Operator Compartment Pads Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Floor Mat / Brake Pedal Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 High Back Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

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1.i

Frame

TOYOTA Electric Stand Up “E” Series

Frame

Battery Rollers There are five battery rollers in the battery compartment. They can be removed and disassembled for cleaning or repair as shown in Figure 1.1.

The battery rollers must be installed in the compartment in the pattern shown in Figure 1.2.

FIGURE 1.2 - Placement of Battery Rollers WARNING Do not operate the truck with a battery gate removed - the battery could slide out of the compartment and could cause damage and/or personal injury.

NOTE The battery must not be able to slide more than 1/2” in any horizontal direction. If necessary, install spacers between the battery and the frame to achieve this specification.

Overhead Guard NOTE Any modifications to the overhead guard must be approved by the manufacturer.

Removal 1 Shaft 2 O-Ring 3 Roller

1. Disconnect the battery and discharge the capacitors. Remove the front cover and top cover. Disconnect any accessory wiring on the overhead guard (such as work lights or flashing lights).

4 Bushing 5 Flat Washer

FIGURE 1.1 - Disassembly of Battery Rollers

2. Attach a lifting device to the overhead guard and take up any slack.

Battery Gates

3. Remove the overhead guard mounting screws from the front crossbar and rear post.

1. To remove a battery gate, slide the gate up so that the rear tab lines up with the cutout in the frame. Rotate the rear of the gate away from the frame, and remove the gate.

4. Use the lifting device to raise the overhead guard off the truck. Do not allow the posts to swing and damage any components of the truck.

2. To install a battery gate, insert the front tab of the gate into the slot in the frame. Line up the rear tab of the gate with the cutout in the frame. Rotate the gate into the cutout and slide the gate all the way down.

Replacement 1. Use a lifting device to position the overhead guard directly over the truck.

2. Do not let the overhead guard legs swing and damage components of the truck. Slowly lower the overhead guard so that the

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TOYOTA Electric Stand Up “E” Series

Frame

mounting holes in the overhead guard line up with the mounting holes in the frame. Install the mounting screws and torque to 120ft.-lbs.

Install the rear post mounting screw and torque to 120 ft-lbs.

4. Once the top of the cover is released, lift upward on the cover and remove from the truck.

3. Reconnect any accessory wiring. Install the top cover and front cover.

1. Place the lower edge of the front cover into the support channels.

REAR POST

2. Gently press the upper portion of the front cover into place until the latch clicks into position.

Replacement

3. Connect the battery.

Removal 1. Disconnect the battery and discharge the capacitors.

Remove the top cover.

Disconnect any accessory wiring through the rear post (such as flashing light).

TOP COVER Removal

2. Attach a lifting device to the rear post and take up any slack.

NOTE The top cover is held in place with 7 frame mounted spring-type retaining clips.

This cover does not require any tools to remove.

Care must be used when removing this cover to avoid possible breakage.

3. Remove the mounting screws from the lower end of the rear post.

4. Remove the mounting screw at the top of the rear post. Lower the post out of the overhead guard, the nraise it out of the truck. Do not allow the post to swing and damage components in the truck.

1. Disconnect the battery and discharge the capacitors.

2. Starting at the corner where the top cover meets the control cover in the operator compartment, gently pull up until the first spring clips release the top cover.

Replacement 1. Use a lifting device to position the post in the truck. Install, but do not tighten the mounting screw at the top of the post.

3. As each spring clip on the left side releases the top cover, move the handhold as close as possible to the next spring clip. Gently pull up until the cover is released from all of the spring clips on the left side.

2. Install the mounting screws at the bottom of the rear post. Torque to 120 lb-ft. Torque the upper screw to 120 lb-ft.

3. Connect any accessory wiring. Install the top cover and connect the battery.

4. To release the right side of the cover, move the battery disconnect forward, grasp the rear edge of the opening, and gently pull upward.

5. Once the top cover is released from the spring clips, lift the rear edge of the cover up until it is clear of the rear leg of the overhead guard.

Move the entire cover toward the rear of the truck until the top cover is free from the front clip and the overhead guard.

FRONT COVER Removal 1. Tilt the mast to the full forward position.

2. Disconnect the battery and discharge the capacitors.

6. Remove the cover from the truck.

3. The front cover is held by a spring clip that engages the overhead guard crossbar. Pull the front cover forward, away from the front of the truck.

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Replacement 1. Tilt the top cover so that the front edge of the cover is lower than the rear edge and slide into place on the truck.

1.2

TOYOTA Electric Stand Up “E” Series 2. Align the cutouts on the front edge of the top cover with the front posts of the overhead guard. Move the front edge of the top cover into place. Lower the rear of the top cover into place.

Frame

the frame of the truck. If the fastener does come loose, clean the area with isopropyl alcohol and reattach it with cyanoacrylate adhesive (“super glue”).

1. Remove the top cover.

3. Align the cut-outs in the lip of the cover with the spring clips on the truck frame.

2. Grasp the outside edge of the pad and carefully separate the pad from the mating portion of the fastener attached to the frame of the truck.

4. Press downward at each spring clip until the cover is secured.

5. Connect the battery.

3. Rotate the pad outward until the remainder of the fasteners release.

4. Remove the pad.

CONTROL COVER Replacement Removal NOTE Refer to PADS AND PLASTIC in the FRAME section of the PARTS Manual for location of operator compartment pads.

1. Disconnect the battery and discharge the capacitors.

2. Remove the top cover (refer to TOP COVER Removal procedure in this section).

1. Align the pad so the halves of the fasteners meet.

3. Remove the steering tiller.

4. Remove the seven screws securing the control cover.

2. Firmly press the pad into place.

3. Gently pull on the outside edges of the pad to verify the attachment.

5. Lift the control cover over the control handle and remove it from the truck.

4. Install the top cover.

Replacement 1. Place the control cover into position over the control handle and start the seven screws - do not tighten.

FLOOR MAT / BRAKE PEDAL PAD NOTE The floor mat in the operator compartment is not glued down. However, normal servicing of the truck does not require the removal of the floor mat.

2. Install the steering tiller.

3. Position the cover so there is no contact with the control handle boot or steer tiller, then tighten the seven screws.

4. Replace the top cover (refer to TOP COVER Replacement procedure in this section).

Removal

5. Connect the battery.

NOTE The brake pedal pad is secured in place with general purpose RTV silicone adhesive. The brake pedal pad will be damaged when removed.

It is recommended that a replacement pad be available prior to removal of the old pad.

OPERATOR COMPARTMENT PADS Removal NOTE The pads in the operator compartment are secured in place with dual-lock fasteners.

When removing the pads, use care to avoid detaching the fastener from either the pad or REV W1 11/02/99

1. Using an appropriate scraper, pry up the outside edge of the pad.

2. Carefully peel the pad away from the brake pedal.

1.3

TOYOTA Electric Stand Up “E” Series 3. Scrape the pedal surface to remove as much of the old pad material as possible.

4. Clean any remaining residue from the pedal with an appropriate solvent.

Replacement 1. On a properly prepared surface, apply a thin film of adhesive to the brake pedal. (Follow the manufacturer's instructions on the label of the adhesive.)

2. Align the brake pedal pad with the brake pedal.

3. Firmly press the pad into position.

4. Allow the adhesive to cure per the manufacturer's recommendations.

HIGH BACK PAD Removal 1. Remove the top cover (refer to TOP COVER Removal procedure in this section).

2. Remove the two cap screws and brackets on the bottom of the pad.

3. Lift the pad off the upper bracket and remove it from the truck.

Replacement 1. Hook the top of the pad over the bracket at the top of the frame.

2. Align the brackets with the lower brackets on the truck frame and install flat washers, lock washers and cap screws through each bracket into the pad. Tighten the cap screws.

3. Install the top cover.

DECALS Make sure all safety decals are in place and readable. Replace worn or missing decals. Refer to the PARTS Manual for decal location drawings.

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1.4

Frame

TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Drive Train Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Drive Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Gearbox Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Drive Wheel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Changing Drive Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 V-Ring Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Drive Wheel Spindle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Drive Unit Rebuild - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Drive Unit Rebuild - Assembly Pinion Gear to Motor Endbell Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Gear Housing to Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Carrier to Gear Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Carrier Rebuild Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

04/05/00

2.i

Drive

TOYOTA Electric Stand Up “E” Series Drive Train Description This lift truck is equipped with dual independent drive trains. Each drive train consists of a drive unit (drive motor and gearbox), and a drive wheel.

Traction drive is transmitted from the drive motor to the gearbox through a pinion gear driven by the motor armature shaft. From the gearbox, the traction drive is transmitted to the drive wheel by a pinion gear on the output end of the gearbox which meshes with a ring gear mounted on the inside of the drive wheel. The drive wheel rotates on a spindle on the frame of the truck.

Each drive train is independently controlled by its own traction amplifier. This allows the truck to monitor and control the power output from each of the drive units, improving the maneuverability of the truck in tight areas. During turns, the inside drive motor decreases speed to improve the turning radius. In addition, each drive motor is equipped with a disc-type brake to ensure positive emergency stopping.

Normal slowing or deceleration is accomplished through "plugging" of the motors.

NOTE Specialized tools, fixtures, and training are required to service any part of the drive unit assembly.

FIGURE 2.1 - DRIVE UNIT

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2.1

Drive

TOYOTA Electric Stand Up “E” Series

a) Lubricate the drive pinion and outer bearing (use a needle nose grease gun to grease the outer bearing). b) Connect a lifting device to the drive unit. c) Lift the drive unit into position in front of the truck. d) Carefully rotate the gearbox so the pinion gear enters the opening in the frame. e) Rotate the drive wheel to engage the pinion with the ring gear and slide the gearbox pilot into the opening until the flange is against the frame.

Drive Unit Removal 1. Disconnect the battery and discharge the capacitors.

2. Remove the mast and front cover (refer to Mast Removal procedure in the ELEVATING section).

3. Put the truck on blocks or stands so the drive wheels are completely off the ground.

4. Disconnect the power cables from the motor, noting their location for correct replacement.

5. Remove the screws securing the drive unit to the frame.

2. Install the disc brake unit (refer to Brake Replacement).

6. Tilt the drive unit forward so the motor is vertical.

NOTE The drive unit is mounted to the frame with four screws. Three screws are 1-1/2" long and one is 1-1/4" long. The 1-1/4" screw goes in the lower front hole (refer to DRIVE TRAIN in the PARTS manual for an illustration).

7. Remove the disc brake unit from the motor (refer to Brake Removal in the BRAKES section).

8. Remove the drive unit:

3. Tilt the drive unit back to line up the mounting holes. Install the four mounting screws and torque to 80 lb-ft.

CAUTION Ensure the lifting device has adequate capacity to handle the weight of the drive unit (approximately 140 lbs).

4. Connect the power cables to the correct terminals on the motor. Plug in the brake unit.

a) Attach a lifting device to the drive unit for support and remove the slack. b) Move the drive unit toward the center of the truck, being careful not to damage the hydraulic connection block in the center of the frame. c) Rotate the drive unit to clear the pinion gear from the frame of the truck. Use caution when rotating the drive unit to prevent the pinion gear from striking the frame of the truck. d) Remove the drive unit from the truck.

5. Ensure the gearbox is filled with the proper lubricant (refer to GEARBOX OIL CHANGE procedure in this section).

6. Before lowering the truck off the blocks or stands, connect the battery and test the drive unit in Diagnostic Output Test 17 or 18 to confirm proper operation.

7. Install the mast (refer to Mast Replacement procedure in the ELEVATING section).

8. Install the front cover.

9. Place the drive unit on a clean, secure work surface.

Replacement 1. Install the drive unit into the truck: CAUTION Ensure the lifting device has adequate capacity to handle the weight of the drive unit (approximately 140 lbs).

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Drive

2.2

TOYOTA Electric Stand Up “E” Series

NOTE If the unit has brush wear indicators, be sure to install the new brush with the indicator wire in the same brush holder and route the indicator wire clear of the rotating armature.

Drive Motor NOTE Specialized tools, fixtures, and training are required to service the drive motor. Refer to DRIVE UNIT REBUILD in this section.

8. Rotate the top endbell housing to gain access to the remaining brushes. When all eight brushes and springs have been replaced, return the endbell to its original position (armature studs forward).

Brush Replacement

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Drive

NOTE Replace all the brushes in one motor as a set.

Units with brush wear indicators will have one brush with an indicator wire. Note the position of this brush for reassembly.

9. Reverse Steps 3 through 6 for reassembly.

10. Install the top cover and front cover. Connect the battery and test the truck for proper operation.

1. Tilt the mast to the full forward position.

2. Disconnect the battery and discharge the capacitors. Remove the top cover and front cover.

3. Remove the brake unit from one motor (refer to the BRAKES Section).

4. Remove the armature cables from the motor, noting their location for correct replacement.

5. Disconnect and remove the cooling fan from the motor.

6. Remove the four 1/4” screws holding the upper endbell to the drive motor.

FIGURE 2.3 - GEARBOX

7. Replace one brush and spring at a time.

Insert the new brush into the brush holder in the correct orientation (see Fig. 2.2). Install the brush spring, insuring it is in the proper position. Tighten the brush lead screw to 15 -18 in.-lbs.

Gearbox NOTE Specialized tools, fixtures, and training are required to service any part of the gearbox.

Refer to DRIVE UNIT REBUILD in this section.

Oil Change

CORRECT INCORRECT

1. Disconnect the battery, discharge the capacitors, and block the wheels of the truck to prevent movement.

2. Place a clean drain pan under the appropriate drive unit.

3. Remove the fill plug from the front of the gearbox.

COMMUTATOR

4. Remove the magnetic drain plug from the bottom of the gearbox and allow the oil to drain completely. Inspect the magnetic plug and the used oil for excessive metal shavings.

FIGURE 2.2 - BRUSH ORIENTATION

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2.3

TOYOTA Electric Stand Up “E” Series

Drive

15 V-Ring Seal 16 Bearing 17 Tab Lock Washer 18 Lock Nut 19 Wheel Cover 20 Screw

FIGURE 2.4 - DRIVE WHEEL INSTALLATION 5. Clean the threads of the drain plug, apply pipe thread sealant to the plug and reinstall the magnetic drain plug.

Drive Wheel Assembly Removal

6. Remove the fluid level plug from the side of the gearbox.

Special Tools: Drive Wheel Lock nut Tool, P/N 00593-11560-71

7. Fill the gearbox through the fill plug hole, with Mobil SHC 50 Synthetic Gear Lubricant or equivalent (SAE 80/90 Gear Oil may be substituted if the truck is not used in Freezer applications) until fluid level is even with the bottom of the fluid level plug hole (approximately 20 oz. for each gearbox).

1. Disconnect the battery and discharge the capacitors.

WARNING Park the truck on a level surface. Block the rear wheel to prevent the truck from rolling.

8. Clean the old sealant from the threads of the fluid level plug, apply new pipe thread sealant to the plug and install the plug.

2. Lift the front of the truck and place it on blocks.

3. Remove the drive wheel cover.

9. Clean the threads of the fill plug, apply pipe thread sealant, and install the fill plug.

4. Bend the tabs of the lock washer out of the slots in the spindle lock nut.

10. Remove the blocks from the wheels and connect the battery. Test drive the truck and inspect for leaks.

5. Use the lock nut tool to remove the lock nut from the spindle. Remove the lock washer with the lock nut.

CAUTION The drive wheel assembly weighs 85 pounds or more.

6. Remove the drive wheel assembly from the spindle. The outer bearing will come off with the wheel.

7. With the drive wheel off, the v-ring seal can be inspected or replaced. Remove the v-ring,

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2.4

TOYOTA Electric Stand Up “E” Series clean the groove, then apply a thin film of the same lubricant used for the final drive gears (Mobilith SHC 007 Synthetic Grease NLGI 00 or equivalent) to the v-ring seal.

Drive

Changing Drive Tires Special Tools: Tire Changing Fixture (P/N 00593-10658-71), Tire Press (40 ton)

Replacement

NOTE There is a flange at the back of the drive wheel that can be broken if the wheel is improperly pressed.

NOTE Before installing the drive wheel assembly on the truck, the outer drive pinion bearing, and wheel bearings must be lubricated with Mobilith SHC 220 Synthetic Grease NLGI 2 or equivalent. Use a needle tipped grease gun to lube the outer drive pinion bearing with this same grease. Lubricate the final drive gears with Mobilith SHC 007 Synthetic Grease NLGI 00 or equivalent.

1. Remove the drive wheel assembly (refer to procedure in this section).

2. Place the larger ring of the tire changing fixture on the press table. Place the wheel and tire, ring gear down, on top of the ring, making sure the ring does not touch the wheel. Center the smaller ring on top of the wheel. Press the wheel out of the tire.

NOTE DO NOT remove the ring gear from the inside of the drive wheel. The ring gear is not available as a separate part. If the ring gear is damaged, replace the drive wheel assembly.

NOTE When replacing the drive tire, make sure the composition and size are such that maneuverability and capacity are maintained.

3. Place the new tire on the press table. Align the wheel on top of the tire with the ring gear up. Press the wheel into the tire.

1. Pack both wheel bearings and place the inner bearing on the spindle. Set the drive wheel onto the spindle. Rotate the drive wheel so the ring gear teeth mesh with the pinion gear teeth, then push the drive wheel completely onto the spindle.

4. Install the drive wheel assembly.

2. Install the outer bearing. Line up the inner tab of a new lock washer with the slot in the spindle and install.

V-Ring Seal See Drive Wheel Removal.

3. Carefully thread the lock nut onto the spindle (beveled side toward the wheel). Seat the bearings by tightening the nut to 60 lb-ft.

4. Back the lock nut off until a tab of the lock washer can be bent into the lock nut.

5. Fasten the wheel cover onto the drive wheel.

6. Lower the truck off the blocks or stands and remove the rear wheel blocks. Connect the battery and test drive the truck for proper operation.

NOTE If the wheel bearings are not properly adjusted, the drive wheel may lock up in one direction.

FIGURE 2.5 - CHANGING DRIVE TIRES

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2.5

TOYOTA Electric Stand Up “E” Series

Drive

Drive Wheel Spindle Removal 1. Remove the drive wheel (refer to the procedure in this section).

2. Remove the screws attaching the spindle to the frame. The spindle is very heavy. DO NOT let the spindle drop and damage the threads or the bearing surfaces.

Replacement 1. Clean old thread locking compound and oil from the holes and bolts before reassembly.

2. Align the cutout in the spindle with the hole in the frame. Insert two screws to keep the spindle in place.

3. Install the remaining screws and lock washers with a small amount of thread lock compound.

Tighten to 80 lb-ft.

4. Remove the first two screws, apply thread lock compound, and reinstall with lock washers. Tighten to 80 lb-ft.

5. Install the drive wheel.

6. Test drive the truck for proper operation.

FIGURE 2.6 - DRIVE UNIT ASSEMBLY 12/20/99

2.6

TOYOTA Electric Stand Up “E” Series

Drive

Drive Unit Rebuild - Disassembly 1. Remove the drive unit from the truck.

CAUTION DO NOT pry the sections apart - this may damage the machined surfaces. If necessary, use a rubber mallet to separate the sections.

2. Remove the four nylon lock nuts (Figure 2.6 Item 14) and separate the gearbox from the motor. Note the thickness of the shim package.

3. Remove the six screws (Figure 2.6 Item 26) and separate the carrier from the housing.

Note the thickness of the old shim package, then discard.

4. If necessary, remove the bottom endbell (including the pinion gear) from the motor.

There may be shim material around the motor shaft in the pinion gear.

5. Remove the O-ring (Figure 2.6 Item 12) and discard.

6. To disassemble pinion: a. Loosen the screw on the side of the clamp nut (Figure 2.6 Item 2) and remove the clamp nut using the pinion locknut wrench (P/N 00593-11952-71) and 3/8” drive pinion wrench (P/N 00593-11953-71).

Figure 2.7- Pinion Gear to Endbell Assembly

b. The spacer (Fig. 2.6 Item 3) and bearings (Fig. 2.6 Item 5) are pressed onto the pinion gear. Carefully press the pinion gear out of the endbell. Press the lower bearing off the pinion gear. Remove the upper seal to remove the upper bearing from the endbell.

1. Refer to Figure 2.7 to assemble the pinion gear to the motor endbell:

c.

must be cleaned only by using a soft cloth and mild, non-abrasive cleaning solvent.

a. Install the lower seal (lip down) and the lower bearing cup. b. Pack the upper bearing with Mobilith SHC 220 synthetic grease (or equivalent) and lubricate the lip of the lower seal. Press the lower bearing all the way onto the pinion using the pinion bearing press die (P/N 00593-11954-71).

To replace the lower seal, press both the seal and the upper bearing cup out together.

c.

Drive Unit Rebuild - Assembly Pinion Gear to Motor Endbell Assembly

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d. Use a hand press and the pinion bearing press die (P/N 00593-11954-71) to press the upper bearing and spacer onto the pinion shaft. Rotate the endbell housing while pressing. Stop pressing when slight drag can be felt. Fill the upper bearing cavity with Mobilith SHC 220 synthetic grease (or equivalent), then install the

NOTE Before assembling the drive unit, all components and machined surfaces must be thoroughly cleaned of any dirt, grime, gasket compound, etc. Machined surfaces

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Cover the threads on the pinion to prevent damaging the seal. Slide the pinion through the endbell and remove the thread covering.

2.7

TOYOTA Electric Stand Up “E” Series upper seal. Install the clamp nut (Fig. 2.7, Item 2) and torque the screw in the side of the clamp nut to 70 in-lb.

