Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up - PDF DOWNLOAD

Service and Parts Manual

TOYOTA

Model

6HBW20

Serial No.

10011 and Up

Date: 10/01/95

Service and Parts Manual

TOYOTA

Introduction

PREFACE This manual indudes information required for maintenance, troubleshooting, and repair of the Model 6HBW20. The object is to insure safe maintenance and repair practices and procedures for this Toyota product.

MANUAL OVERVIEW This manual consists of both a ServiceManual and a Parts Manual for the specific equipment listed on the cover.

The Table of Contents provides easy location of all subject matter within the manual.

The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

DENOTES A SERIOUS HAZARD THAT COULD CAUSE INJURY OR DEATH TO THE OPERATOR OR OTHER PERSONNEL FROM A PARTICULAR ACTION OR CONDITION.

ACAUTlON

DENOTES A LESS SERIOUS HAZARD FROM AN ACTION OR CONDITION THAT COULD CAUSE MINOR INJURY TO THE OPERATOR OR MAINTENANCE PERSONNEL, OR CAUSE DAMAGE TO THE EQUIPMENT ITSELF.

Denotes a particular statement pertaining to a particular procedure or explanation.

Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the page, opposite revised, added or deleted material. Revision lines indicate only current revisions with changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, the physical location of the material or complete page additions are not identified by revision lines.

Copyright @ 1995 by Toyota lndustrial Equipment, a Division of Toyota Motor Sales, U.SA., Inc. All rights reserved. No portion of the manual may be reproduced mechanically, electronically or by any other means, induding photocopying, electronic retreival or transfer, or recording without the written permission of the publisher.

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

Service and Parts Manual Table of Contents

TOYOTA

..................................... ............................. ................................... ....................................... .........................................

General Information General Maintenance Instructions Maintenance Practices Specifications Hydraulic Component Identification Standard Torque Data For Bolts Conversion Table Decals Decimal Equivalent Chart Planned Maintenance (PM) Inspection Form PM Schedule and Procedure Daily Inspection Monthly PM Service (or 100 Hrs.) Semiannual Service (or 500 Hrs.) Annual PM Service (or 1000 Hrs.) Lubrication Points Fill Points PM Chart Lubrication Equivalency Chart

1 1 1 2 2 3

................................. ............................. 6 ..................................... 7 ............................................ 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Scheduled Maintenance Batteries Battery Cleaning Electrolyte Process Battery Cleaning Procedure Battery Electrical