Drive

RIGHT

LEFT

NOTE Tightening the screw in the clamp nut will increase the turning torque on the pinion.

Always measure the turning torque with the clamp nut installed and the locking screw on the side tightened. e. Measure the turning torque on the pinion using the 1/4” drive pinion wrench (P/N 00593-11955-71) and a torque wrench. The turning torque should be 13-17 in.-lbs. If the turning torque is greater, loosen the clamp nut and make slight adjustments with a hand press on the pinion. If the turning torque is less, slight adjustment can be made by tightening the clamp nut, or remove the clamp nut and make slight adjustment with a hand press on the spacer.

Figure 2.8 - Drive unit orientation.

Use Procedure 2 when the number on the end of the pinion is illegible or there is no number.

D + 2.061 - C = Shim Package Refer to Fig. 2.9 Procedure 2 A is the distance from the back surface of the pinion gear to the mounting face of the motor Measure using the Pinion Height Dial Indicator (P/N 00593-11729-71) zeroed at 1.000”. To get the correct distance, measure to the top of the bearing , not to the endbell casting surface. The number should be around 1.40”

2. Apply anti-seize compound to the motor shaft spline. Attach the endbell to the motor. If shim stock was removed during during disassembly, replace it only if using the same motor.

3. Install a new O-ring (Fig 2.6, Item 12) on the motor pilot flange.

B is the distance from the back face of the pinion gear to the theoretical center of the matching ring gear. This number is etched on the end of the pinion gear. If this number is not legible or there is no number, use Procedure 2.

Gear Housing to Motor Assembly NOTE Before assembling the gear housing to the motor, you must first determine whether you are to build a left or a right drive unit. As an assembler holds a drive unit with the brake end of the motor up and the terminal lugs pointing forward, a right drive unit would be assembled with the gearbox pointing to the right; a left drive unit would be assembled with the gearbox pointing to the left (see Fig. 2.8).

C is the distance from the center of the gearbox housing to the mounting face of the motor mounting face. This number is stamped on the back of the gear housing casting. The stamped number may or may not begin with a four. If the number reads 4.611, for example, record this number as Distance C. If the number reads only .611, for example, assume a four at the beginning.

Distance C would therefore be 4.611.

1. Determine the thickness of the 4-hole shim package required between the motor endbell and gear housing. The thickness of the shim package is determined by one of the following formulas:

D is the distance from the end of the pinion to the mounting face of the motor. If the number on the end of the pinion is not legible, then measure D using the Pinion Height Dial Indicator zeroed at 2.500” . The number should be around 2.57”

Use Procedure 1 when you have both the number on the end of the pinion, and the number on the gearbox housing.

A + B - C = Shim package Refer to Fig. 2.9 Procedure 1 12/20/99

2.8

TOYOTA Electric Stand Up “E” Series

Procedure 2 Measure D if there is no number on the end of pinion.

Drive

Procedure 1 Measure A if there is a number on the end of pinion.

Figure 2.9 - CALCULATE 4-HOLE SHIM THICKNESS. Example for Procedure 1: Measurement A = 1.394 Etched on Pinion B = 3.240 Stamped on Gearbox C = 4.611 1.394 + 3.240 - 4.611 = 0.023 4-Hole Shim Package = 0.023"

Example for Procedure 2: Measurement D = 2.573 Add 2.061 Stamped on Gearbox C = 4.611 2.573 + 2.061 - 4.611 = 0.023 4-Hole Shim Package = 0.023 2. Assemble a 4-hole shim package as determined in Step 1 (verify thickness with a micrometer) and install on the motor mounting face.

3. Remove the carrier assembly from the gear housing. Apply a thin coat of grease to the outer diameter of the motor pilot flange and secure the gear housing to the motor using four 3/8-16 nylon lock nuts (torqued to 30 lb-ft) as either a left or right drive unit as required.

Correct alignment

Carrier to Gear Housing Assembly 1. Place a 6-hole shim package (Fig. 2.6, Item 18) over mounting flange on gear housing.

Initially use 0.022” or the same thickness that was removed during disassembly.

Incorrect alignment

2. Coat an approximately 30o area of the ring gear with marking compound for checking the tooth contact pattern.

Figure 2.10 - Carrier to Housing Alignment

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2.9

TOYOTA Electric Stand Up “E” Series

Drive

7. Once backlash conditions are met, remove the flag assembly and backlash tool. Rotate the motor shaft several revolutions both forward and reverse. Remove the carrier from the gear housing and observe the contact pattern on the gear: a. The correct pattern, as shown in Example 1, is well centered on the bevel gear tooth with lengthwise contact clear of the toe.

The length of the pattern in an unloaded condition is approximately one-half to two-thirds of the bevel gear tooth. The backlash (6-hole) and motor to gear box (4-hole) shims are correct.

00593-11730-71

Figure 2.11 - Backlash Tool NOTE When installing carrier to gear housing, ensure alignment of flange mounting holes is correct (see Fig. 2.10) 3. Place the carrier on the gear housing ensuring gear teeth are meshed. Temporarily fasten by tightening at least three of the six screws supplied with the gearbox. Rotate the pinion gear to make sure it turns freely.

4. Attach the drive unit backlash tool to the gearbox as shown in Fig. 2.11. Make sure the dial indicator is aligned as shown.

5. Install the flag assembly on the spur gear with the flag in the upright position.

6. Rotate the flag until it moves about halfway into the dial indicator's range of motion.

Then, rock the flag back and forth (firmly, but not hard enough to rotate the motor shaft) and observe the dial indicator readings. The difference between the highest and lowest reading is the backlash. Backlash should be greater than 0.003" but should not exceed 0.013". Check backlash at every other tooth for a full revolution. If this condition is not met, disassemble the carrier from the gear housing and add or remove shims as required (if backlash is too great, remove shims; if backlash is too small, add shims). Repeat these steps as necessary until backlash conditions are met.

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Example 1 b. Example 2 indicates an incorrect 4-hole shimming package between the motor and the gear housing. The contact pattern in the left illustration indicates that the pattern is too close to the root of the gear tooth or off the tooth root. If this condition occurs, add some 4-hole shims between the motor and the gearbox and test again. The illustration to the right shows a pattern that is too close to the tooth top land and off center. If this condition exists, remove some 4-hole shims between the motor and gearbox and test again.

Example 2 c. Example 3 indicates a backlash error caused by an incorrect 6-hole shim package between the carrier and the gear housing. The illustration to the left shows the pattern too far off the tooth toe. As was noted in Example 1, there should be an area between the contact 2.10

TOYOTA Electric Stand Up “E” Series pattern and the tooth toe that is not in contact with the gear set. To correct for this condition, remove the carrier from the gear housing, add additional shims, reassemble and test again.

The illustration to the right however shows the pattern moving too far along the tooth toward the tooth heel. To correct for this condition, remove the carrier, remove some shims, reassemble and test again.

Drive

2. Remove the three cap screws (Fig. 2.6, Item 19) securing the bevel gear to the pinion shaft.

3. Remove the cap (Fig. 2.6, Item 20) and any shims underneath.

4. Lift the spiral bevel gear off of the pinion shaft.

5. Slide the pinion shaft out of the carrier housing.

6. Remove bearings, bearing cups, and seals as necessary, being careful not to damage gear teeth or machined surfaces.

Carrier Assembly 1. Ensure castings and machined surfaces are clean and free of foreign material. Clean only with a rag and mild non-abrasive solvents.

Example 3

2. Stand carrier housing on end with large mounting flange down.

8. Once gear teeth pattern conditions are met, remove carrier from gear housing and set the shim package aside. Apply a thin coat of suitable gasket compound to mounting surfaces of the carrier and housing then replace shim package. Reattach carrier to housing using the six bolts supplied with the gearbox and a thread locking compound.

Torque to 40 lb-ft.

3. Lubricate the outside diameter of the seals (Fig. 2.6, Item 27), and carefully press into the housing individually. Ensure that the lip of the first seal is downward . Ensure that the lip of the second seal is pointing upward.

4. Lubricate outside diameter of the bearing cup (Fig. 2.6, Item 28), and press evenly into the carrier housing until properly seated against the stop.

9. Using grease gun containing Mobilith SHC 220 grease, ensure the cone bearing on gear shaft is greased.

5. Turn the carrier housing over so that the large flange is pointing up. Lubricate bearing cup (Fig. 2.6, Item 24), and press evenly into the carrier housing until properly seated against the stop.

10. Ensure motor terminal lugs are tight.

11. Reinstall drive unit into the truck.

Carrier Rebuild Carrier Disassembly NOTE The bearings on the drive shaft are pressed on with an interference fit.

Disassembly is recommended only when one of the carrier's bearings or seals need to be replaced or the carrier has excessive endplay (greater than 0.002"). Refer to DRIVE UNIT REBUILD DISASSEMBLY for disassembly of the drive unit.

1. Place the carrier assembly with the spiral bevel gear facing up.

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6. Pack the cone roller bearing (Fig. 2.6, Item 29) with Mobilith SHC 220 grease, or equivalent. Stand the pinion shaft on end with the spur gear down. Lubricate the inside diameter of the packed cone roller bearing and press evenly onto pinion shaft as shown until properly seated against the spur gear.

7. Place the bevel gear face down with support under the center section opposite the bearing seat preventing the gear teeth from being damaged (see Fig. 2.12). Lubricate the inside diameter of the cone roller bearing (Fig. 2.6, Item 23) and press onto the bevel gear as shown until properly seated against the stop.

This bearing should not be packed with heavy grease. It will eventually be lubricated by gearbox oil in the gear housing.

2.11

TOYOTA Electric Stand Up “E” Series

Drive

17. Pry upward on the cap to observe the endplay. Add or remove shims as necessary until an endplay of 0.000" to 0.002" is obtained.

Figure 2.12 - Support Spiral Bevel Gear 8. Lubricate the inner diameter of the seals installed in Step 3 above. Using a twisting motion, insert the pinion shaft through the carrier housing.

9. With the spur gear end of the shaft in the downward position on the table, install the bevel gear over splined end of the shaft.

10. Apply light pressure to the bevel gear and shaft. Spin the carrier housing several times to seat the bearings.

11. Place the cap (Fig. 2.6, Item 20) over the spiral bevel gear and secure using three 5/16-18 screws (Fig. 2.6, Item 19). Torque bolts to 20 lb-ft to ensure bearings and bearing cups are seated properly. Remove the three bolts and the cap.

12. Using a depth micrometer, measure and record the depth from the face of the bevel gear to the end of the pinion shaft (see Fig. 2.13). A carrier shaft shim package (Fig. 2.6, Item 21) should be assembled 0.003" greater than the recorded bevel gear to pinion shaft depth. Verify shim package thickness using a micrometer; then place the package on pinion shaft end.

Example: Measured Depth = 0.010" Add 0.003 = 0.003" + Total Shim Package = 0.013" 13. Place the cap over the shim package and secure using three 5/16-18 screws. Torque to 20 lb-ft.

Figure 2.13 - Measure Shim Depth NOTE If there is no endplay, and the pinion shaft cannot be turned freely by hand, the bearings are too tight. Increase the shim thickness under the cap.

18. Remove retaining bolts and reassemble using a permanent thread locking compound with a minimum temperature rating of at least 450o F. If there are no wire tie holes in the bolts, torque to 20 lb-ft.

19. Refer to DRIVE UNIT REBUILD - ASSEMBLY to reassemble the drive unit.

14. Again, spin housing to seat bearings.

15. Invert the carrier with ring gear down and place supporting blocks on the mounting flange at the bolt circle diameter. This will suspend the ring gear.

16. Place a magnetic base indicator on the small flange end of the carrier with indicator probe on end of spur gear.

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2.12

TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Brake System Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Disc Brake Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Brake Pedal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Brake Adjustments Brake Pedal Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Brake Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Braking Force (Clamping Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

04/04/00

3.i

Brakes

TOYOTA Electric Stand Up “E” Series

traveling.

For example a fully loaded truck traveling 6 MPH should stop within about 6.6 feet.

Theory of Operation The brake system of this lift truck is to be used as a parking brake and for emergency stopping only.

Slowing or stopping the lift truck is normally done through "plugging" of the traction motors.

Plugging is a method of slowing the rotation of the drive wheels by changing the direction of current flow through the traction motor. In an emergency, the truck can be stopped by lifting the foot off of the brake pedal.

The brakes should hold a fully loaded truck on a 10% grade.

The brake system is designed to mechanically apply the brakes when the operator removes his foot from the pedal. The brakes are electrically released when the operator depresses the pedal.

The brake system consists of a brake pedal, an electric brake relay, and two self-contained disc brake units. The disc brake units are attached to the commutator end of the drive motors to take advantage of the increase in torque supplied by the gearbox.

Internal coil springs in the disc brake units supply the force which clamps the rotating friction plate.

An electric solenoid coil acts against these springs to release the brakes. The friction plate floats on the arbor so that equal pressure is applied to both sides.

When the operator releases the brake pedal, two micro-switches are actuated. One signals the system controller to cut power to the traction motors. The second signals the brake relay to cut power to the disc brake units, thus applying the brakes. The system controller does not monitor the operation of the disc brake units or the relay.

NOTE Many of the brake adjustments interact with one another.

When performing any adjustments on the brake system, please follow the order of the list below. When servicing the brakes, check all of the adjustments listed below (See Brake Adjustments).

1.

2.

3.

4.

Brake Pedal Height Brake Switch Adjustment Disc Brake Air Gap Braking Force (Clamping Pressure)

The brakes should stop a fully loaded truck on a dry, level floor within 1.1 feet per MPH the truck is

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Brakes

3.1

TOYOTA Electric Stand Up “E” Series

Brakes

Disc Brake Unit Description The brake unit is an electrically released, spring applied disc brake. The friction plate (2) fits onto splines on the arbor (1), which is keyed to the motor shaft. Shims (7) are used to position the arbor on the shaft, while the friction plate is free to move up and down on the arbor. Clamping pressure is applied by 10 springs (3) inside the magnet/coil assembly. Three screws on top of the unit adjust clamping pressure. The magnet/coil assembly is secured to the mounting plate by three screws. The air gap between the armature (upper pressure plate) and the magnet/coil assembly (see Fig. 2) is set by the shims (6) under each spacer – 0.008” to 0.015” allowable. When power is applied to the brake unit, the armature is retracted, closing the air gap and releasing the brake. If the air gap is too small, or there is no gap, the brake may drag. If the air gap is too large, the clamping pressure may be weak, resulting in long stopping distance.

Removal 1. Unplug the disc brake unit from the brake relay harness.

2. Remove the three hex screws (10) securing the mounting base to the top of the drive motor. Lift the brake unit off of the arbor.

3. If necessary, remove the arbor from the motor shaft by removing the upper snap ring (9), shims (7) and spacer (8). Note the number and thickness of shims above and below the arbor and spacer.

Disassembly 1. Place the brake assembly on a clean, dry work surface with the magnet/coil assembly up. Loosen the three screws in equal increments to ensure the spring pressure is reduced gradually and evenly.

NOTE Turn the brake unit upside down before removing the bottom plate. This will prevent the shims, springs, and discs from falling out and getting lost.

Figure 1 - Disc Brake Unit

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3.2

TOYOTA Electric Stand Up “E” Series

Brakes

2. The brake assembly can now be fully dismantled and the parts examined. Note the number and thickness of shims (6) at each hole. Do not lose the three discs (4) used under the springs in the adjustment screw holes.

Assembly 1. Clean all parts thoroughly.

2. Turn the magnet/coil assembly upside down.

Place all springs in the magnet/coil assembly.

Remember to put discs (4) under the three springs in the adjustment screw holes (see Figure 3).

3. Assemble the magnet/coil assembly, armature (upper pressure plate), friction plate, and mount plate using the three screws, spacers, and shims. The shims should be placed next to the mount plate. Try to center the friction plate during assembly to make installation on the motor easier. After tightening the three screws, measure the air gap near each screw.

Add or remove shims as necessary to achieve an even 0.010” to 0.015” air gap. If the air gap exceeds 0.015” with no shims, then replace the friction plate.

Figure 3 - Adjustment Screws

2. Slide the brake unit onto the motor and secure in position with three screws. The plug lead should be toward the rear of the truck. If necessary, release the brake by plugging it in and holding the pedal down (battery must be connected).

3. Plug the brake unit into the relay harness.

Perform a braking distance test.

Figure 2 - Air Gap

Replacement

Brake Pedal

1. Install the arbor on the motor shaft using a woodruff key and the same number and thickness of shims noted in step 3 of removal.

The typical setup is: four 0.020” shims under the arbor, one 0.020” shim on top of the arbor, and six 0.020” shim on top of the spacer.

Verify that the friction plate will slide completely onto the arbor, and the arbor cannot move up and down on the motor shaft.

Removal 1. Disconnect the battery and discharge the capacitors.

2. Remove the access panel at the front-lower-left corner of the operator compartment.

3. Remove the clevis pin from the brake pedal rod clevis.

4. Remove the brake pedal pivot shaft, nylon bushings and machine bushings.

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3.3

TOYOTA Electric Stand Up “E” Series

Brakes

4. Loosen the jam nut on the brake rod end.

5. Remove the brake pedal.

5. Rotate the rod end to lengthen or shorten the brake rod. (Rotating the rod end counterclockwise will lower the brake pedal, rotating the rod end clockwise will raise the brake pedal.)

Replacement 1. Position the brake pedal in the pivot bracket.

2. Install the brake pedal pivot shaft with two nylon bushings, and two machine bushings.

6. Tighten the jam nut on the rod end.

3. Attach the brake pedal rod to the brake pedal.

7. Attach the rod end to the brake lever arm.

4. Install the access panel into the opening in the bottom of the operator compartment.

8. Check the height of the brake pedal and repeat steps 3 through 7 if necessary.

5. Connect the battery.

9. After the brake pedal height has been adjusted, verify that the brake switches are adjusted properly.

Brake Adustments

10. Install the control cover and the top cover.

Brake Pedal Height

11. Connect the battery.

Specification: 4.75 ± 0.25 inches (see Fig. 4)

Brake Switches

1. Disconnect the battery and discharge the capacitors.

1. Disconnect the battery and discharge the capacitors.

2. Remove the top cover and the control cover.

2. Remove the top cover and control cover.

3. Disconnect the rod end on the brake rod from the brake lever arm.

3. With the brake pedal released, loosen the screws securing the brake switch. Move the

Figure 4 - Brake Pedal Height

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3.4

TOYOTA Electric Stand Up “E” Series brake switches toward the brake lever arm until they actuate (click).

4. Slowly depress the brake pedal while watching the brake lever arm. The brake switches must de-actuate after the pedal moves about one inch. The contacts on the brake switches should not be pressed all the way in when the brake pedal is up. Readjust as needed, then tighten the screws securing the brake switches.

5. Replace the control cover and top cover 6. Connect the battery.

7. Test the brake operation of the lift truck.

Disc Brake Air Gap See Disc Brake Unit for adjustment procedures.

Braking Force (Clamping Pressure) NOTE This adjustment does not affect the air gap.

See Disc Brake Unit Assembly to set the air gap.

The three adjustment screws in the top of each disc brake unit are used to adjust clamping pressure. Before adjusting these, verify that the air gap is 0.008” to 0.015” for both brakes (see Figure 2). Turn the screws clockwise to increase clamping pressure; turn the screws counter-clockwise to decrease clamping pressure.

Adjust all three screws on one brake unit the same amount. Both brakes should apply equal pressure so that the truck does not pull to one side during braking. The brakes should stop a fully loaded truck on a dry level surface in 1.1 feet per mile per hour. For example, a truck traveling 6 MPH should stop in about 6.6 feet when the brakes are released.

NOTE Clamping pressure adjustment is for minor corrections only. If the braking distance is excessive, check for other problems with the brake units, such as contamination of the friction plate.

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Brakes

TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Pump and Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Steer Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Steer Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Steer Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Hydraulic Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Steer Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Steer Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Steer Wheel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Changing Steer Tires

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Steer Position Potentiometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

04/05/00

4.i

Steering

TOYOTA Electric Stand Up “E” Series Removal

Steering System

1. Disconnect and remove the battery and discharge the capacitors.

The steering system of this lift truck consists of the following components: the steer pump motor and pump, the steer control valve and tiller, the hydraulic motor, the steering gears and the steer fork assembly. A potentiometer is attached to the top of the steering fork which is used by the system controller to determine the position of the steer tire. An indicator is incorporated in the operator's display to show the angle of the steer wheel(s).

2. Tilt the left drive unit (the drive unit in front of the steer pump and motor assembly) (refer to DRIVE UNIT Removal procedure in the DRIVE section).

3. Label and disconnect the electrical cables from the steer pump motor.

4. Clean the area around the hydraulic connections to the steer pump. Disconnect and cap the hydraulic lines from the steer pump.

Hydraulic fluid from the reservoir is drawn into the steering system by the steer pump. This gear pump is driven by a DC electric motor and is controlled by a contactor. Included in the pump assembly is a pressure relief valve. This valve prevents the buildup of excessive pressure in the steering system. It is designed to limit the pressure in this system to 900 PSI.

5. Attach a lifting device to the steer pump and motor assembly for support.

6. Remove the screws securing the steer pump and motor assembly to the front frame of the truck. Remove the steer pump and motor assembly from the truck.

Pressurized fluid is directed to the steer control valve. The steer control valve meters the flow rate and direction of the oil flow to the hydraulic motor. Speed and direction of hydraulic motor rotation is dependent on the amount of oil the steer control valve passes and the direction of the flow.

Replacement 1. Align the steer pump and motor assembly with the mounting holes in the front frame of the truck.

2. Attach the steer pump and motor assembly to the front frame of the truck.

The hydraulic motor converts the hydraulic flow into rotational movement. Fluid is directed to the motor in proportion to the amount of movement of the steering tiller. As the tiller is moved, a metered amount of hydraulic fluid is directed to the hydraulic motor. As this fluid enters the motor, the output shaft of the motor is rotated. A pinion gear attached to the output shaft of the motor rotates the spur gear, which is attached to the steer fork assembly.

3. Attach the hydraulic lines to the steer pump.

4. Reattach the electrical cables on the steer pump motor. (Ensure the electrical cables are returned to the correct terminals.)

5. Replace the left drive unit (refer to DRIVE UNIT Replacement procedure in the DRIVE section).

6. Install and reconnect the battery.

After the hydraulic motor and control valve, the hydraulic fluid is returned to the reservoir.

Steer Motor Brushes 1. Remove the steer pump motor from the truck (refer to Steer Pump and Motor Removal procedure in this section).

Steer Pump and Motor Assembly

2. Remove the endbell from the motor.

NOTE The steer pump can be removed from the motor without removing the steer pump and motor assembly from the truck. Refer to STEER PUMP Removal procedure in this section.

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Steering

3. Replace brushes and brush springs. Push the brushes into the holders and insert a pin in the holes to retain them.

4. Install the endbell. Remove the pins holding the brushes.

4.1

TOYOTA Electric Stand Up “E” Series

Steering

5. Install the steer pump and motor on the truck (refer to Steer Pump and Motor Assembly Replacement procedure in this section).

4. Turn the steer tiller until the fork reaches either stop. Continue to turn the tiller and read the pressure gauge while the pump operates against relief. The pressure should reach approximately 900 psi.

Steer Pump

5. Use a #3 slotted “stubby” screwdriver to adjust the relief pressure. Turn the screw clockwise to increase pressure, and counter-clockwise to decrease pressure.

Removal NOTE If the steer pump and motor assembly has already been removed from the truck, proceed to Step 6.

6. When relief pressure is set, install the hex cap over the adjustment screw. Remove the pressure check hose and gauge.

1. Tilt the mast to the full forward position.

2. Disconnect the battery and discharge the capacitors.

Steer Control Valve

3. Remove the front cover.

Removal

4. Clean the area around the hydraulic connections to the steer pump.

1. Disconnect the battery and discharge the capacitors.

5. Disconnect and cap the hydraulic lines from the steer pump.

2. Remove the tiller, top cover and the control cover.

6. Remove the hex screws securing the steer pump to the steer pump motor.

3. Remove the pad on the left side of the operator compartment.

7. Separate the steer pump from the steer pump motor. Remove the steer pump.

4. Place identifying tags on all of the hydraulic hoses. Note the orientation of the steer control valve to the mounting bracket.

Replacement

CAUTION Before loosening any hydraulic hose, allow the truck to sit for 1 to 2 minutes to relieve pressure. When removing hydraulic hoses, use care to avoid contaminating electrical components with oil.

1. Position the steer pump on the steer pump motor shaft.

2. Attach the steer pump to the steer pump motor and tighten the screws to 17 lb-ft.

3. Attach the hydraulic lines to the steer pump in the correct locations.

5. Disconnect and cap the hydraulic hoses from the steer control valve.

4. Reinstall the front cover and connect the battery.

6. Remove the steer control valve mounting bracket from the truck.

7. Place the steer control valve and bracket on a clean work surface. Remove the mounting screws. The steering column will separate from the bracket and valve.

Steer Pressure Adjustment 1. Attach a pressure gauge to the test port on the outlet fitting of the steer pump using the pressure check hose kit 00593-11491-71.

Replacement

2. Remove the hex cap covering the relief pressure adjustment screw on the bottom of the pump.

1. Attach the steer control valve and the steering column to the mounting bracket in the same orientation noted in Step 4 of Removal.

3. Turn the steer pump motor on using Output Test 02 (refer to Programming and Diagnostics section).

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2. Install the steer control valve and mounting bracket assembly to the truck.

4.2

TOYOTA Electric Stand Up “E” Series 3. Install the hydraulic hoses in the correct locations.

Steering

Replacement 1. Install the hydraulic motor onto the mounting bracket, making sure to use the correct length screws. Longer screws may crack the motor case.

4. Install the steering tiller.

5. Connect the battery.

6. Check the operation of the steering system.

2. Install the steer pinion gear onto the hydraulic motor shaft. Use tool P/N 00593-11490-71 to hold the pinion gear and torque the nut to 115 lb-ft. Install a cotter pin.

7. Check all hydraulic connections for leaks.

8. Disconnect the battery and remove the steering tiller.

3. Lower the hydraulic motor and bracket into position and align the mounting holes with the studs.

9. Install the left hip pad in the operator compartment.

10. Install the control cover and the top cover.

11. Connect the battery.

4. Install the mounting screws until finger tight.

Gradually tighten the mounting screws in an alternating pattern. Torque to 23 lb-ft.

Hydraulic Motor

5. Install the steer position potentiometer (refer to STEER POSITION POTENTIOMETER Replacement procedure in this section).

Removal

6. Install the hydraulic hoses in the correct locations.

1. Disconnect the battery and discharge the capacitors.

7. Connect the battery and test the steering system for proper operation. Inspect all of the hydraulic hoses and fittings for leaks.

2. Remove the top cover.

3. Remove the steer position potentiometer (refer to STEER POSITION POTENTIOMETER Removal procedure in this section).

8. Install the top cover.

Steer Gear

NOTE The hydraulic lines must be removed before removing the mounting screws from the hydraulic motor. Hoses should be labeled to help install them correctly.

Removal 1. Disconnect the battery and discharge the capacitors.

4. Remove the hex screws securing the mounting bracket.

2. Remove the top cover and the control cover (it is not necessary to remove the tiller for this procedure).

5. Remove the hydraulic motor mounting plate by threading two 3/8" x 3" screws through the threaded holes (Item 1 in Fig. 4.1).

Alternately tighten the screws until the mounting plate is free.

3. Remove the steer control valve bracket screws and move it aside. Remove the hydraulic motor and steer position potentiometer. It is not necessary to remove the hydraulic hoses.

6. Loosen the lock nut from the hydraulic motor shaft. Use tool P/N 00593-11490-71 to hold the pinion gear.

4. Remove the lock nut securing the steering gear to the steer fork assembly.

5. Lift the steering gear off the steer fork shaft and out of the truck.

7. Remove the screws securing the hydraulic motor to the mounting bracket.

Replacement

8. The motor shaft is tapered. Use a suitable puller to remove the pinion gear from the shaft utilizing the mounting bracket as part of the puller.

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1. Before installing the steering gear, make sure the steer fork is properly positioned with the stop pin toward the forks.

4.3

TOYOTA Electric Stand Up “E” Series 2. Install the steering gear on the splined portion of the steer fork shaft with the proper machine bushing above and below.

Steering

CAUTION The steer fork assembly must be supported prior to removing the lock nut. If the steer fork assembly is not supported, serious damage to the lift truck or the steer fork may occur.

Personal injury is also possible.

3. Install the lock nut on the steer fork and tighten to 60 lb-ft.

NOTE Over tightening or under tightening of this nut can cause excessive wear on the bearings and steer fork shaft.

4. Use a 5/16” eyebolt and chain that will fit through the lock nut to support the steer fork.

Remove the lock nut and lower the fork out of the truck.

4. Install the hydraulic motor and the steer position potentiometer (refer to procedures in this section).

NOTE During the removal and installation of the steer fork, use care to avoid damaging the bearing seals or the threads and splines on the steer fork shaft.

5. Install the steer control valve.

6. Check all hydraulic lines on the steering components for tightness.

7. Install the control cover and top cover.

5. Lower the steer fork assembly to the floor and remove it.

8. Connect the battery and test the truck for proper operation.

Replacement

Steer Fork Assembly

NOTE The steer fork must be installed with the stop pin toward the forks.

1. Put the lower bearing in place and drive the lower seal into position with the lip facing down.

Removal NOTE To allow for the removal of the steer fork from the lift truck, the entire lift truck must be at least 27" off the floor. The steer fork assembly is 36" long. If the truck is not 27" off the floor, there is not enough clearance to remove the steer fork from the truck.

1. Disconnect and remove Discharge the capacitors.

the

2. Put the upper bearing in place and drive the upper seal into position with the lip facing up.

Stack the lower machine bushing, steer gear, upper machine bushing and lock nut in position.

3. Thread the eyebolt and chain through the stacked parts and screw it into the steer fork.

battery.

4. Carefully raise the steer fork into position.

Tighten the lock nut to 60 lb-ft. Make sure the steer fork can rotate freely.

2. Remove the control cover and the control cover mount bracket. Remove the hydraulic motor (it is not necessary to remove the hoses) and steer position potentiometer.

5. Lower the lift truck to the ground. Install the hydraulic motor and steer position potentiometer (refer to procedures in this section). Install the control cover bracket and the control cover.

CAUTION The lift truck, without a battery weighs from 6,000 to 8,000 pounds. Use a lift or stands with adequate capacity.

6. Install and connect the battery. Test the truck for proper operation.

Steer Wheel Assembly

3. Raise and safely support the entire lift truck at least 27" off the floor.

Removal 1. Disconnect the battery and discharge the capacitors.

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1.4

TOYOTA Electric Stand Up “E” Series

Steering

2. Remove the seals and bearings.

2. Jack the rear of the truck just until the steer wheel can turn. Rotate the steer fork so the axle nut is visible.

3. Align the old wheel and tire on top of the new tire. Press the wheel out of the old rim and tire into the new one.

3. Remove the axle nut. Rotate the steer fork 180° and remove the axle.

4. Install the bearings and seals.

4. Raise the truck until the wheel can be removed.

5. Install the steer wheel assembly.

NOTE Inspect the steering axle, bearings, and seals for wear or damage. Replace all worn or damaged parts prior to replacing the steer wheel assembly into the steer fork.

Steer Position Potentiometer Removal 1. Go into Diagnostic Output Test 05 (refer to Programming & Diagnostics). Rotate the tiller so that the voltage reading decreases until the steer fork hits the stop.

Replacement 1. Rotate the steer fork so that the larger hole with the lock bar above is visible.

2. Disconnect the battery and discharge the capacitors.

2. Position the steer wheel assembly in the steer fork. Lower the truck to align the center hole of the steer wheel assembly with the axle holes in the steer fork.

3. Remove the top cover.

4. Disconnect the 3-pin connector between the steer position potentiometer and the wiring harness.

3. Install the steer axle through the steer fork and the steer wheel assembly.

5. Loosen the nut (Item 23 Fig 4.1) and remove the hex screw holding the potentiometer mounting bracket to the hydraulic motor mounting bracket.

4. Rotate the steer fork 180° to install the axle nut.

NOTE Do not over tighten the axle nut on the steering axle. This nut serves as a bearing tightening adjustment. The nut should be tightened enough to remove any lateral play yet allow the steer wheel assembly to turn freely. If the nut is over tightened or under tightened, the bearings and the steer axle may be damaged.

6. Loosen the hex nut (Item 44 Fig 4.1) on the steer fork insert, and unscrew the insert to remove the steer position potentiometer assembly.

7. Tighten the axle nut and install the cotter pin.

8. Using a grease gun, fill the cavity of the steer wheel with grease. The grease fitting is in the end of the axle.

9. Lower the truck completely, connect the battery and test the truck for proper operation.

Changing Steer Tires 1. Remove the steer wheel assembly.

NOTE The capacity of the press must be approximately 40 tons.

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Figure 4.1 - Steer Position Potentiometer

1.5

TOYOTA Electric Stand Up “E” Series NOTE The potentiometer, torque arm, and steer fork insert cannot be disassembled. The potentiometer shaft is permanently attached to the steer fork insert.

Replacement 1. Make sure the potentiometer is tight on the torque arm. Thread the hex nut all the way on the steer fork insert. Insert the hex screw through the torque arm and thread the hex nut onto the screw.

2. Screw the steer fork insert into the steer fork and the hex screw into the hydraulic motor mount plate. Leave an 1/8” gap between the torque arm and the hex screw head to allow the torque arm to float, then tighten the hex nut down to the hydraulic motor mount plate.

3. Connect the 3-pin plug from the steer position potentiometer. Connect the battery and turn on the truck. Run Diagnostic Input Test 05.

The display will show the steer position potentiometer voltage.

4. If Step 1 of the Removal procedure was performed, the steer wheel is in the full left position. If not, rotate the tiller until the steer wheel is in the full left position (visually verify). Turn the steer fork insert so that the voltage display is around 0.50V. 5. Hold the steer fork insert so that the voltage reading does not change, and tighten the hex nut onto the steer fork shaft. Verify that the voltage display did not change.

6. Calibrate the steer position potentiometer (see PROGRAMMING & DIAGNOSTICS).

7. Install the top cover.

8. Test the truck for proper operation.

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1.6

Steering

TOYOTA Electric Stand Up “E” Series

Operator Controls

TABLE OF CONTENTS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Control Handle Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Control Handle Potentiometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Battery Disconnect Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Horn Button Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Lift & Travel Springs Removal & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Control Handle Replacement Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Light and Auxiliary Rocker Switches Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Keyswitch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

07/17/99

5.i

TOYOTA Electric Stand Up “E” Series

Operator Controls

OPERATOR CONTROLS are blank panels inserted in their place. These switches are covered in the ELECTRICAL section.

DESCRIPTION The operator controls of the 6BNCUE lift truck consist of the control handle, the battery disconnect lever, the steering tiller, the brake pedal, the key switch, and the light and auxiliary selector switches (if so equipped).

The control handle is a molded plastic handle used to control travel, lift, tilt, sideshift and auxiliary functions (if so equipped), and the horn.

Travel and lift are proportionally controlled by moving the control handle forward or backward, and left or right. Tilt and sideshift are single speed functions controlled by a four way rocker on the top of the handle. Auxiliary functions are controlled by the sideshift switches and a rocker switch on the display. The horn switch is located on the edge of the handle, under the thumb.

The control handle is mounted to a dual-axle mechanism with a potentiometer on both axes for the travel and lift proportional controls. Return springs keep the handle centered, and stop blocks limit the movement of the handle.

The battery disconnect lever mechanically separates the battery connectors, cutting power to the truck. The truck connector is mounted to the frame. When the lever is pushed forward, it pushes against the battery connector and separates it from the truck connector.

The steering tiller controls the direction of the steer fork and wheels. The steering tiller is covered in the STEERING section.

The brake pedal releases the parking brakes of the lift truck and enables traction functions. The brake pedal is covered in the BRAKES section.

The key switch is located on the operator display.

It has three positions, O, I, II. In position O, no truck functions are available. In the I position, the system controller is powered up. When rotated to the II position, power is available to all systems.

For more information, refer to the ELECTRICAL section.

The light and auxiliary selector switches are rocker switches on the operator display. On trucks without lights or auxiliary equipment, there

3/30/00 5.1

TOYOTA Electric Stand Up “E” Series

Operator Controls back, and disconnect the potentiometer from the harness.

CONTROL HANDLE ASSEMBLY Removal

3. Loosen the set screw holding the shaft of the potentiometer in the pivot shaft.

1. Disconnect the battery and discharge the capacitors (refer to ELECTRICAL).

4. Remove the screw holding the potentiometer bracket to the dual-axle mechanism.

2. Remove the top cover.

5. Remove the potentiometer assembly from the dual-axle mechanism.

3. Disconnect the control handle harness from the system controller at connector J8 (refer to decal on back of system controller).

6. Remove the lock nut on the collar of the potentiometer and remove the potentiometer from the mounting bracket. Remove the nylon washer from the potentiometer.

4. Pull the control handle boot up through the opening in the control cover.

5. Remove the screws securing the control handle to the frame and remove the control handle assembly.

Replacement 1. Place a nylon washer and mount bracket over the collar of the potentiometer and secure with the lock nut (make sure the potentiometer is oriented so that the wires exit toward the bend in the bracket).

Replacement 1. Place the four mounting screws in the control handle mechanism. Thread the handle harness through the opening in the control cover.

2. Slide the potentiometer shaft into the hole in the end of the axle shaft.

3. Attach the bracket to the dual-axle mechanism.

2. Position the control handle assembly in the unit and secure in place. Ensure the handle angle is correct for a forward or side stance unit.

4. Make sure the flat on the potentiometer shaft is facing the set screw then tighten the set screw.

3. Tuck the boot into the control cover opening.

Make sure the boot does not drag and the control handle operates smoothly through its full range.

5. Wire-tie the potentiometer wires to the mount bracket and route the wires through the standoff guide. Plug the connector in to the control handle harness.

4. Connect the control handle harness to J8 (refer to decal on back of system controller).

6. Slide the sleeving back over the connectors and seal the end with electrical tape.

5. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

7. Install the control handle in the truck (refer to CONTROL HANDLE Replacement procedure in this section).

6. Connect the battery and calibrate the traction and lift potentiometers (refer to PROGRAMMING AND DIAGNOSTICS section).

BATTERY DISCONNECT LEVER Removal

CONTROL HANDLE POTENTIOMETER 1. Disconnect the battery and discharge the capacitors.

Removal

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

1. Remove the control handle (refer to CONTROL HANDLE Removal procedure in this section).

3. Disconnect the return spring from the handle.

4. Remove the retaining ring and flat washer from the shaft.

2. Remove the electrical tape around the sleeving on the control handle harness, pull it 3/30/00 5.2

TOYOTA Electric Stand Up “E” Series

Operator Controls

5. Remove the battery disconnect lever.

LIFT AND TRAVEL SPRINGS

Replacement

Removal & Replacement

NOTE When replacing the battery disconnect lever, ensure the flange side of the bushing is toward the frame.

Refer to Fig. 5.3.

1. Remove the control handle from the truck and place it on a clean flat work surface (refer to CONTROL HANDLE Removal procedure in this section).

1. Slide the battery disconnect lever over the shaft.

2. Install the flat washer and the retaining ring.

CAUTION Position the control handle so that the potentiometers, wiring, and other parts of the control handle and mechanism are not damaged during removal and installation of the roll pins.

3. Connect the return spring.

4. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

5. Make sure the screw is installed in the battery connector. Connect the battery and test the disconnect for proper operation.

2. Remove and replace one spring at a time.

A: Support the stop block in a vise or against a solid surface or use the roll pin removal tool, P/N 00593-11956-71. Use an appropriate size pin punch to drive the roll pins out of the stop block. Slide the stop block and nylon washer off the cross shaft.

B: Grasp the outer leg of the spring with pliers and move it to the other side of the bracket arm to release tension, then remove the spring.

C: Slide the correct spring onto the shaft so that the inner leg falls into the notch in the bracket arm. Grasp the outer leg of the spring with pliers and pull it to the other side of the bracket arm until it snaps into the notch.

D: Slide the nylon washer onto the shaft.

Slide the stop block onto the shaft so that the leg of the stop block fits between the legs of the spring.

E: Support the stop block in a vise or against a solid surface. Drive a 1/4” x 1¼” roll pin approximately half way into the stop block.

Insert a 5/32” x 3/4” roll pin into the first roll pin with the open sides 180° apart. Drive the smaller pin into the larger pin until flush, drive the assembly the rest of the way in. Insert a piece of the stainless steel wire through the roll pin assembly, wrap it around the back of the stop and twist it together to prevent the pins from coming out. See Figure 2 for wire location. Bend the twisted ends back toward the roll pin to prevent them from catching on the boot.

HORN BUTTON SPRING Removal 1. Disconnect the battery and discharge the capacitors.

2. Remove the control handle bezel.

3. Carefully lift the horn button out of the handle and remove the horn button spring.

Replacement 1. Install the new horn button spring in the correct orientation (see Fig. 5.2) 2. Engage the horn switch to prevent damaging the arm and install the horn button.

3. Install the bezel and test the horn button for proper operation (listen for a click when the switch closes and opens).

4. Connect the battery and test the horn, tilt and sideshift switches.

3/30/00 5.3

TOYOTA Electric Stand Up “E” Series

Operator Controls

Horn Switch - when installing horn button, engage switch to avoid damaging arm.

Horn Button

Horn Button Spring - note that bent end of spring goes in horn button.

FIGURE 5.2 - HORN BUTTON SPRING REPLACEMENT

3. Make sure there is no play in the neutral position. Adjust the set screws in the brackets so that there is no play and the upper bracket is level when the control handle is released.

the wires through the mechanism and remove the handle from the mechanism.

Replacement 1. Install the control handle boot on the handle.

Thread the lower jam nut onto the shaft.

4. Test the control handle for binding and full movement. Ensure that the control handle returns to neutral when released.

2. Feed the handle harness wires through the mechanism. Make sure the wires will not rub against any moving parts.

5. Install the control handle on the truck, calibrate traction and lift, and test for proper operation.

3. Screw the control handle onto the mechanism. The bottom of the threaded shaft should be flush with the bottom surface of the bracket. Make sure the control handle is oriented correctly for a forward or side stance truck, then tighten the lower jam nut against the bracket.

CONTROL HANDLE REPLACEMENT Removal 1. Remove the control handle assembly from the truck (refer to Control Handle Removal procedure in this section).

4. Secure the control handle harness wires to the mechanism with the loom clip and wire tie. Route the wires through the standoff guide. Connect the five-pin plugs, cover with the mesh, and secure with electrical tape.

2. Slide back the mesh over the control handle harness connectors. Separate the two control handle (five-pin) connectors. Note the harness routing, then remove the loom clip and wire tie to remove the wires from the mechanism.

5. Install the control handle assembly in the truck (refer to Control Handle Replacement procedure in this section).

3. Loosen the lower jam nut and unscrew the control handle from the mechanism. Rotate the wires while unscrewing the handle. Pull 3/30/00 5.4

TOYOTA Electric Stand Up “E” Series

Operator Controls

Figure 5.3 - Mechanism and Springs

Light and Auxiliary Rocker Switches

Replacement

Removal

1. Insert the switch into the cover until the switch locks in place.

1. Disconnect the battery and discharge the capacitors (refer to Capacitor Discharge procedure in the Electrical section). Remove the top cover.

2. Connect the wires to rocker switches and plug the key switch into the system controller.

3. Install the system controller cover. Install the system controller in the bracket.

2. Remove the system controller from the bracket (leave all harnesses connected).

Remove the cover from the system controller.

Avoid straining the wires connected to the switches.

4. Install the top cover and connect the battery.

Keyswitch Removal

3. Unplug the key switch from the system controller and disconnect all wires from the rocker switches.

1. Disconnect the battery and discharge the capacitors (refer to Capacitor Discharge procedure in the Electrical section).

4. Release the retaining catches on the rocker switch and remove it from the cover.

2. Remove the top cover and remove the system controller from the bracket (leave the harnesses connected).

3/30/00 5.5

TOYOTA Electric Stand Up “E” Series 3. Remove the system controller cover. Avoid straining the wires connected to the switches.

4. Unplug the key switch from the system controller. Disconnect the wires to the rocker switches.

5. Remove the lock nut from the back of the keyswitch and remove the keyswitch from the cover.

Replacement 1.

Install the keyswitch through the system controller cover.

2. Install and tighten the locknut on the keyswitch.

3. Plug the keyswitch into the system controller.

Connect the wires to the rocker switches.

4. Install the cover on the system controller.

5. Install the system controller in the mount bracket.

6. Install the top cover and connect the battery.

3/30/00 5.6

Operator Controls

TOYOTA Electric Stand Up “E” Series

Lift and Uxiliary Hydraulics

TABLE OF CONTENTS Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Lift Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Lift Pump & Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Lift Pump Motor Brushes Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Valve Cartridges Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Hydraulic Oil Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Hydraulic Oil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Tilt Cylinders Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Relief Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

04/05/00

6.i

TOYOTA Electric Stand Up “E” Series

Lift and Auxiliary Hydraulics

LIFT AND AUXILIARY HYDRAULICS low-voltage signal at J4 Pin 1, opening the lower valve and allowing the hydraulic oil to flow back to the lift/lower proportional valve. The voltage signal at J4 Pin 6 is varied to operate the lift/lower proportional valve which controls the amount of fluid returned to the reservoir and, therefore, the lowering speed. A flow regulator element is placed in-line with the lift/lower proportional valve to further control the oil flow.

The flow regulator element monitors the pressure on both sides of the lift/lower proportional valve and maintains the pressure on the outlet side of the proportional valve. In case of electrical failure, a manual lowering valve on the manifold will allow the mast to be lowered.

THEORY OF OPERATION Hydraulic power is provided by a gear pump directly driven by a series-wound DC motor. This motor/pump assembly provides fluid forces distributed by an electrically controlled valving manifold system. Pump motor speed is fixed and is controlled by a contactor and the valves are controlled by the system controller.

The truck uses two independent valves to control the lifting and lowering of the mast and carriage.

Since the pump runs at a fixed speed, lift speed is varied by the lift/lower proportional valve, which allows some of the fluid to return to the reservoir. Lowering speed is controlled by the lift/lower proportional valve, and limited by the flow regulator element.

Each of the hydraulic cylinders in the lift system has flow fuses installed in the hose connections.

If there is an out-rush of oil exceeding 25 gallons per minute from the center cylinder or 15 gallons per minute for the outer cylinders, the fuse closes off the opening, stopping the flow of oil and the descent of the carriage. The flow fuses can be reset once the failure is repaired by applying pressure to the system. A pressure-compensated flow control with reverse flow bypass is also installed in the lift circuit at the mast. This device limits the maximum lowering speed under normal conditions without affecting lift speed.

LIFT SEQUENCE To lift, the control handle is moved to the right.

The voltage output from the lift/lower potentiometer increases at J8 pin 1 signaling the system controller to start the lifting sequence (Note: the truck may be programmed such that the lift sequence will not begin unless the brakes are engaged, and/or the truck is not moving in reverse). The lift pump motor is turned on. The system controller switches to a low-voltage signal at J4 pin 2, opening the lift valve and allowing oil to flow from the pump to the lift cylinders. The voltage signal at J4 Pin 6 is varied to operate the lift/lower proportional valve which controls the lifting speed by varying the amount of fluid returned to the reservoir. A check valve is installed in the manifold ahead of the lift valve to prevent the load from dropping prior to the build-up of hydraulic pressure in the system. An adjustable relief valve in the manifold limits the maximum pressure of the hydraulic system.

When the voltage signal at J8 Pin 1 returns to the neutral range, the pump motor is turned off and the lift and lift/lower proportional valves are closed.

TILT AND SIDESHIFT The tilt and sideshift/auxiliary functions share a common supply circuit. Hydraulic oil is supplied from the lift pump prior to the lift valve. The same check valve mentioned in LIFT SEQUENCE prevents oil from flowing back through the pump. The same relief valve which limits lift pressure also prevents the pressure in the tilt and auxiliary systems from becoming too great.

IT IS IMPORTANT TO NOTE THAT TILT AND SIDESHIFT/AUXILIARY RELIEF PRESSURE ARE THE SAME AS MAIN (LIFT) RELIEF PRESSURE.

LOWER SEQUENCE To lower, the control handle is moved to the left.

The voltage output from the lift/lower potentiometer decreases at J8 Pin 1, signaling the system controller to start the lowering sequence. The system controller switches to a

To tilt the mast forward, press the top of the tilt/sideshift disk. This provides a voltage signal at J8 Pin 6. The lift pump is started, and the system controller then switches to a low-voltage signal at J4 Pin 4, energizing the tilt-forward

03/21/00 6.1

TOYOTA Electric Stand Up “E” Series

Lift and Auxiliary Hydraulics

solenoid. To tilt the mast back, press the bottom of the tilt/sideshift disk. This provides a voltage signal at J8 Pin 13. The lift pump motor is started, and the system controller then switches to a low-voltage signal at J4 Pin 7, energizing the tilt-back solenoid. During forward and back tilt operation, the proportional valve is partially opened to remove excess fluid.

The counterbalance valve maintains back pressure on the tilt cylinders for steady forward tilt speed when loaded. An orifice disc under the tilt cylinder front port fitting on the manifold controls the backward tilt speed.

6. Remove the screws securing the lift pump to the lift pump motor. [2 cap screws & lock washers]

To sideshift left, press the left side of the tilt/sideshift disk. This provides a voltage signal at J8 Pin 14. The lift pump motor is started, and the system controller then switches to a low-voltage signal at J4 Pin 5, energizing the sideshift-left solenoid. To sideshift right, press the right side of the tilt/sideshift disk. This provides a voltage signal at J8 Pin 7. The lift pump motor is started, and the system controller then switches to a low-voltage signal at J4 Pin 8, energizing the sideshift-right solenoid. During sideshift operation, the proportional valve is partially opened to remove excess fluid. There is an orifice disc under the sideshift valve cartridge to reduce the speed of operation of the sideshift cylinders.

3. Attach the hydraulic lines to the lift pump.

7. Separate the lift pump from the lift pump motor and remove from the truck.

Replacement 1. Position the lift pump on the lift pump motor shaft.

2. Attach the lift pump to the lift pump motor and tighten the bolts to 30 lb-ft. [2 cap screws & lock washers] 4. Reinstall the top cover and front cover (refer to TOP COVER and FRONT COVER Replacement procedures in the FRAME section).

5. Connect the battery.

6.01 LIFT PUMP & MOTOR ASSEMBLY Removal NOTE The lift pump can be removed from the motor without removing the motor from the truck (refer to LIFT PUMP Removal procedure in this section).

LIFT PUMP

1. Disconnect and remove the battery, and discharge the capacitors (refer to APPENDIX A: INDUSTRIAL BATTERY, and the ELECTRICAL section).

Removal NOTE If the pump is replaced due to failure, also replace the hydraulic oil filter element.

2. Remove the overhead guard (refer to OVERHEAD GUARD Removal procedure in the FRAME section).

NOTE If the lift pump and motor assembly has been removed from the truck, skip to Step 6.

3. Label and disconnect the power cables to the lift pump motor.

1. Tilt the mast to the full forward position.

4. Clean the area around the hydraulic connections to the lift pump.

2. Disconnect the battery and discharge the capacitors.

5. Disconnect the hydraulic lines from the lift pump and cap them.

3. Remove the front cover and top cover (refer to FRONT COVER and TOP COVER Removal procedures in the FRAME section).

6. Attach a lifting device to the lift pump and motor assembly for support.

4. Clean the area around the hydraulic connections to the lift pump.

7. Remove the bolts securing the lift pump and motor assembly to the frame of the truck. [4 hex bolts, 4 flat washers, 4 flange lock nuts]

5. Disconnect the hydraulic lines from the lift pump and cap them.

03/21/00 6.2

TOYOTA Electric Stand Up “E” Series 8. Remove the lift pump and motor assembly from the truck.

Lift and Auxiliary Hydraulics 7. Remove the brush.

Replacement

Replacement NOTE If any brush needs replacing, replace all the brushes as a set. It is recommended to stone the commutator when replacing brushes.

1. Align the lift pump and motor assembly with the holes in the front frame of the truck.

2. Attach the lift pump and motor assembly to the frame of the truck. [4 hex bolts, 4 flat washers, 4 flange lock nuts]

1. Insert the brush assembly into the brush holder.

3. Attach the hydraulic lines to the lift pump in the correct locations.

2. Reposition the end of the brush spring on the brush.

4. Install the power cables to the proper terminals on the lift pump motor.

3. Attach the brush lead to the brush terminal and tighten the screw.

5. Install the overhead guard (refer to Overhead Guard Replacement procedures in the FRAME section).

4. Reinstall the lift pump and motor assembly (refer to LIFT PUMP AND MOTOR ASSEMBLY Replacement procedure in this section).

6. Install and connect the battery (refer to APPENDIX A: INDUSTRIAL BATTERY).

5. Replace the front cover (refer to FRONT COVER Replacement procedure in the FRAME section).

6.02 LIFT PUMP MOTOR BRUSHES TABLE 6 NEW Brush Length 1.35 in.

Spring Tension 65 oz.

Commutator Dia.* 2.92 in. * Replace at 2.75 in. Diameter

6. Connect the battery.

MIN 0.62 in.

40 oz.

2.80 in.

6.03 VALVE CARTRIDGES

Removal

Refer to the LIFT & AUX section of the PARTS Manual for an illustration of the components of the manifold.

NOTE Two of the lift pump motor brushes may be inspected without removing the lift pump motor from the truck.

WARNING Before disconnecting any hydraulic lines, relieve the pressure in the lines. Allow the truck to sit for approximately five minutes.

1. Tilt the mast to the full forward position.

Removal

2. Disconnect the battery and discharge the capacitors.

1. Lower the mast completely and tilt the mast to the full forward position.

3. Remove the front cover (refer to FRONT COVER Removal procedure in the FRAME section).

2. Disconnect the battery and discharge the capacitors.

4. Remove the lift pump and motor assembly (refer to LIFT PUMP AND MOTOR ASSEMBLY Removal procedure in this section).

3. Remove the front cover and top cover (refer to FRONT COVER and TOP COVER Removal procedures in the FRAME section).

5. Remove the brush covers. Release the spring tension on the brush by rotating the brush holder spring away from the brush.

4. When working on any of the valves in the lift/lower circuit, open the manual lowering valve to relieve pressure.

6. Remove the screw securing the brush lead to the brush holder.

5. If applicable, mark the coil connections for correct replacement. Remove the coil retaining nut and slide the coil(s) off the valve.

03/21/00 6.3

TOYOTA Electric Stand Up “E” Series 6. Place a shop towel over the top of the valve cartridge and loosen 1/4 turn. Allow any internal pressure to equalize. Remove the valve cartridge.

Lift and Auxiliary Hydraulics 3. Remove the front cover (refer to FRONT COVER Removal procedure in the FRAME section).

4. Use a filter wrench to loosen the filter.

Unscrew the filter and lift it out.

Replacement

Replacement

1. Make sure the O-ring on the valve cartridge is in place and in good condition. Insert the cartridge into the opening and hand tighten.

1. Lubricate the seal of the new filter with hydraulic fluid.

2. Tighten the valve cartridge to the correct torque as listed in Table 6.2. If installing the sideshift valve, make sure the restrictor is installed under the valve with the beveled side down.

2. Screw the filter onto the filter housing until the gasket seats and then turn another ¼ turn.

3. Connect the battery and operate the hydraulic system.

4. Check the hydraulic oil level and fill to the proper level using the correct type of hydraulic oil (refer to the Scheduled Maintenance and Inspection Table in the PREVENTIVE MAINTENANCE Section.

3. Close the manual lowering valve if it was opened during removal.

4. If applicable, install the coil(s) in the correct position and install the retaining nut. Tighten to the torque listed in Table 6.2.

5. Install the front cover (refer to FRONT COVER Replacement procedure in the FRAME section).

5. Connect the battery and test for leaks and proper operation.

6. Install the top cover and front cover (refer to TOP COVER and FRONT COVER Replacement procedure in the FRAME section).

HYDRAULIC OIL Removal

TABLE 6.2 Valve Cartridge

Torque Valve to

Torque Coil Retaining Nut to

Double-Coil (Tilt, Sideshift)

25 lb-ft

5 lb-ft

Single-Coil (Lift, Lower)

25 lb-ft

5 lb-ft

Proportional

35 lb-ft

17 lb-ft

Manual Lowering

25 lb-ft

N/A

Relief Valve

25 lb-ft

N/A

Check Valve

25 lb-ft

N/A

Flow Regulator

35 lb-ft

N/A

1. Lower the carriage to the ground (collapse all lift cylinders).

2. Tilt the mast to the full forward position.

3. Disconnect the battery and discharge the capacitors.

4. Remove the front cover (refer to FRONT COVER Removal procedure in the FRAME section).

5. Place the lift truck on blocks to access the drain plug in the bottom of the hydraulic oil tank (refer to PUTTING THE LIFT TRUCK ON BLOCKS in the GENERAL section).

6. Remove the breather cap from the filler tube of the hydraulic reservoir.

6.08 HYDRAULIC OIL FILTER

7. Place a pan of adequate size, minimum 10 gallon capacity, underneath the drain plug.

Removal

8. Remove the drain plug from the bottom of the hydraulic reservoir.

1. Lower the carriage to the ground and tilt the mast to the full forward position.

9. Allow the oil to completely drain from the reservoir.

2. Disconnect the battery and discharge the capacitors.

03/21/00 6.4

TOYOTA Electric Stand Up “E” Series 10.Remove the hydraulic oil filter (refer to HYDRAULIC OIL FILTER Removal procedure in this section).

Lift and Auxiliary Hydraulics 7. Disconnect the tilt cylinder from the mast by removing the screw and retaining washer and pulling the tilt cylinder pin out of the mount.

Replacement w

WARNING DO NOT use fingers to remove the tilt cylinder pins.

Support the tilt cylinder when removing the pin so that it does not drop and damage the truck or the tilt cylinder.

1. Install a new hydraulic oil filter (refer to HYDRAULIC OIL FILTER Replacement procedure in this section).

w

2. Use pipe thread sealant (Loctite 545 or equivalent) on the threads of the drain plug and install it in the opening of the hydraulic reservoir and tighten.

8. Remove the plastic plug from the hole in the side of the truck.

9. Remove the cotter pin from the tilt cylinder pin.

3. Insert a funnel into the filler neck of the hydraulic reservoir and pour the new hydraulic oil into the reservoir.

a 1/2" x 12" drift pin, drive the tilt cylinder pin from the frame mount and remove the tilt cylinder from the truck.

4. Using the markings on the front of the reservoir, check the level of the hydraulic oil.

Add oil until the proper level is attained.

Replacement

5. Install the front cover (refer to FRONT COVER Replacement procedure in the FRAME section).

1. Make sure the rear bushing is in place in the frame mount. Insert the base of the tilt cylinder into the mount in the frame of the truck.

6. Connect the battery and operate the lift system. Check oil level and fill as needed.

2. Insert the pin into the mount from the inner side.

6.09 TILT CYLINDERS

3. Install the cotter pin into the end of the tilt cylinder pin and replace the plastic plug in the frame hole.

Removal

4. Connect the hydraulic hoses to the tilt cylinder and tighten all fittings.

1. Lower the carriage to the floor and tilt the mast to the vertical position.

2. Disconnect the battery and discharge the capacitors.

5. Align the rod end of the tilt cylinder with the mounting bracket on the mast. Make sure the front bushing is in place in the mast mount.

3. Wrap a chain around the top cross members of the mast and attach it to a lifting device.

6. Insert the tilt cylinder pin through the tilt cylinder and mast mount.

4. Remove the slack from the chain so the lifting device will support the weight of the mast. DO NOT lift the front of the truck off the floor.

7. Install the retaining washer and screw.

8. Remove the lifting device supporting the mast assembly.

5. Remove the front cover (refer to FRONT COVER Removal procedure in the FRAME section).

9. Connect the battery.

10.Operate the tilt function to test for proper operation and to check for leaks.

WARNING Before disconnecting any hydraulic lines, relieve the pressure in the lines. Allow the truck to sit for approximately five minutes.

11.Install the front cover (refer to FRONT COVER Replacement procedure in the FRAME section).

6. Loosen the hydraulic connections to the tilt cylinders and disconnect the hoses from the tilt cylinder fittings (leave the 90o fittings on the cylinder).

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TOYOTA Electric Stand Up “E” Series

Lift and Auxiliary Hydraulics

6.10 TILT ANGLE ADJUSTMENT

RELIEF PRESSURE ADJUSTMENT

Test Procedure

Special Tools: P/N 00593-11491-71 Pressure Check Adapter & Hose Kit

The following conditions mean the tilt cylinders need to be adjusted: a. Tilt the mast fully forward. As the mast is tilted forward, watch both tilt cylinder ends. If one end stops before the other, adjustment is required. b. Tilt the mast to the full back position. As the mast is tilted back, watch both of the tilt cylinder ends. If one cylinder stops before the other, adjustment is required. c. Tilt the mast to the full forward position.

Use an angle protractor to measure the angle of the mast. If the tilt angle does not match the specifications listed on the serial plate, both tilt cylinders need adjustment.

1. Locate the pressure check port for the lift system. This port is on the lift pump outlet fitting.

2. Connect an appropriate pressure gauge to the port using the adapter and hose kit.

3.

Place a maximum capacity load on the carriage. Read the pressure gauge while lifting in the second stage and record the highest pressure observed. Continue lifting to the stops. Record the pressure while lifting against the stops. DO NOT lift against the stops for more than 5 seconds.

4. The relief pressure should be approximately 200 psi above the lifting pressure (for a triplex mast, approximately 2400 psi). Relief pressure may be adjusted at the relief valve on top of the manifold. Loosen the lock nut on the valve and turn the internal screw clockwise to increase pressure or counter-clockwise to decrease pressure. When the relief pressure is correct, tighten the lock nut.

Adjustment 1. Disconnect the rod end from the mast (refer to TILT CYLINDER Removal procedure in this section).

2. Loosen the rod end clamp screw (Item 8 Figure 6.1).

3. Rotate the tilt cylinder rod end to adjust the length of the cylinder.

NOTE Connect the rod end to the mast and test both forward and backward tilt after each change in tilt cylinder length to verify proper adjustment. Continue adjusting as necessary until both tilt cylinders stop at the same time in both the forward and backward tilt, and the tilt angle is correct.

4. Once proper adjustment is attained, tighten the clamp screw to lock the rod end.

5. Test the tilt cylinder adjustment per the Test Procedure above.

Figure 6.1

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TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Mast Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 Center (Free-Lift) Cylinder Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Outer Lift Cylinders Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Checks and Adjustments Check for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Lift Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Load Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Brass Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 Outer Cylinder Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

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TOYOTA Electric Stand Up “E” Series

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Description 3

The FSV Mast has three rails; outer, middle, and inner. The rails are telescopic and use load rollers (bearings) and brass set screws to keep them in alignment. Two single-stage outer (main) lift cylinders and a center (free-lift) cylinder are used to raise the carriage and extend the mast rails. It is called a full free-lift mast because the carriage can travel to the top of the inner rail without extending the inner rail.

2

Load rollers are installed at the top inside of the outer and middle rails. Load rollers are also installed at the bottom outside of the middle and inner rails. The load rollers travel along the flanges of the rails. The angle of the load rollers permits them to control the forces from the front, back, and sides of the mast. The load rollers are adjustable with shims.

1

6

The brass set screws are installed at the top rear of the outer and middle rails and help keep the correct clearance between the rails. The brass set screws at the top of the outer rail are adjustable and are locked in place by stainless steel set screws. The brass set screws at the top of the middle rail are adjustable and are locked in place by jam nuts.

4 5

The two outer (main) lift cylinders are installed at the back of the outer rail. The base of each lift cylinder sits in a mount at the bottom of the outer rail and is secured with a roll pin. The top of each outer lift cylinder (cylinder rod) is bolted to the top crossbar of the middle rail. The center (free-lift) cylinder is mounted in the inner rail and is held in place with a snap ring and strap. All three lift cylinders are displacement-type cylinders equipped with internal hydraulic cushioning (see Figs. 7.2 and 7.3).

7

One pair of lift chains is connected to adjustable anchor bolts near the top of the outer rail. These chains go over sheaves (pulleys) at the top of the middle rail and fasten at the bottom of the inner rail. The free-lift chains are connected to adjustable anchor bolts at the middle crossbar of the inner rail. These chains go over sheaves on the head of the center cylinder and fasten to the carriage.

1. Outer Rail 2. Middle Rail 3. Inner Rail 4. Outer Lift Cylinder

The three hydraulic cylinders are connected by hoses and tubes as shown in Fig. 7.4. To extend the mast, oil from the main control valve flows to all cylinders at the same time. The center cylinder extends first because it lifts the least amount of weight and has the larger area. The center

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5. Center Lift Cylinder 6. Free-Lift Chain 7. Carriage

FIGURE 7.1 - FSV MAST

7.1

TOYOTA Electric Stand Up “E” Series

CENTER CYLINDER The center cylinder is cushioned at the top of its stroke. There is hydraulic oil on the rod side of the piston. There are two orifices in the rod, one larger than the other (Items 3 and 4). As the rod extends, the hydraulic oil on the rod side is forced underneath the rod through the large orifice (3). When the rod extends near the end of its stroke, the gland nut at the top of the cylinder closes the large orifice (3). The remainder of the hydraulic oil must flow through the small orifice (4) providing a cushioning effect.

2 1

3

s

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s

1. Cylinder Rod Assembly 2. Cylinder Shell 3. Large Orifice 4. Small Orifice 5. Wear Ring

4

5

FIGURE 7.2 - CENTER CYLINDER CUSHIONING

OUTER CYLINDERS The outer cylinders are cushioned at the bottom of their stroke. As the rod retracts, the hydraulic oil flows out of the cylinder through the port (3).

When the rod is retracted near the end of its stroke, the piston ring (6) is below the port opening. The hydraulic oil below the rod must flow through the small orifice (4). This cushion effect prevents a sudden stop at the end of the lowering sequence, making a smoother lowering operation.

1

2

3

1. Cylinder Rod Assembly 2. Cylinder Shell 3. Port 4. Small Orifice 5. Wear Ring 6. Piston Ring

5 4 6

FIGURE 7.3 - OUTER CYLINDER CUSHIONING

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7.2

TOYOTA Electric Stand Up “E” Series cylinder raises the carriage to the top of the inner rail. After the center cylinder reaches the end of its stroke, the outer lift cylinders begin to extend.

As the outer cylinders extend, the middle rail is raised. The inner rail is raised by the lift chains.

During lowering, the outer lift cylinders retract first because they have the greater load and the smaller area. After the outer cylinders have retracted, the center cylinder lowers. All oil from the lift cylinders flows through the lowering control valve which limits the lowering speed. Flow fuses at each cylinder port close to prevent the mast from dropping in the event of a sudden outrush of oil from a broken hose or tube. Once the problem has been repaired, raise the mast to reset the flow fuses.

Safety Procedures When Working on the Mast The following procedures must be used when inspecting or working on the mast. Additional precautions and procedures can be required when repairing or removing the mast.

WARNING Mast parts are heavy and can move.

Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or carriage. Ÿ Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or safety chains are installed. Also make sure the power is off and the key is removed. Put a “DO NOT OPERATE” tag in the operator compartment. Ÿ Be careful of the forks. When the mast is raised, the forks can be at a height to cause injury. Ÿ DO NOT climb the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. Ÿ DO NOT use blocks to support the mast rails or to restrain their movement. Ÿ Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in this manual.

FIGURE 7.4 - HYDRAULIC SCHEMATIC

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7.3

TOYOTA Electric Stand Up “E” Series 1

2

3

4

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5

6 8

5 6

4

LOWERED 8

7

7

3

FULLY RAISED 2 FREE-LIFT

1

1. Outer Rail 2. Outer Lift Cylinders 3. Middle Rail 4. Center Lift Cylinder 5. Inner Rail 6. Carriage 7. Outer Lift Chains 8. Free-Lift Chains FIGURE 7.5 - OPERATION

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7.4

TOYOTA Electric Stand Up “E” Series

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4. Route auxiliary (sideshift) hoses over the hose sheave on the center cylinder and connect them to the carriage.

Carriage Removal 1. Tilt the mast to vertical. Remove the forks and load backrest. Disconnect any hydraulic connections to the carriage. Remove the two carriage stop bolts at the top of the inner rail.

5. Install the carriage stop bolts at the top of the inner rail.

2. Connect a lifting device to the carriage. Use the lifting device to raise the carriage so there is slack in the free-lift chains.

Mast

WARNING When disconnecting the lift chains, keep control of the ends to prevent them from falling and causing injury or damage.

NOTE If the mast must be disassembled, remove the forks and carriage before removing the mast.

Make sure rails are completely lowered and open the manual lowering valve to relieve pressure in the hydraulic lines.

Removal

3. Remove the pin from each chain anchor at the carriage. Disconnect the chains from the carriage. Remove the chain sheaves and hose sheave from the center cylinder. NOTE: if the mast is to be disassembled, disconnect the free lift chains at the inner rail middle crossbar and remove them.

1. Before removing the mast, check the length of the lift chains to see if they need replacing (refer to Cleaning and Inspection).

2. Fully lower all of the rails and the carriage.

Use chains to fasten all the rails together and connect a lifting device to the mast. Make sure the chains will not damage the sheaves, tubing, hoses, or other parts of the mast.

Make sure the lifting device has a capacity of at least 2500 lb (1150kg).

4. Use the lifting device to raise the carriage out of the top of the inner rail. Lower the carriage to the floor so that it lays face down.

5. If any of the load rollers must be replaced, make a note of the number and location of shims. See Checks and Adjustments for correct adjustment of load rollers.

3. Put a drain pan under the area of the hydraulic fittings. Disconnect the hydraulic lines from the truck to the mast. Cap the hydraulic lines from the truck.

Replacement CAUTION The carriage bearings could fall off while lifting the carriage above the mast.

1. Install the load rollers and shims on the carriage. Use a lifting device to raise the carriage directly above the inner rail. Check and adjust the clearance of the load rollers (refer to Checks and Adjustments in this section).

2. Lower the carriage below the center cylinder clevis head. Install the chain sheaves and hose sheaves on the center cylinder clevis head.

3. Route the free-lift chains over the chain sheaves and connect them to the chain anchors on the carriage. Make sure the lift chains are adjusted correctly as described in Checks and Adjustments.

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FIGURE 7.6 - TILT CYLINDER

7.5

TOYOTA Electric Stand Up “E” Series

on the inner rail are visible in the notches at the top of the middle rail.

4. Make sure there is no slack in the lifting device or chains. Remove the metric screw, lock washer, and retainer washer (Item 12, Fig 7.6) from the tilt cylinder rod end.

5. Lift the inner rail out of the middle rail.

Remove the load rollers at the bottom of the inner rail and the top of the middle rail. Make a note of the shim arrangement at each load roller location. The shim arrangement will be approximately the same during assembly.

5. Support the tilt cylinder while removing the front cylinder pin. Rest the tilt cylinder on the frame of the truck being careful not to damage the cylinder rods.

6. Remove the screws, washers, and spacer sleeves at the top of the outer cylinders (do not allow the cylinder rod to spin). Make a note of all shims at the top of either cylinder rod.

6. Repeat Steps 4 and 5 for the other tilt cylinder.

7. Make sure the mast is vertical. Remove the mast mount plates and use the lifting device to raise the mast and separate it from the truck. Put the mast on the floor so that the back of the mast is down.

7. Push the middle rail half way out of the outer rail and connect a lifting device to it. Now push the middle rail out until the load rollers at the bottom of the middle rail are visible in the notches at the top of the outer rail.

Disassembly NOTE If the carriage has already been removed, start with Step 3.

Hoses are installed under tension.

8. Lift the middle rail out of the outer rail.

Remove the load rollers at the bottom of the middle rail and the top of the outer rail. Make a note of the shim arrangement at each load roller location. The shim arrangement will be approximately the same during assembly.

1. Disconnect all hydraulic connections from the carriage. Loosen chain anchor bolts and disconnect the chains from the carriage and middle crossbar of the inner rail and remove.

Remove the chain and hose sheaves from the center cylinder.

9. If the outer cylinders need repair, disconnect the hydraulic tubes at the bottom of the outer cylinders, remove the roll pin from the base, remove them from the outer rail and mark them as right and left. Retain any shims noted in Step 6 with the cylinder. Remove hydraulic tubes, manifold and fittings from the rails as necessary.

2. Remove the two carriage stop bolts at the top of the inner rail. Attach a lifting device to the carriage. Slide the carriage out the top of the inner rail. Lay the carriage on the floor face down. Remove the load rollers, noting the number and location of shims at each load roller. The shim arrangement will be approximately the same during reassembly.

Cleaning and Inspection 1. Inspect the chain sheaves and load rollers for wear or damage. DO NOT use steam to clean the lift chains, sheaves, or load rollers.

The bearings in the sheaves and load rollers are lubricated and sealed.

3. Disconnect and remove the hydraulic hoses for the center cylinder and auxiliary (sideshift) attachment back to the outer rail. Remove the tube connecting the center cylinder to the distributor block. Remove the snap ring at the bottom of the center cylinder and the center cylinder strap. Remove the center cylinder.

WARNING When using cleaning solvents, always follow the manufacturer’s recommended safety precautions.

4. Loosen the chain anchor bolts and disconnect the lift chains at the bottom of the inner rail and the top of the outer rail and remove.

Remove the chain sheaves at the top of the middle rail. Push the inner rail half way out the top of the middle rail and connect a lifting device to the inner rail. Now push the inner rail out of the middle rail until the load rollers

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2. Clean the lift chains with solvent. Remove all dirt and grease. Inspect the lift chains for wear or damage. The lift chains must be installed on the mast before they can be checked for length. A lift chain becomes longer when it is worn. Most wear occurs in the section that goes over a sheave. If a chain is 3% longer than a new lift chain, a new 7.6

TOYOTA Electric Stand Up “E” Series

the load rollers as described in Checks and Adjustments.

PAIR of lift chains must be installed. Use a chain scale if one is available to check the lift chains. If you do not have a chain scale, measure 20 links of the chain. For ¾ inch pitch chain, the length of 20 links of new chain is 15 inches. The wear limit, or maximum allowable length of 20 links of ¾ inch pitch chain is 15.45 inches. Replace the pair of chains if the length of 20 links reaches the wear limit. Lubricate the chains with clean SAE 40 motor oil. The best procedure is to soak the lift chains in motor oil.

4. Connect the outer cylinder rods to the middle rail using the screws, washers, spacer sleeves, and shims noted during disassembly (do not allow the rod to spin). If either of the outer cylinders was replaced, see Checks and Adjustments to determine if shims are needed. If removed, connect the hydraulic tubes and fittings between the lift distributor block and the outer cylinders. Make sure the arrows on the flow fuses point away from the cylinder ports.

WARNING Never replace just the worn section of a chain; replace the complete chain. Never replace just one chain of a pair; install new chains in pairs.

5. Connect a lifting device to the inner rail.

Install the load rollers and shims at the bottom of the inner rail and the top of the middle rail.

6. Fit the load rollers on the inner middle rail into the notches at the top of the middle rail. Slide the inner rail into the middle rail. Adjust the load rollers as described in Checks and Adjustments.

3. Inspect the chain anchors and pins. Replace worn or damaged parts.

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing and gloves. Never expose your skin to steam.

7. Connect the lift chains to the chain anchors at the top of the outer rail and bottom of the inner rail. Install the chain and hose sheaves at the top of the middle rail.

4. Clean the mast rails with steam or solvent.

8. Connect the center cylinder feed hoses and auxiliary (sideshift) attachment feed hoses to the outer rail. Route the hoses over the hose sheaves on the middle rail and connect them to the inner rail.

5. Inspect the load roller contact surfaces for wear or damage. Inspect all welds for cracks.

Assembly

9. Install the center cylinder in the mount on the inner rail. Install the cylinder strap and the snap ring. Install the tube between the center cylinder and the distributor block. Make sure the arrow on the flow fuse points away from the cylinder port.

NOTE The shims for the load rollers keep the rails parallel and give correct clearance. During assembly, the shim arrangement will be approximately the same as before disassembly. Check the clearance and adjust the shims for wear or changes caused by repairs. See Checks and Adjustments for the correct procedures.

10. Connect the free-lift chains to the anchors at the middle crossbar of the inner rail.

11. The carriage may be installed at this time (refer to Carriage installation procedure).

1. Put the outer rail on the floor with the back side down. If removed, install both outer cylinders in their original locations using spiral roll pins in the mounts at the bottom of the outer rail.

Installation 1. Connect a lifting device to the top of the mast using chains. Make sure all the rails are fastened together and that the chains will not damage the sheaves, hoses, or other parts of the mast. The lifting device must have a capacity of at least 2500 lb (1150 kg).

2. Connect a lifting device to the middle rail.

Install the load rollers and shims at the bottom of the middle rail and top of the outer rail.

3. Fit the load rollers at the bottom of the middle rail into the notches at the top of the outer rail.

Slide the middle rail into the outer rail. Adjust

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2. Use the lifting device to set the mast on the pivot points. Install the mast mount caps and grease the bearings.

7.7

TOYOTA Electric Stand Up “E” Series

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3. Make sure that the bushing is in place in the tilt cylinder mount on the mast. Line up the tilt cylinder rod end and insert the front tilt cylinder pin. Install the retainer washer, lock washer and metric screw. Repeat for opposite side.

1 2

8

4. Connect the hydraulic lines to the mast. Make sure the arrow on the lowering control points down. Close the manual lowering valve on the manifold.

3

5. Install the carriage if it was not installed during mast assembly.

4

6. Check for proper tilt angle. Operate the mast and check for leaks and proper operation.

Check the lift chains as described in Checks and Adjustments. Adjust the brass set screws as described in Checks and Adjustments.

5

Center (Free-Lift) Cylinder Repacking 1. Place a pallet or blocks under the forks and lower the carriage completely. Disconnect the free-lift chains and auxiliary attachment (sideshift) hoses from the carriage.

6

2. Lift the center cylinder clevis head out of the cylinder rod and set it aside. If oil is present inside the hollow tube, there is a leak between the piston and the tube (refer to Figure 7.2).

3. Use a spanner wrench to remove the gland nut. Replace the O-rings, back-up rings, wiper, and seal.

4. Install the gland nut on the cylinder and torque to 350 to 400 lb-ft.

7

1. Wiper 2. Rod Seal 3. Gland 4. Back-up Ring 5. O-Ring 6. Rod Assembly 7. Wear Ring 8. Cylinder Shell

5. Place the clevis head into the center cylinder rod. Connect the chains and hoses to the carriage.

FIGURE 7.6 - CENTER CYLINDER

6. Bleed the center cylinder.

Removal 1. Raise and support the carriage.

Installation

2. Put a drain pan under the area of the hydraulic fittings. Disconnect the tube from the cylinder.

1. Set the cylinder in the mount bracket in the inner rail. Install the cylinder strap and the snap ring.

3. Remove the snap ring at the bottom of the cylinder and the cylinder strap. Remove the cylinder.

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2. Connect the tube to the cylinder port.

3. Lower the carriage.

7.8

TOYOTA Electric Stand Up “E” Series

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4. Bleed the air out of the lift system.

1 4

Outer Lift Cylinders 2

10

Repacking 3

Tools: 00593-11957-71 FSV Gland Nut Tool

7

5

1. Operate the lift function so that the outer cylinders are extended about 12 to 24 inches.

4

2. For this procedure, use a chain with a capacity that is greater than the weight of the mast. Do not use blocks to support the elevated mast sections. Use the chain to secure the top crossbar of the outer rail to the bottom crossbar of the middle rail.

5 9

3. Slowly lower the mast so that the chain supports the weight of the elevated sections.

The carriage will be completely lowered.

4. Remove the screw securing the outer cylinder rod to the top crossbar (do not allow the rod to spin). If resealing both cylinders, remove both screws at this time.

6

5. Open the manual lowering valve so that the cylinder rods retract into the cylinder. Be careful not to lose any shims on the top of the rods. Note their location for reinstallation (typically, only one side will be shimmed).

6. Use a prybar or a large wrench on the port at the base of the cylinder to prevent the cylinder from rotating while loosening the gland nut.

Use the proper gland nut tool to loosen and remove the gland nut from the top of the cylinder.

7 8

7. Install new seals and lubricate them with clean hydraulic fluid. Carefully slide the gland nut over the cylinder rod and thread it into the cylinder. Make sure the cylinder does not rotate while tightening the gland nut. The gland nut should be torqued in excess of 100 lb-ft.

FIGURE 7.7 - OUTER CYLINDER 9. Slowly raise the mast just enough to take the tension off the chain. Remove the chain from the mast and lower it completely.

8. Close the manual lowering valve. Operate the lift control to extend the cylinder rods to the top crossbar. Make sure any shims that were found on top of the rods in Step 5 are in place. Install and tighten the hardware removed in Step 4.

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1. Wiper 2. Rod Seal 3. Gland 4. Back-up Ring 5. O-Ring 6. Rod Assembly 7. Wear Ring 8. Piston Ring 9. Spacer 10. Cylinder Shell

10. Check for leaks as described in the Checks and Adjustments section. If the mast leans to one side at full extension, the cylinder rods are not properly shimmed (refer to Checks and Adjustments for shimming instructions).

7.9

TOYOTA Electric Stand Up “E” Series Removal NOTE Most repairs to the outer cylinders, such as repacking the gland nut, can be made without removing the cylinder from the mast. The outer cylinders can be removed with the mast on or off the truck; the procedures are similar.

The mast must be completely extended to remove the outer cylinders.

1. Attach a lifting device to the top crossbar of the middle rail only. Remove the screws and spacer sleeves at the top of both outer cylinders (do not allow the rod to spin).

Disconnect the hydraulic tubes from both cylinders. Remove the roll pin from the cylinder to be removed.

2. Use the lifting device to raise the mast near full extension. Make a note of the shims between the cylinder rod and the middle rail crossbar. Lift the cylinder up and out of the top of the mast.

Replacement 1. Install the outer cylinder through the top of the mast. Place the bottom of the cylinder in the mount and install a spiral roll pin.

NOTE If a different cylinder is being installed, shims may need to be added. Refer to Checks and Adjustments for proper procedures.

2. Lower the rails and extend the cylinder rod until they contact. Place the shims noted during removal between the cylinder rod and the middle rail crossbar. Install the screws and spacer sleeves to secure the rods to the middle rail. Lower the mast completely.

Connect the hydraulic tubes to the cylinder ports.

3. Bleed the lift cylinders.

Elevating

pressure. Hydraulic oil can be injected into the body by the pressure.

Operate the hydraulic system. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise and lower the load several times. Check the lift cylinders and all hydraulic connections for leaks. Leave the mast elevated for several minutes to check for drift.

Lift Chain Adjustments When the lift chains are correctly adjusted: Ÿ The tension will be the same on each chain of the pair. Check tension by pushing on both chains at the same time. Ÿ The chain length will be correct. Ÿ The chains must travel freely through the complete cycle.

1. Lower the mast completely. Adjust the lift chains at the top of the outer rail so that the top of the inner rail is even with the top of the middle rail within 0.060” 2. Adjust the free-lift chains at the middle crossbar of the inner rail so that the heel of the forks are 1/4” to 3/8” off the floor when the mast is vertical (bottom of the carriage will be 3” - 3½“ off the ground).

3. When the chain adjustments are complete, tighten the second nut on each chain anchor and make sure the cotter pin is in place.

4. Check the clearance of the carriage when center cylinder is at full extension. The carriage stop blocks must not touch the stop bolts at the top of the inner rail.

Load Rollers During assembly, the shim arrangement will be approximately the same as before disassembly.

Check the clearance and adjust for wear or changes because of repairs.

The load rollers control the alignment of the rails.

The alignment conditions are listed below in order of importance:

Checks and Adjustments

a) The rails must be parallel to each other.

Check for Leaks

b) Use shims to adjust the load rollers so that there is 0.001 to 0.010 in. clearance between the load roller and the channel at the point of tightest fit.

WARNING DO NOT try to find hydraulic leaks by putting your hand on hydraulic components under

3/10/00

c) The number and thickness of shims under a load roller must be approximately the same as

7.10

TOYOTA Electric Stand Up “E” Series

Elevating

that under the load roller on the opposite side of the rail.

A

Perform the following procedure to adjust the mast load rollers.

B

2

1. Use a pry bar to move the rails from side to side while measuring the movement.

Measure the movement in a minimum of three different positions of the rails.

2. Separate the rails and add or remove shims as required. Slide the rail all the way from top to bottom and find the tightest fit.

1

3. Repeat Steps 1 and 2 until there is 0.001 to 0.010 in. clearance at the point of tightest fit.

DO NOT shim the load rollers too tight.

Check for free movement by sliding rail through full extension by hand.

UPPER LOAD ROLLERS

1

4. Measure the distance between the channels of the rails on the top and bottom. Change shims to keep the distance equal at the top and bottom so that the rails are parallel within 0.060 in.

C 2

Brass Set Screws 1. Shim load rollers to 0.000 0.010 in. at tightest point.

2. Brass set screws.

NOTE The brass set screws can only be adjusted with the mast installed on the truck and the mast tilted forward.

The brass set screws reduce the front to back movement between the rails. The brass set screws are too loose if there is excessive front to back play in the rails when extended. On the FSV mast, there are two pairs of brass set screws.

One pair is located at the top of the outer rail, secured by smaller set screws. The other pair is located at the top of the middle rail, secured by jam nuts.

A±0.060 B±0.060

1

1. Tilt the mast fully forward. Loosen the small set screw or jam nut.

1

2. Turn the brass set screw through the rail so it is tight against the next rail. Back the screw off by ¼ turn.

3. Tighten the small set screw or jam nut to lock the brass set screw.

LOWER LOAD ROLLERS

C ±0.060

4. Operate the mast and check the adjustment.

Outer Cylinder Shims Shims between the outer cylinder rods and the middle rail keep the mast from being cocked to one side at full extension. If one cylinder extends 3/10/00

FIGURE 7.8 - MAST ADJUSTMENTS 7.11

TOYOTA Electric Stand Up “E” Series slightly longer than the other, or if one cylinder mount is slightly higher than the other, shims must be used to keep the mast level.

Raise the mast to full extension. If the middle rail cocks to one side when it reaches full extension, add shims at the top of the cylinder rod on the short side, or remove shims from the top of the cylinder rod on the low side to bring it level with the opposite side.

3/10/00

7.12

Elevating

TOYOTA Electric Stand Up “E” Series TABLE OF CONTENTS Capacitor Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 System Controller / Operator Display Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Operator Display Board / Memory Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Traction Amplifier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Contactor Tips Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Main Power Contactor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Lift and Steer Contactors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Fuses Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Horn Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Horn Relay Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 Amplifier Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

04/05/00

8.i

Electrical

TOYOTA Electric Stand Up “E” Series

Electrical

CAPACITOR DISCHARGE WARNING Discharge the capacitor bank prior to performing any service on the lift truck.

Failure to follow proper discharging procedures can result in personal injury or damage to the electronic circuitry of the truck.

The normal method of discharging the capacitors is: 1. Turn the key switch OFF (Position '0').

2. Disconnect the battery.

3. Turn the key switch ON (Position 'I'). The operator display will light then slowly dim.

Once the operator display goes black, the capacitors are fully discharged.

FIG. 8.1 - SYSTEM CONTROLLER DECAL

4. Turn the key switch OFF.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE procedure in this section).

The above method cannot be used if the 15 amp fuse for the System Controller is open. In this event, the capacitors can be discharged by the following method:

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

3. Scribe lines on the mounting bracket to mark the position of the display box. Loosen (do not remove) the four mounting screws securing the system controller/operator display box to the bracket.

1. Turn the key switch OFF. 2. Disconnect the battery.

3. Use an INSULATED electrical cable or wire to short the Positive and Negative bus bars at the capacitors.

4. Rotate the top of the system controller/ operator display box upward until the connectors on the back are accessible.

SYSTEM CONTROLLER / OPERATOR DISPLAY BOX w w

5. Unplug all connectors from the back of the system controller (make sure they are labeled for correct replacement).

WARNING Tampering with the System Controller may void warranty.

Switching System Controller from truck to truck will void warranty.

6. Lift the system controller/operator display box from the mounting bracket.

Replacement NOTE The System Controller must be electrically isolated from the frame of the truck. The back plate of the system controller is B-.

CAUTION To avoid damage to the system controller and operator display, follow the CAPACITOR DISCHARGE PROCEDURE at the beginning of this section.

1. Line up the lower mounting screws on the system controller/operator display box with the slots in the mounting bracket and slide the box into the bracket.

Removal

4/3/00

8.1

TOYOTA Electric Stand Up “E” Series

Electrical board to the standoffs on the system controller pc board.

2. Plug all connectors into the correct ports in the back of the system controller (refer to Figure 8.1).

CAUTION The operator display board and system controller are connected by a single 32-pin connector. The memory board and system controller are connected by two connectors.

Be careful not to damage the pins or connectors when removing the operator display board or memory board.

3. Rotate the top of the system controller/operator display box down until the upper mounting screws are in the slots in the bracket. Align the display box with the lines scribed in Step 3 of Removal. Tighten all four screws.

4. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section). Check for proper alignment of the display with the cutout in the top cover; adjust if necessary.

6. Gently lift the operator display board or the memory board off of the system controller.

Replacement

5. Connect the battery.

CAUTION w Be careful not to damage the pins or connector when installing the operator display board or memory board. w Refer to the procedures for handling static-sensitive assemblies in the GENERAL INFORMATION section

OPERATOR DISPLAY BOARD / MEMORY BOARD Removal CAUTION To avoid damage to the system controller and operator display, follow the CAPACITOR DISCHARGE PROCEDURE at the beginning of this section.

1. Line up the connectors on the operator display pc board or memory board with the mating connectors on the system controller pc board.

2. If replacing the operator display board, mount it onto the standoffs on the system controller and secure it with four screws. If replacing the memory board, make sure it is fully seated on the system controller and the foam block is in place on the memory board.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE procedure in this section).

2. Remove the system controller/operator display box from the mount bracket (leave all harnesses attached).

3. Plug in the key switch and light or auxiliary selector switches (if so equipped). Make sure the key switch is plugged in correctly (not off by one pin).

NOTE When removing the cover from the system controller/operator display box, be careful not to break the wires from the key switch and light or auxiliary selector switches (if so equipped).

4. Install the plastic cover over the system controller/operator display.

NOTE If the cover is too high, the LED display will appear fuzzy. Ensure the cover is seated against the display board, but does not distort the overlay.

3. Remove the 8 screws that attach the plastic cover and lift the cover off the system controller.

CAUTION Refer to the procedures for handling static-sensitive assemblies in the GENERAL INFORMATION section.

5. Reinstall the system controller/operator display box in the mount bracket.

4. Unplug the key switch and light or aux. selector switches (if so equipped).

5. If replacing the operator display, remove the four screws securing the operator display pc 4/3/00

8.2

TOYOTA Electric Stand Up “E” Series

Electrical

TRACTION AMPLIFIER Replacement WARNING with the amplifier

void

1. Apply an even film of heat-sink compound to the bottom of the amplifier before installation.

CAUTION To avoid damage to the system controller and amplifiers, follow the CAPACITOR DISCHARGE procedure at the beginning of this section.

2. Make sure the mounting surface on the truck is clean and free from any foreign materials which might prevent the amplifier base from making full contact. Position the amplifier in place and align the mounting holes in the amplifier base with the holes in the truck frame. Install the 6 mounting screws, lock washers, and flat washers. Torque the screws to 13 lb-ft. in the pattern shown in Figure 8.3. Tighten all screws to approximately ½ the final torque, then repeat the sequence, tightening all screws to the full

Tampering warranty.

may

FIG. 8.2 - TRACTION AMPLIFIER DECAL FIG. 8.3 - AMPLIFIER TORQUE SEQUENCE Removal torque.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE procedure in this section).

Remove the top cover.

3. Connect the FB+ cable from the 80-amp fuse to the FB+ terminal on the rear of the amplifier.

4. Connect the B- jumper cable to the Bterminal at the back of the amplifier.

2. Disconnect the system controller-to-amplifier harness at P2 on the amplifier.

5. Attach the diode module bus bar and motor A2 cable to the A2 terminal of the amplifier.

3. Disconnect the jumper cable from the Bterminal at the back of the amplifier.

6. Connect the field cables from the motor to the proper terminals on the amplifier.

4. Disconnect the FB+ cable from the amplifier to be removed.

7. Plug the system controller-to-amplifier harness into P2 on the amplifier.

5. Label and disconnect the two field cables (F1 and F2) from the front of the amplifier.

8. Install the TOP COVER (refer to TOP COVER Replacement procedure in the FRAME section).

6. Disconnect the short bus bar and cable from the A2 terminal of the amplifier.

7. Remove the battery. Remove the six screws, lock washers, and flat washers securing the amplifier assembly to the frame of the truck and remove the amplifier.

9. Install and connect the battery and test the truck for proper operation.

4/3/00

8.3

TOYOTA Electric Stand Up “E” Series

Electrical

CONTACTOR TIPS

overheating. Use a backup wrench to prevent bending the bus bars.

CAUTION NEVER manually close the main power contactor. Damage to the system controller and/or the amplifiers may occur.

5. Connect the power cables and wires as noted during Step 3 of Removal.

6. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

CAUTION To avoid damage to the system controller and amplifiers, follow the CAPACITOR DISCHARGE PROCEDURE at the beginning of this section.

7. Connect the battery.

MAIN POWER CONTACTOR

Removal

CAUTION NEVER manually close the main power contactor. Damage to the system controller and/or the amplifiers may occur.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE PROCEDURE in this section).

CAUTION To avoid damage to the system controller and amplifiers, follow the CAPACITOR DISCHARGE PROCEDURE at the beginning of this section.

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

3. Note the location of all power cables and wires for correct replacement. Disconnect the cables and wires from the bus bars on the contactor. Use a backup wrench to prevent bending the bus bars.

Removal

4. Remove the nylon lock nuts securing the upper contactor tips in place.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE PROCEDURE in this section).

5. Remove the insulators and springs from the armature. Remove the contactor tips.

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

6. Remove the lock nuts securing the insulator block to the contactor body. Remove the insulator and the bus bars.

3. Disconnect the B+ and capacitor supply cables from the bus bar of the main power contactor (the bus bar toward the front of the truck).

Replacement 1.

2.

3.

4.

4. Remove the bus bar between the contactor and the fuses.

Install the bus bars on the insulating base.

Be sure the holes in the bus bars engage the locators on the insulating base.

5. Label and disconnect the wires from the main power contactor.

Install the insulator on the bus bars and secure with the lock nuts.

6. Remove the bus bar between the contactor and the lift (600 amp) fuse.

Install the upper tips over the insulators attached to the armature.

7. Remove the nuts securing the panel to the frame of the truck and rotate the panel to access the contactor mount screws.

Install the springs and insulating washers and secure with the lock nuts.

8. Remove the screws holding the contactor to the bracket and remove the contactor.

NOTE DO NOT over-tighten the nuts securing the cables and wires to the bus bars of the contactor.

Over-tightening the nuts can cause the bus bars to bend, resulting in misalignment of the contactor tips and

Replacement 1. Align the mounting holes in the contactor with the holes in the panel and install the screws.

4/3/00

8.4

TOYOTA Electric Stand Up “E” Series

Electrical

2. Install the contactor-fuse panel assembly to the frame.

FUSES

3. Install the bus bar between the contactor and the lift (600 amp) fuse.

Removal

4. Connect the power cables to the fuses, starting with the lowest fuse.

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE procedure in this section).

5. Connect the wires to the main power contactor in the correct locations noted during Step 5 of Removal.

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

3. Remove fuse.

6. Connect the B+ and capacitor bank supply cables to the contactor bus bar.

Replacement

7. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

1. Install the proper fuse and tighten the screws.

2. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

8. Connect the battery.

3. Connect the battery.

LIFT AND STEER CONTACTORS Removal

HORN

1. Disconnect the battery and discharge the capacitors (refer to CAPACITOR DISCHARGE Procedure in this section).

Removal 1. Disconnect the battery.

2. Remove the top cover (refer to TOP COVER Removal procedure in the Frame section).

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

3. Label and disconnect the power cables and wires from the contactor bus bars and coil.

Use a backup wrench to prevent bending the bus bars.

3. Disconnect the 2-pin connector.

4. Remove the two screws securing the horn to the frame.

4. Remove the screws securing the contactor to the top plate. Remove the contactor.

Replacement

Replacement

1. Install the horn with two screws.

2. Connect the 2-pin connector.

1. Align contactor with mounting holes in top plate. Install screws and tighten.

3. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

2. Connect power cables and wires to contactor in correct locations as noted in Step 3 of Removal.

4. Connect the battery.

3. Install top cover (refer to TOP COVER Replacement procedure in the Frame section).

HORN RELAY

4. Connect the battery.

Removal 1. Disconnect the battery.

2. Remove the top cover (refer to TOP COVER Removal procedure in the FRAME section).

4/3/00

8.5

TOYOTA Electric Stand Up “E” Series 3. Disconnect the 2-pin connectors from the horn and from the main harness.

4. Remove the two screws securing the horn relay to the frame.

Replacement 1. Install the horn relay with two screws.

2. Connect the 2-pin connectors to the horn and the main harness.

3. Install the top cover (refer to TOP COVER Replacement procedure in the FRAME section).

4. Connect the battery.

AMPLIFIER DIODES Special Tools: Digital Volt-Ohm Meter (DVOM) with diode test function.

Test for both forward and reverse bias at room temperature and at 180° F following the diode test instructions in the meter manual.

4/3/00

8.6

Electrical

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics

PROGRAMMING AND DIAGNOSTICS INTRODUCTION

PERFORMANCE AND DIAGNOSTICS MENU

This section covers the operator interface of the 6BNCUE lift truck, from pre-operational information to operational modes. This section also includes calibration of control input hardware, configuring the performance characteristics to suit individual operators/applications, and diagnostic testing.

The Performance and Diagnostics menu consists of three submenus; CALib (calibration of control input functions), ProG (performance configuration), and diAG (diagnostic input and output tests and error history).

To enter the Performance and Diagnostics Menu, the user must enter a password.

PRE-OPERATION INFORMATION When the key switch is rotated from the 'O' position to the 'I' position, power is applied to the controllers. After performing internal checks, the following menu is available to the user: b-100 HourS SEr n CodE PErF

1234.5 e1234 6.08 _____

Menu Convention The Tilt/Sideshift disk on the control handle is used to scroll through the menu structure. To scroll up or down through the menu, press tilt forward or tilt back, respectively. To view or change selection settings, press sideshift right.

Press the horn button to make a selection and go back to the menu or press sideshift left to leave a selection unchanged.

Move up or down through the menu by pressing tilt forward or tilt back on the Tilt/Sideshift disk. w b-100 is the battery state-of-charge. w HourS displays the total operational hours of the forklift. w SEr n is the unit serial number. w CodE displays the software version. w PErF: To enter the Performance and Diagnostics menu, press sideshift right when PErF appears in the display.

A password is required to access the Performance and Diagnostics menu (see below).

Password Entry When in password entry mode, pressing tilt forward and tilt back on the Tilt/Sideshift disk will scroll through the numbers available. Pressing sideshift right and sideshift left on the Tilt/Sideshift disk will move the cursor position right or left. When the entire password is displayed, pressing the horn button will send it.

04/03/00

9.1

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics

PERFORMANCE AND DIAGNOSTICS MENU Prog

f spd R spd Dr ac

Steer L cut

Idle L int

^5 ^5 reg Fast Slo on d 16 se 10 20 30 on Off br-lf

Software Version 6.08

on Off off On re Fd Both Off short Reg Long

Re-lf B alr

dir

Durat

F pad Pass Defau Diag

input Outs Histo

Calib

tract Lift steer

off On _____ yes

04/03/00

9.2

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics

CALIBRATION MENU (CALIBRAT) This menu is used to calibrate the travel, lift/lower, and steer position potentiometers.

7. Return the control handle to the neutral position and press sideshift left until PErF is dispayed. Turn the key to the “O” position to save the calibration.

Steer Position Potentiometer Calibration Traction Calibration Make sure there is no play in the control handle when in neutral position (refer to the Operator Controls section). To calibrate the travel potentiometer:

To adjust the steer position potentiometer, refer to STEERING POTENTIOMETER Adjustment in the ELECTRICAL section. To calibrate the steer position potentiometer:

1. From the main menu, select the PErF option and enter a the password.

1. From the main menu, select the PErF option and enter the password.

2. Select the CALib option.

2. Select the CALib option.

3. From the CALib menu, select trACt. The potentiometer voltage reading will be displayed.

3. From the CALib menu, select StEEr. The potentiometer voltage reading will be displayed.

4. Move the control handle forward and hold it against the stop. Press the horn button to enter the voltage.

4. Rotate the steering tiller in the direction which increases the voltage reading on the display.

5. Return the control handle to the neutral position and press the horn button to enter this reading.

5. When the steer fork reaches the stop, press the horn button to accept the voltage reading.

6. Move the control handle toward the rear and hold it against the stop. Press the horn button to accept the reading.

6. Rotate the steering tiller in the opposite direction, decreasing the voltage reading. When the steer fork reaches the stop, press the horn button to accept the reading.

7. Return the control handle to the neutral position and press sideshift left until PErF is displayed. Turn the keyswitch to the “O” position to save the calibration.

7. Rotate the steering tiller until the steer wheel(s) are centered and press the horn button.

8. Press sideshift left until PErF is displayed. Turn the keyswitch to the “O” position to save the calibration.

Lift Calibration Make sure there is no play in the control handle when in the neutral position (refer to the Operator Controls section).

To calibrate the lift potentiometer: 1. From the main menu, select the PErF option and enter the password.

2. Select the CALib option.

3. From the CALib menu, select LiFt. The potentiometer voltage reading will be displayed.

4. Move the control handle right and hold it against the stop. Press the horn button to enter the reading.

5. Return the control handle to the neutral position and press the horn button to accept this reading.

6. Move the control handle toward the left and hold it against the stop. Press the horn button to accept the reading.

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9.3

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics (durAt) selection allows the user to set the length of the backup alarm tone.

PROGRAM MENU The Program menu is used to configure the performance of the lift truck to suit the operator or application. Scroll through the menu as described under Menu Conventions in this section. When sideshift right is pressed, the current setting for the selection will be displayed. To change the setting, press tilt forward or tilt back. To save the new setting and return to the Program menu, press the horn button. To return to the Program menu without changing the setting, press sideshift left.

F SPd / R SPd / 3.0-6.7 These selections allow the user to independently set the maximum forward and reverse speeds of the truck in increments of one-tenth MPH.

PASS - _ _ _ _ _ This selection allows the user to view or change the password that is required to access the Performance and Diagnostics Menu. dEFAu - YES This selection allows the user to return all selections to the factory default settings.

dr AC / rEG FASt SLo This selection allows the user to set the acceleration and deceleration (plugging) characteristics of the truck.

StEEr / on d 16 SE This selection allows the user to set the time delay before the steer pump shuts off. When set to on d the steer pump will activate when the control handle is moved forward or backward, and will remain on for 5 seconds after no movement of the control handle is detected.

L Cut / 10 20 30 This selection allows the user to set the minimum battery state-of-charge before lift functions are disabled. idLE / on oFF This selection allows the user to toggle the reset function.

When set to ON, the truck will return to pre-operational mode (battery charge displayed) after 15 minutes without operation.

L int / br-LF / rE-LF The Brake/Lift (br-LF) selection allows the user to set the lift system to operate only when the brake pedal is depressed (on), or, independent of the brake pedal (oFF).

The Reverse/Lift (rE-LF) selection allows the user to set the lift system to shut down when the truck is traveling in reverse (on), or, independent of travel direction (oFF). b ALr / dir / rE Fd botH oFF durAt / Short rEG LonG This selection allows the user to set the operation of the backup alarm. The Direction (dir) selection allows the user to set the backup alarm to operate when the truck is traveling forward, reverse, both, or not at all. The Duration 04/03/00

9.4

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics

DIAGNOSTIC MENU (DIAG DIAG) DIAGNOSTIC INPUT TESTS TEST

TEST NAME

NORMAL OPERATION DISPLAY

FAULT ERROR DISPLAY

I 01

Start Switch

I 01 - oFF - I 01 - on

I 02

Brake Pedal Switch

I 02 - uP - I 02 - dn

E17

I 03

Travel Potentiometer Voltage

I 03 - Voltage 3.1 - 4.6 Full Forks First 1.9 - 3.1 Neutral 0.4 - 1.9 Full Tractor First

E06

I 04

Lift/Lower Potentiometer Voltage

I 04 - Voltage 3.1 - 4.6 Full Lift 1.9 - 3.1 Neutral 0.4 - 1.9 Full Lower

E07

I 05

Steer Position Potentiometer Voltage

I 05 - Voltage 0.4 - 1.9 Full Left 1.9 - 3.1 Straight 3.1 - 4.6 Full Right

E09

I 14

Floorpad Switch

I 14 - oFF - I 14 - on

E16

DIAGNOSTIC OUTPUT TESTS ALERT UNIT COULD RUN TEST

TEST NAME

NORMAL OPERATION DISPLAY

FAULT ERROR DISPLAY

O 01

Main Power Contactor

oPEn CLSd

E27a-f

O 02

Steer Motor

oFF on

E41

O 03

Lower Solenoid

oPEn CLSd

E30

O 04

Lift Solenoid

oPEn CLSd

E31

O 06

Tilt Forward Solenoid

oPEn CLSd

E33

O 07

Tilt Back Solenoid

oPEn CLSd

E34

O 08

Sideshift Left Solenoid

oPEn CLSd

E35

O 09

Sideshift Right Solenoid

oPEn CLSd

E36

O 14

Lift/Lower Proportional Solenoid

oPEn CLSd

E29

O 15

Horn

oFF Horn sounds

E32

O 16

Display

oFF All LEDs lit

O 17

Left Field.Armature Amps

oFF 25-30.40-70

E51L, E61L-E65L

O 18

Right Field.Armature Amps

oFF 25-30.40-70

E51R, E61R-E65R

O 19

Lift Motor

oFF on

E49

04/03/00

9.5

TOYOTA Electric Stand Up “E” Series

Programming and Diagnostics

ERROR HISTORY (HiSto) The last 62 errors are stored in memory with a timestamp.

OPERATIONAL FEEDBACK DEVICES The operator's display provides visual feedback on all functions of the truck. It consists of a five-digit LED display and several LED indicator symbols.

Shutdown Mode When a fault which could cause damage or unsafe conditions occurs, the truck will shut down the function until the condition is cleared (in some cases, the key switch must be cycled after the condition is cleared). Either the lift system or the travel system may be shut down independently, or the shutdown may be total. In some cases, when the lift system is shut down, lowering is still available. The LED display will display the fault code.

Refer to System Fault Codes at the end of this section.

Battery State-of-Charge Indicator with Lift Interrupt The Battery State-of-Charge indicator contains ten LEDs; five green, three yellow, two red. The number of LEDs lit indicates the amount of charge remaining before lift cutout occurs. When the last LED starts to slowly flash, the battery has less than 5% charge remaining before lift cutout. When this changes to a faster flash, less than 2% remains. When lift cutout occurs, all LEDs are off, and an error code will be displayed. The lift system, except lower, is disabled.

Wheel Position Indicator The Wheel Position indicator contains seven LEDs arranged in a semi-circle which light to indicate the position of the steer wheel.

LED Display The display is a bank of five seven-segment LEDs. The display is used to show the battery state-of-charge, warranty hours, program settings, calibration voltages, input and output tests, and error codes.

OPERATIONAL MODES Power-On Self Test When the key switch is rotated to the "II" position and released, the Power on Self Test begins and the display reads "POST". When all tests are complete, and no failures have occurred, the message "PASS" is shown in the dot matrix display. If any of the tests fail, a message indicating the specific error will be scrolled through the display. If there is more than one error, the user can scroll through the errors by pressing tilt forward or tilt back on the Tilt/Sideshift disk.

Run Mode When POST is passed, the truck is in RUN mode.

04/03/00

9.6

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

The numbers in this drawing correspond to the numbers in the first column of the SCHEDULED MAINTENANCE & INSPECTIONS TABLE.

FIG. 10.1 - SCHEDULED MAINTENANCE AND INSPECTION POINTS 4/3/00

10.1

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

SCHEDULED MAINTENANCE AND INSPECTION TABLE COMPONENT 1

Battery

2

Battery Disconnect

CHECK/ACTION

HOURS DAYS

Charge - Normal Charge - Equalizing Check water level and cleanliness Connector in good condition, bolt installed

X

Check for free movement of the lever Check that the lever disconnects the battery Do Not Lubricate

X X X

Battery Gates

Check that they are securely in place Lubricate (as needed)

5

Brakes

Released when brake pedal is depressed and stops the unit within the specified distance when pedal is returned to up position Brake pads - inspect and replace (as needed)

G

X

E

E

X

C C

C C

X

B B

A A

F

G

E H

E H

X

Brake Pedal / Brake Linkage

Check for smooth operation, no binding, and the pedal comes up when foot is removed Do Not Lubricate

X

7

Brake Switches

Locks out travel capability when pedal is up

X

Carriage / Load Backrest / Forks

Inspect for cracks, bends, and damage Lubricate sideshift carriage

X

9

Contactor Tips

Check condition, inspect for pitting, adequate tip contact surface, signs of burning

10

Control Handle

Check for smooth and full movement forward, reverse, lift, and lower; check horn, tilt, and all auxiliary functions for operation Do Not Lubricate

X

X

11

Decals

Check operational, safety, and warning decals Replace if missing or unreadable

X

12

Gearbox

Check operation Check fluid level and fill (as needed) Change fluid at first 100 hours, then:

X

Check for leaks Check level and fill (as needed) Change hydraulic oil and filter Breather cap - check and clean

X

Lift Chains

F

X

8

14

32oF to 120oF

2000 360

X

Battery Rollers

Hydraulic System

350 60 X

3

13

40 5

X

4

6

8 1

LUBRICATION

-40oF to 32oF

X

X X

Check for wear, damage, and cotter pins in place on connector pins at anchor bolts Lubricate and adjust

X X

15

Lights

Function when switched on

X

16

Mast

Inspect for damage Check for cotter pins in place on tilt cylinder pins

X X

17

Motor Brushes

Check for wear and proper seating Replace (as needed)

18

Steering

Turns without binding - no excess play

X

19

Tires

Inspect tires for cracks, gouges, and wear

X

20

Wheels

Lubricate wheel and final drive pinion bearings Lubricate final drive gears

21

Static Straps

Touch the floor.

X

X X X

LUBRICATION REFERENCE TABLE A

Texaco 32 / Tellus 32 / Mobil DTE 24

E

Mobilith SHC 220 Synthetic Grease NLGI 2 or equivalent

B

McCollister Arctic Blue Hydraulic Oil 3028

F

SAE 20W Motor Oil

C

Mobil SHC 50 Synthetic Gear Lubricant or equivalent

G

SAE 40W Motor Oil

H

Mobilith SHC 007 Synthetic Grease NLGI 00 or equivalent

4/3/00

10.2

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

8-HOUR / DAILY INSPECTION GENERAL

WARNING If repairs are required, install a "DO NOT OPERATE" tag on the control handle.

Remove the key and disconnect the battery.

DO NOT operate a damaged or defective lift truck until it has been repaired.

STARTUP SEQUENCE The lift truck is equipped with a "Static Return to Off" circuit that prevents operation of the truck if the starting sequence is not correct. The function of this circuit is to make sure the operator is in the correct position to operate the controls before the lift truck will travel. The following is the starting sequence:

BATTERY

1. Turn the key switch to the "I" (ON) position.

After the system controller performs internal checks, the display will read "b-100".

w

2. With the brake pedal released, turn the key switch to the "II" (RUN) position and release it. If the internal self-tests are passed, the truck will enter run mode. If errors are detected, the code number will be displayed.

E-82 indicates that the brake pedal is not released.

w

3. Use only one foot to depress and hold down the brake pedal. Traction functions are now enabled.

w

w w

w

4. Move the control handle forward or backward to initiate travel.

If the control handle is moved forward or backward before the brake pedal is depressed, the truck will not travel in either direction. The control handle must be completely released to enable travel functions.

w w w

The lift truck must not be operated if this circuit does not function correctly.

w w

GENERAL FUNCTIONS

w

Perform the starting sequence as described above and check the following operations: w w w w w w

WARNING Read the battery charger manual before charging batteries.

DO NOT smoke or use spark producing devices near batteries.

DO NOT expose the batteries to open flames.

Always charge batteries in a well ventilated area to avoid hydrogen gas concentration.

Clean batteries regularly; corrosion causes grounds and the possibility of sparks.

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

Charge batteries at the indicated rates.

DO NOT lay tools, chains, or other metal objects on top of batteries.

Always wear protective clothing and eye protection when handling, checking, or filling batteries.

DO NOT overcharge batteries.

DO NOT connect the battery charger to the lift truck.

Ensure charger voltage is correct for the battery being charged.

Refer to APPENDIX A: INDUSTRIAL BATTERY for detailed battery safety precautions.

Operator Display Horn Lift, tilt, sideshift (if so equipped), and auxiliary functions (if equipped) Brakes Steering system Direction and speed control

9/1/99 10.3

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance necessary, install spacers to achieve this specification.

CHARGING THE BATTERY WARNING DO NOT connect the battery charger to the lift truck.

BRAKES

NOTE See APPENDIX A: INDUSTRIAL BATTERY for detailed information about charging and maintaining batteries.

NOTE Release the brake pedal only in an emergency. The forklift will stop abruptly which may cause the load to fall.

Never discharge a battery below the limits listed in APPENDIX A. Discharging a battery below the design limits will decrease the service life of the battery.

Make sure the battery voltage and the weight are correct as shown on the nameplate.

The brakes, operated by the brake pedal, are primarily for use as a parking brake and for emergency stopping.

When the brakes are applied (pedal released), a microswitch informs the system controller to disable traction.

Give the battery a DAILY CHARGE using a charger designed for the battery. Check with the manufacturer of your battery or your dealer for a suitable battery/charger combination. The DAILY CHARGE is normally 8 hours in length and will keep the battery fully charged if it has not been discharged below the limit.

Verify that the brakes disengage when the brake pedal is depressed, and that they engage when the brake pedal is released. The brakes should hold the truck with a capacity load on a 15% grade ( a drop of 1.5 feet in a 10 foot run). If the brakes do not hold the truck on the grade, refer to the BRAKE ADJUSTMENT procedures in the BRAKES section of MAINTENANCE.

Changing the Battery

BRAKE PEDAL / BRAKE LINKAGE

Refer to APPENDIX A: INDUSTRIAL BATTERY for detailed information and procedures for changing the battery.

Check the operation of the brake pedal.

Operation should be smooth with no binding or dragging. The return spring should easily raise the pedal to its mechanical stop. The brake pedal does not require lubrication.

BATTERY CONNECTOR 1. Operate the battery disconnect lever. The lever should move freely, and return to the original position. Check to see that the battery connectors are separated. The battery disconnect lever does not require lubrication.

BRAKE SWITCHES The function of the brake switch is to prevent operation of the travel functions of the lift truck when an operator is not properly positioned in the operator compartment.

To test the switch, release the brake pedal so that it returns fully to its mechanical stop (brakes fully applied). With the key switched to "II" (RUN) and while standing in the operator compartment, operate the control handle in both the forward and reverse directions.

The traction motors should not engage, and the truck should not move. If the brake switch does not work properly, refer to the BRAKES section in MAINTENANCE. The second brake switch is used to control the electric brake units through a relay.

2. Check the battery connectors and cables for damage, cracks, breaks, or corrosion.

Ensure the connector from the battery has the bolt and lock nut correctly installed for the battery disconnect.

BATTERY GATES 1. Ensure the battery gates are securely in place and have not shifted.

2. The battery should not be able to shift more than 1/2" in any horizontal direction. If 9/1/99 10.4

TOYOTA Electric Stand Up “E” Series w

CARRIAGE / LOAD BACKREST / FORKS Inspect the carriage, load backrest, and forks for cracks bends and damage. Never repair forks by heating them; replace worn or damaged forks.

w w

CONTROL HANDLE

LIGHTS (OPTIONAL) If your unit is equipped with overhead guard-mounted work lights, a flashing light, or stop/tail lights, ensure they function correctly and are tight.

Test all operations of the control handle (travel, lift/lower, tilt, sideshift, aux, horn). Movement of the handle should be smooth and full.

DECALS

MAST

Check to see that none of the operational, safety, or warning decals are missing or unreadable.

Each of these decals serves a vital function; to protect the operator, those around the truck, or the truck itself. Replace any decal that is missing or unreadable. Refer to the FRAME section of the PARTS manual for type and placement of decals on your model lift truck.

WARNING DO NOT work under a raised carriage. Lower the carriage and forks to the ground or use a suitable locking device to prevent the carriage and inner rails from lowering when performing maintenance on the mast.

1. Inspect the welds on the rails of the mast for cracks. Make sure all nuts and bolts are tight, and that the cotter pins are in place on the tilt cylinder pins.

GEARBOX 1. Inspect the gearboxes for fluid leaks and loose mounting bolts.

2. Check the channels for wear in the areas of roller contact. Check the rollers for wear or damage.

2. Drive the truck forward and reverse in a straight line. Drive the truck in a tight circle to the left and right. Operation should be smooth and free of any unusual noise.

3. Check that the chain and hose sheaves operate smoothly and are not damaged.

4. Raise the carriage slowly without a load.

Check for smooth operation and the correct sequence when the carriage and rails make their telescoping movements within the channels. A wrong sequence when the mast is raised and lowered indicates that adjustment is necessary. Refer to the ELEVATING section.

HYDRAULIC SYSTEM

w

Hydraulic oil under pressure can be injected into the skin. Never check for leaks by putting hands on a hydraulic line under pressure.

Disconnect the battery while servicing.

Never operate the pump without oil in the hydraulic system. Doing so will damage the pump.

Check the hydraulic system for leaks and damaged or loose components. Report damage immediately. DO NOT operate the lift truck until problems are corrected. If repair is required, put a "DO NOT OPERATE" tag on the control handle.

WARNING If any function does not operate correctly, repair the fault immediately. DO NOT operate the lift truck until the problem is corrected.

Put a "DO NOT OPERATE" tag on the control handle, remove the key, and disconnect the battery.

w

Preventive Maintenance

CAUTION The operating temperature of the hydraulic oil is - 160oF. Before disconnecting any hydraulic lines, relieve the pressure in the lines.

9/1/99 10.5

TOYOTA Electric Stand Up “E” Series 5. Operate the mast and check visually for equal tension of the chains through the complete cycle. If the chains do not have equal tension, adjustment is necessary; refer to the ELEVATING section.

STEERING Check that the steering system operates smoothly and provides good steering control.

TIRES / WHEELS Inspect the tires for wire, rocks, glass, pieces of metal, holes, cuts, and other damage. Tire wear will vary depending on the operating surface, load weight, and the method of operation.

STATIC STRAPS Check that the static straps (attached to the frame under the brake pedal and at the hydraulic tube clamp) are in place and are touching the floor. Replace a worn or missing static strap.

9/1/99 10.6

Preventive Maintenance

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

40-HOUR / 5-DAY INSPECTION BATTERY

LIFT CHAINS

Keep the battery case and the battery compartment clean and painted. Leaks and corrosion from the battery can cause a malfunction in the electrical controls of the lift truck. Use a water and soda solution to clean the battery and the battery compartment. Keep the top of the battery clean, dry, and free of corrosion. Refer to APPENDIX A: INDUSTRIAL BATTERY for more detailed procedures for cleaning the battery.

WARNING DO NOT work under a raised carriage. Lower the carriage and forks to the ground or use a suitable locking device to prevent the carriage and rails from lowering when performing maintenance on the lift chains.

1. Visually inspect the lift chains for cracks or broken links and pins. Check for corrosion or worn holes in the links. As the links and pins wear, the chain will become longer.

Where applicable, check the level of the electrolyte on all cells. Refer to the instructions from the manufacturer of your battery for the correct operating level of the electrolyte.

2. Use a chain scale to check the lift chains. If a chain scale is not available, measure 20 links of chain. Replace the chain if the length of 20 links of the worn chain is more than 15.45”.

HYDRAULIC SYSTEM w WARNING w The operating temperature of the hydraulic oil is 90oF - 160oF. w Disconnect the battery while servicing. w Before disconnecting any hydraulic lines, relieve the pressure in the lines. w Hydraulic oil under pressure can be injected into the skin. Never check for leaks by putting hands on a hydraulic line under pressure.

w

WARNING Replace a worn chain - DO NOT try to repair it.

If one chain in a pair has a defect, replace both chains.

3. Inspect the chain anchors and pins. Replace the chain anchors if there are cracks or worn holes. Replace chain anchor pins that are worn or damaged. Replace broken or missing cotter pins.

4. Check the lift chains for dryness. If needed, lubricate them as described in the 350-HOUR / 60-DAY INSPECTION section.

CAUTION w DO NOT permit dirt to enter the hydraulic system when checking the oil level. w Never operate the steer or lift pump without oil in the hydraulic system. Doing so will damage the pump.

1. Lower the carriage and tilt the mast fully forward. Check the hydraulic oil level with the dipstick. Make sure the temperature of the oil is at least 90oF. 2. If the oil level is low, carefully check for leaks and damaged or loose components.

9/1/99 10.7

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

350-HOUR / 60-DAY INSPECTION BATTERY

CONTACTOR TIPS

WARNING w DO NOT connect the battery charger plug to the lift truck. w Read the battery charger manual before charging batteries. w DO NOT smoke or use spark-producing devices near the battery. w DO NOT expose the battery to open flames. w Always change batteries in a well-ventilated area to avoid hydrogen gas concentration. w Clean batteries regularly; corrosion causes grounds and the possibility of sparks. w Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks. w Charge batteries at the indicated rates. w DO NOT lay tools, chains, or other metal objects on top of the battery. w Always wear protective clothing and eye protection when handling, checking, or filling batteries. w DO NOT overcharge the battery. wEnsure charger voltage is correct for the battery being charged.

WARNING Disconnect the battery and discharge the capacitor bank (refer to the ELECTRICAL section) before making any inspections or repairs to the contactor.

In normal operation, the contact surfaces become rough and turn a dark color. Cleaning is usually not necessary as this does not interfere with proper operation. The contact surfaces are silver alloy on a copper base. Replace the contacts when the silver surface wears through to the copper base. Always replace the contacts in sets.

Refer to CONTACTOR TIP Removal / Replacement procedures in the ELECTRICAL section.

GEARBOX Park the lift truck on a level surface. Check the oil level in the gearbox by removing the fluid level plug on the side of the gearbox. The fluid level should be even with the bottom of the hole.

CAUTION DO NOT permit dirt to enter the gearbox.

Refer to APPENDIX A: INDUSTRIAL BATTERY for detailed battery safety precautions.

HYDRAULIC SYSTEM

1. Give the battery an EQUALIZING CHARGE, using a charger designed for the battery.

This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is usually for 3 hours at a low rate, in addition to the regular charging cycle. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge.

Check the breather cap for accumulation of material that could prevent the easy passage of air.

LIFT CHAINS WARNING DO NOT work under a raised carriage. Lower the carriage and forks to the ground or use a suitable locking device to prevent the carriage and rails from lowering when performing maintenance.

2. Check with the manufacturer of your battery or with your dealer for a suitable battery/charger combination and for specific details about the equalizing charge for your battery.

1. Inspect the chains for accumulation of dirt, especially if the lift truck is operated in dusty 9/1/99 10.8

TOYOTA Electric Stand Up “E” Series conditions. Wipe the chains to remove any surface dirt.

2. Use a thin paint brush to liberally coat the full length of the lift chains with motor oil. Use SAE 20W for operating temperatures from -40oF to 32oF. Use SAE 40W for operating temperatures above 32oF. 3. Check the chain tension by fully lowering the carriage and tilting the upright to a vertical position.

4. Press on each chain, using moderate pressure. Each chain should have equal tension. Refer to the ELEVATING section for adjustment procedures.

MOTOR BRUSHES WARNING Disconnect the battery before making any inspections or repairs.

Drive Motors Check the condition of the brushes in the drive motors.

Brushes must be replaced if they measure less than 0.7".

Inspect and clean the commutator.

9/1/99 10.9

Preventive Maintenance

TOYOTA Electric Stand Up “E” Series

Preventive Maintenance

2000-HOUR / 360-DAY INSPECTION BRAKES

Filter

The brakes need adjusting when the lift truck wil not stop within 1.1 ft./mph after applying the brakes, running at full speed, with a full load. If after adjustment, the brakes do not meet these specifications, replace the disc brake unit (refer to DISC BRAKE UNIT Removal / Replacement procedures in the BRAKES section).

1. Use a filter wrench to remove the oil filter.

2. Use hydraulic oil to lubricate the seal on a new filter of the same type as the old one.

3. Install the new filter and tighten it by hand.

DO NOT overtighten.

4. Fully cycle the tilt function one time.

GEARBOX

5. Check the hydraulic oil level and check the filter for leaks around the seal.

1. Park the truck on a level surface, and completely lower the carriage and mast.

2. Disconnect the battery.

SIDESHIFT CARRIAGE

3. Change the oil in both gearboxes as described in GEARBOX Oil Change in the DRIVE section.

Lubricate the sideshift carriage with the lubricant recommended in the chart on Page 1.

TIRES / WHEELS HYDRAULIC SYSTEM

Lubricate the steer wheel at the grease fitting, using the correct lubricant as specified in the Scheduled Maintenance and Inspections Table at the beginning of this section.

NOTE This procedure is best done with the lift truck positioned approximately one foot off of the floor on a level surface. Make sure the lift truck is securely blocked (refer to Putting the Lift Truck on Blocks in the GENERAL MAINTENANCE section).

1. Remove the drive wheel (refer to DRIVE WHEEL Removal in the DRIVE section).

2. Clean the old grease from the drive wheel bearings, the ring gear, the pinion, and pinion bearings.

Oil 1. The drain plug is accessed through a hole in the underside of the chassis. Put a pan under the drain hole.

3. Inspect the drive wheel V-ring seal and replace if damaged.

2. Remove and clean the drain plug. When the oil has drained, install the drain plug.

4. Repack and install the wheel bearings. Apply enough grease to the ring gear and pinion (as specified in the Scheduled Maintenance and Inspections Table) to fill all the teeth.

3. Fill the hydraulic reservoir with oil as specified in the Scheduled Maintenance and Inspection Table at the beginning of this section.

5. Use a needle-nose grease gun to apply grease to the pinion gear shaft bearing. Use grease as specified in the Scheduled Maintenance and Inspection Table.

4. Replace the breather cap.

9/1/99 10.10

TOYOTA Electric Stand Up “E” Series

Troubleshooting

ELECTRONIC FAULT ISOLATION PROCEDURE SOFTWARE VERSION 6.08

E01

Fault condition RELEASE THROTTLE TO RESUME OPERATION Resulting Effect

Criteria

TRACTION system shutdown until condition is cleared.

Travel potentiometer voltage is not in the neutral range (±0.12V from calibrated center) when the brake pedal is depressed.

Possible Cause

Solution

PERFORM INPUT TEST 03 - TRAVEL POTENTIOMETER VOLTAGE. Look for constant repeatable voltage reading in neutral.

The control handle is not in neutral when the brake pedal is depressed.

Return control handle to neutral.

Travel potentiometer out of calibration.

Perform travel potentiometer calibration procedure.

Excess “play” in the control handle.

Adjust springs so there is no play in the neutral position. Calibrate the control handle.

Bad travel potentiometer.

Replace travel potentiometer and calibrate.

E02

Fault condition BRAKE LIFT INTERLOCK WARNING Resulting Effect

Criteria

LIFT system shutdown until condition is cleared.

Programmable brake-lift interlock is enabled. Lift potentiometer voltage is not in the neutral range (±0.14V from calibrated center) when brake pedal is depressed.

Possible Cause

Solution

PERFORM INPUT TEST 04 - LIFT/LOWER POTENTIOMETER VOLTAGE. Look for constant repeatable voltage reading in neutral.

The control handle is not in neutral when the brake pedal is depressed.

Return control handle to neutral.

Lift/lower potentiometer out of calibration.

Perform lift potentiometer calibration procedure.

Excess “play” in the control handle.

Adjust springs so there is no play in the neutral position. Calibrate the control handle.

Bad lift/lower potentiometer.

Replace lift/lower potentiometer and calibrate.

REV 12/5/99 TS.1

TOYOTA Electric Stand Up “E” Series

E04

Troubleshooting

Fault condition REVERSE LIFT INTERLOCK WARNING Resulting Effect

Criteria

LIFT system shutdown until condition is cleared.

NOTE: if rE Lf is enabled in programming and traveling in reverse, this is normal.

Programmable reverse-lift interlock is enabled. Lift potentiometer voltage is in the lift range (more than 0.14V above calibrated center) and travel potentiometer voltage is in the reverse range (more than 0.12V below calibrated center) while brake pedal is depressed.

Possible Cause

Solution

PERFORM INPUT TESTS 03 & 04 - TRAVEL & LIFT/LOWER POTENTIOMETER VOLTAGE. Look for constant repeatable voltage readings in neutral.

The control handle is not in neutral when the brake pedal is depressed.

Return control handle to neutral.

Lift/lower potentiometer out of calibration.

Perform lift potentiometer calibration procedure.

Excess “play” in the control handle.

Adjust spring set screws so there is no play in the neutral position. Calibrate the control handle.

Bad lift/lower potentiometer.

Replace lift/lower potentiometer and calibrate.

E05

Fault condition BATTERY VOLTAGE OUT OF RANGE Resulting Effect

TOTAL shutdown.

Criteria Battery voltage is out of the normal operating range.

Possible Cause

Solution

Battery voltage outside of normal working range: Maximum Minimum 41.2 V 29.5 V A freshly charged battery which has not been allowed to sit for the recommended time may exceed the voltage range.

Check working voltage of battery. It must be within the range listed at left. Replace the battery if the voltage is above the maximum or below the minimum listed voltages. After charging, allow the battery to sit for the time period recommended by the manufacturer.

E06

Fault condition TRAVEL POTENTIOMETER VOLTAGE OUT OF RANGE Resulting Effect

TRACTION system shutdown.

Criteria Travel potentiometer voltage is outside the normal operating range (0.39V to 4.63V). Note: actual voltage supplied to potentiometer is 15V.

Possible Cause

Solution

PERFORM INPUT TEST 03 - TRAVEL POTENTIOMETER VOLTAGE. Look for “dead spots”, sudden voltage jumps, etc.

Wiring to travel potentiometer broken or shorted. Inspect and repair wiring as necessary.

Bad potentiometer.

Replace travel potentiometer.

REV 12/5/99 TS.2

TOYOTA Electric Stand Up “E” Series

E07

Troubleshooting

Fault condition LIFT/LOWER POTENTIOMETER VOLTAGE OUT OF RANGE Resulting Effect

LIFT system shutdown.

Criteria Lift potentiometer voltage is outside the normal operating range (0.39V to 4.63V). Note: actual voltage supplied to potentiometer is 15V.

Possible Cause

Solution

PERFORM INPUT TEST 04 - LIFT/LOWER POTENTIOMETER VOLTAGE. Look for “dead spots”, sudden voltage jumps, etc.

Wiring to lift potentiometer broken or shorted.

Inspect and repair wiring as necessary.

Bad potentiometer.

Replace lift potentiometer.

E09

Fault condition STEER POSITION POTENTIOMETER VOLTAGE OUT OF RANGE Resulting Effect

TRACTION system shutdown.

Criteria Steer position potentiometer voltage is outside the normal operating range (0.29 V to 4.7 V). Note: actual voltage supplied to potentiometer is 15V.

Possible Cause

Solution

PERFORM INPUT TEST 05 - STEER POSITION POTENTIOMETER VOLTAGE. Look for “dead spots”, sudden voltage jumps, etc.

Steer position potentiometer out of adjustment.

Adjust steer position potentiometer or replace if necessary.

Wiring to steer potentiometer broken or shorted.

Inspect and repair wiring as necessary.

Bad potentiometer.

Replace steer position potentiometer.

E13L E13R

Fault condition LEFT/RIGHT TRACTION CONTROL TEMPERATURE SENSE VOLTAGE OUT OF RANGE Resulting Effect

TRACTION shutdown.

Criteria Left/right traction amplifier temperature sensor voltage is outside the normal operating range.

Possible Cause Bad amplifier harness or amplifier.

Solution Swap amplifier harness connections at J2 and J6 on the controller. If the error code changes sides, then the controller is good. If the code does not change sides, the controller is bad. Now swap the harness connections at the amplifiers. If the code changes back to the original side, then the amplifier is bad.

If the code does not change back, the harness is bad.

Warning: Tampering with traction amplifier may void warranty.

REV 12/5/99 TS.3

TOYOTA Electric Stand Up “E” Series

E15

Troubleshooting

Fault condition FLOORPAD SWITCH VOLTAGE OUT OF RANGE Resulting Effect

TRACTION SYSTEM shutdown.

Criteria Programmable floorpad option is enabled and system controller sensing improper input from the floorpad switch.

Possible Cause

Solution

PERFORM INPUT TEST 14 - FLOORPAD SWITCH. Harness to floorpad switch broken, shorted, or disconnected.

Inspect harness and repair as necessary.

Bad floorpad switch.

Test the resistor on the floorpad switch connector.

Replace floorpad switch.

e16

Fault condition REPOSITION RIGHT FOOT TO RESUME OPERATION Resulting Effect

Truck will coast to a stop.

Criteria Programmable floorpad option is enabled, and floorpad switch reading is open while truck is traveling.

Possible Cause

Solution

PERFORM INPUT TEST 14 - FLOORPAD SWITCH. Should indicate “ON” when right foot is on switch.

Operator’s right foot not properly positioned during travel.

Keep right foot on floorpad switch during travel.

Harness to floorpad switch broken, shorted, or disconnected.

Inspect harness and repair as necessary.

Bad floorpad switch.

Replace floorpad switch.

E17

Fault condition BRAKE FAILURE Resulting Effect

TOTAL shutdown.

Criteria System controller sensing improper input from the brake switch (greater than 2K ohm resistance).

Possible Cause

Solution

PERFORM INPUT TEST 02 - BRAKE LIMIT SWITCH. Should indicate “DN” when brake pedal is depressed and “UP” when released.

Wiring to the brake limit switch broken, shorted, or disconnected.

Check for defects in the wiring harness to the brake limit switch and replace if necessary. Resistance with pedal down should be 1.5K ohm ± 200 ohms.

Bad brake limit switch.

Replace brake limit switch.

REV 12/5/99 TS.4

TOYOTA Electric Stand Up “E” Series

E27A

Troubleshooting

Fault condition MAIN POWER CONTACTOR WIRING FAULT Resulting Effect

TOTAL shutdown.

Criteria The main power contactor coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 01 - MAIN POWER CONTACTOR. Broken or shorted wiring to the contactor.

Check and repair damaged wires to the contactor.

Test resistance from B+ to J4 pin 9 for 28 ohms.

Measure B+ and B- on coil.

Main contactor coil is open or shorted internally.

Replace main power contactor.

Malfunction of the main power contactor coil driver.

Replace system controller field fix.

If error codes 29-42 occur at the same time; J4 pin 3 not connected to switched B+.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace.

E27E

Fault condition MAIN POWER CONTACTOR WELDED Resulting Effect

TOTAL shutdown.

Criteria System controller senses current at both amplifier fields during POST indicating that Main Power Contactor is closed.

Possible Cause

Solution

PERFORM OUTPUT TEST 01 - MAIN POWER CONTACTOR. Contactor tips have been allowed to deteriorate, causing them to become welded. Check for movement of contactor tips.

Replace contactor tips.

Binding of the contactor solenoid shaft.

Replace main power contactor.

Conductive material between contactor tips.

Inspect contactor tips and remove foreign material.

REV 12/5/99 TS.5

TOYOTA Electric Stand Up “E” Series

E27F

Troubleshooting

Fault condition MAIN POWER CONTACTOR OPEN Resulting Effect

TOTAL shutdown.

Criteria No field current at both traction amplifiers when the coil driver for the main power contactor is energized.

Possible Cause

Solution

Contactor tips are not passing battery voltage when the coil is activated.

Check for foreign material between the contactor tips. Replace the contactor tips if necessary.

No battery voltage is supplied to the main power contactor tips.

Check the condition of the cables to the main power contactor and repair as necessary.

No field currrent at both traction amplifiers.

Check the power cables to the traction amplifiers and perform Diagnotic Output Tests 17 and 18.

80 amp fuse is blown.

Test fuse and replace if necessary.

E29

Fault condition LIFT/LOWER PROPORTIONAL VALVE WIRING FAULT Resulting Effect

LIFT system shutdown.

Criteria The lift/lower proportional valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 14 - LIFT/LOWER PROPORTIONAL SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

REV 12/5/99 TS.6

TOYOTA Electric Stand Up “E” Series

E30

Troubleshooting

Fault condition LOWER VALVE WIRING FAULT Resulting Effect

Criteria

LIFT system shutdown.

The lower valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 03 - LOWER SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

E31

Fault condition LIFT VALVE WIRING FAULT Resulting Effect

Criteria

LIFT system shutdown.

The lift valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 04 - LIFT SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

REV 12/5/99 TS.7

TOYOTA Electric Stand Up “E” Series

E32

Troubleshooting

Fault condition HORN WIRING FAULT Resulting Effect

DISPLAY code.

Criteria The horn circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 15 - HORN. Broken or shorted wiring to the horn.

Check and repair damaged wires to the horn.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Horn is open or shorted internally.

Replace horn.

Malfunction of the horn driver.

Replace system controller field fix.

E33

Fault condition TILT FORWARD VALVE WIRING FAULT Resulting Effect

LIFT system shutdown.

Criteria The tilt forward valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 06 - TILT FORWARD SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

REV 12/5/99 TS.8

TOYOTA Electric Stand Up “E” Series

E34

Troubleshooting

Fault condition TILT REVERSE VALVE WIRING FAULT Resulting Effect

LIFT system shutdown.

Criteria The tilt reverse valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 07 - TILT BACK SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

E35

Fault condition SIDESHIFT LEFT VALVE WIRING FAULT Resulting Effect

LIFT system shutdown.

Criteria The sideshift left valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 08 - SIDESHIFT LEFT SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

REV 12/5/99 TS.9

TOYOTA Electric Stand Up “E” Series

E36

Troubleshooting

Fault condition SIDESHIFT RIGHT VALVE WIRING FAULT Resulting Effect

Criteria

LIFT system shutdown.

The sideshift right valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 09 - SIDESHIFT RIGHT SOLENOID. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Solenoid coil is open or shorted internally.

Replace coil.

Malfunction of the coil driver.

Replace system controller field fix.

E41

Fault condition STEER CONTACTOR WIRING FAULT Resulting Effect

Criteria

TRACTION system shutdown.

The steer contactor coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 02 - STEER MOTOR. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Contactor coil is open or shorted internally.

Replace contactor.

Malfunction of the coil driver.

Replace system controller field fix.

REV 12/5/99 TS.10

TOYOTA Electric Stand Up “E” Series

E42

Troubleshooting

Fault condition LIFT CONTACTOR WIRING FAULT Resulting Effect

LIFT system, except lower shutdown.

Criteria The lift contactor coil circuit is overheated, shorted to supply, shorted to ground, or disconnected.

Possible Cause

Solution

PERFORM OUTPUT TEST 19 - LIFT MOTOR. Broken or shorted wiring to the coil.

Check and repair damaged wires to the coil.

If error codes 29-42 occur at the same time; 15 Amp fuse in main harness is bad.

Check 15 amp fuse on main harness, wiring on all hydraulic valve coils, repair or replace. Check for B+ at J4 Pin 3.

Contactor coil is open or shorted internally.

Replace contactor.

Malfunction of the coil driver.

Replace system controller field fix.

E51L E51R

Fault condition LEFT/RIGHT TRACTION MOTOR OVERHEATED Resulting Effect

TRACTION system shutdown.

Criteria The temperature of the traction motor (based on field resistance) has reached a point at which damage may occur.

Possible Cause

Solution

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.

Left and right field current should not differ by more than 5 amps.

Steer not properly calibrated.

Calibrate steer position potentiometer.

Continuous low speed travel operation, short runs, hard acceleration / plugging.

Change style of operation.

Loose motor terminals, brake drag, mechanical binding of drive unit or wheel.

Check motor terminals, brake clearance, operation of drive unit and wheel.

Bad traction motor (field resistance greater than 0.9 ohm at room temp).

Replace traction motor.

Bad traction amplifier.

Replace traction amplifier.

REV 12/5/99 TS.11

TOYOTA Electric Stand Up “E” Series

E55L E55R

Troubleshooting

Fault condition LEFT/RIGHT TRACTION CONTROL OVERHEATED Resulting Effect

TRACTION system shutdown.

Criteria The temperature sensor in the traction amplifier indicates that the temperature has reached a level which may damage components.

Possible Cause

Solution

Continuous travel operation, short runs, hard acceleration / plugging.

Reduce operation.

Loose motor terminals, brake drag, mechanical binding of drive unit or wheel.

Check motor terminals, brake clearance, operation of drive unit and wheel.

Open or shorted diode.

Test diode and replace if necessary.

Inadequate heat sink.

Check amplifier base for full contact and heat sink grease.

Bad traction amplifier temperature sensor.

Replace traction amplifier.

Warning: Tampering with traction amplifier may void warranty.

E61L E61R

Fault condition LEFT/RIGHT MOTOR BRUSH WEAR FAILURE Resulting Effect

SPEED limited.

Criteria Indicator sensor in brush is worn and has 36 volts from armature.

Possible Cause

Solution

Left/right traction motor brushes are worn.

Replace all left/right traction motor brushes.

Brush indicator wire shorted to 36V.

Inspect brush indicator wire and repair.

E62L E62r

Fault condition LEFT/RIGHT TRACTION MOTOR FIELD CURRENT HIGH Resulting Effect

TRACTION system shutdown. Will not pass POST.

Criteria The traction motor field current draw is greater than the system controller expects.

Possible Cause

Solution

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.

Left and right field current should not differ by more than 5 amps.

Shorted F1 or F2 cable from traction amplifier to Check cables, repair or replace. traction motor.

Bad traction amplifier.

Replace traction amplifier.

Bad traction motor (shorted winding).

Replace traction motor.

REV 12/5/99 TS.12

TOYOTA Electric Stand Up “E” Series

E63L E63R

Troubleshooting

Fault condition LEFT/RIGHT TRACTION MOTOR FIELD CURRENT NOT PRESENT Resulting Effect

TRACTION system shutdown. Will not pass POST.

Criteria The system controller detects no current to the traction motor field when there should be.

Possible Cause

Solution

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.

Left and right field current should not differ by more than 5 amps.

Broken or loose F1 or F2 cable from traction amplifier to traction motor.

Check cables, repair or replace.

Bad traction amplifier.

Replace traction amplifier.

Bad traction motor (open winding).

Replace traction motor.

E64L E64R

Fault condition LEFT/RIGHT TRACTION MOTOR ARMATURE HIGH Resulting Effect

TRACTION system shutdown. Will not Pass POST.

Criteria The traction motor armature current draw is greater than the system controller expects.

Possible Cause

Solution

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.

Left and right field current should not differ by more than 5 amps.

Shorted A1 or A2 cable from traction amplifier to Check cables, repair or replace. traction motor.

Bad diode.

Test diode and replace if necessary.

Bad traction amplifier.

Replace traction amplifier.

Bad traction motor (shorted winding).

Replace traction motor.

REV 12/5/99 TS.13

TOYOTA Electric Stand Up “E” Series

E65L E65R

Troubleshooting

Fault condition LEFT/RIGHT TRACTION MOTOR ARMATURE CURRENT NOT PRESENT Resulting Effect

TRACTION system shutdown. Will not pass POST.

Criteria The system controller detects no current to the traction motor armature when there should be.

Possible Cause

Solution

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.

Left and right field current should not differ by more than 5 amps.

Open armature fuse (400 Amp).

Replace fuse.

Broken or loose A1 or A2 cable from traction amplifier to traction motor.

Check cables, repair or replace.

Diode failure.

Test diode and replace if necessary.

Bad traction amplifier.

Replace traction amplifier.

Bad traction motor (open winding).

Stone the commutator, clean or replace brushes; replace traction motor if necessary.

E69

Fault condition SYSTEM CONTROL +5 VOLTAGE OUT OF RANGE Resulting Effect

TOTAL shutdown.

Criteria The internal 5V power supply is out of range.

Possible Cause

Solution

Battery voltage too low, especially if error occurs Test battery under load and replace if necessary. while operating truck.

Damaged or defective system controller.

E70

Replace system controller field fix.

Fault condition

SYSTEM CONTROL +15 VOLTAGE OUT OF RANGE Resulting Effect

TOTAL shutdown.

Criteria The internal 15V power supply is out of range.

Possible Cause

Solution

Battery voltage too low, especially if error occurs Test battery under load and replace if necessary. while operating truck.

Electrical shorts to chassis.

Locate and eliminate any shorts to chassis.

Bad amplifier.

Disconnect amplifier harnesses one at a time until fault changes. (Turn truck off while unplugging harnesses)

Bad system controller.

Replace system controller field fix.

REV 12/5/99 TS.14

TOYOTA Electric Stand Up “E” Series

E72L E72R

Troubleshooting

Fault condition LEFT/RIGHT TRACTION CONTROL +15 VOLTAGE OUT OF RANGE Resulting Effect

Criteria

TOTAL shutdown.

Possible Cause

Solution

Battery voltage too low, especially if error occurs Test battery under load and replace if necessary. while operating truck.

Bad traction amplifier. To check, switch amplifier harnesses and see if fault follows.

Replace traction amplifier.

Bad amplifier harness.

Check amplifier harness for shorts or broken wires and replace if necessary.

Bad system controller.

Test by swapping left and right amplifier harness connections. Replace system controller field fix.

E77

Fault condition SYSTEM CONTROL HARDWARE FAILURE Resulting Effect

TOTAL shutdown.

Criteria A/D chip failure.

Possible Cause

Solution

Bad system controller.

Replace system controller field fix.

E78A

Fault condition SYSTEM CONTROL SOFTWARE FAILURE Resulting Effect

Criteria

TOTAL shutdown.

Possible Cause

Solution

Software corrupted in memory.

Replace software board.

E78D

Fault condition DISPLAY CONFIGURATION DATA LOST Resulting Effect

Criteria

TOTAL shutdown.

Possible Cause Bad operator display board.

Solution Replace operator display board.

REV 12/5/99 TS.15

TOYOTA Electric Stand Up “E” Series

E79c

Troubleshooting

Fault condition SYSTEM CONTROL CONFIGURATION ERROR Resulting Effect

Criteria

TOTAL shutdown.

Possible Cause

Solution

Bad system controller.

Replace system controller field fix.

E79d

Fault condition DISPLAY CONFIGURATION FAILURE Resulting Effect

Criteria

TOTAL shutdown.

Possible Cause Bad operator display board.

E80 LO BATT

Solution Replace display board.

Fault condition

LIFT CUTOUT DUE TO LOW BATTERY STATE OF CHARGE

Resulting Effect LIFT system, except lower, shutdown.

Criteria The battery state of charge (BSOC) reading has reached the programmed limit.

Possible Cause Discharged battery.

E81

Solution Replace with fully charged battery.

Fault condition

EACH BUTTON STUCK Resulting Effect

LIFT system, except lower, shutdown.

Criteria Both tilt switches or both sideshift switches closed at the same time.

Possible Cause

Solution

Operator pressing opposite sides of the tilt/sideshift disk at once or too fast.

Cycle keyswitch.

Foreign material in keypad switch.

Disassemble and clean.

Damaged or defective keypad switch and/or pcb Replace upper control handle. in control handle.

Wires shorted in control handle harness.

Replace upper control handle.

REV 12/5/99 TS.16

TOYOTA Electric Stand Up “E” Series

E82

Troubleshooting

Fault condition ENGAGE BRAKE TO CONTINUE POST Resulting Effect

POST will not continue.

Criteria The brake pedal is depressed during the Power On Self-Test (POST).

Possible Cause

Solution

Brake pedal is depressed during POST.

Raise brake pedal.

Bad brake limit switch.

Replace brake limit switch.

E89L E89r

Fault condition LEFT/RIGHT AMP HARDWARE FAILURE Resulting Effect

Criteria

TOTAL SYSTEM shutdown and open MAIN POWER CONTACTOR. Possible Cause

Solution

Battery voltage too low, especially if error occurs Test battery under load and replace if necessary. while operating truck.

Bad traction amplifier.

E99

Replace amplifier.

Fault condition

LOST ERROR HISTORY Resulting Effect

Criteria

Display message (only in error history).

Possible Cause Operator display was replaced, or error history was reset by factory.

Solution No action necessary. This error code for information only.

REV 12/5/99 TS.17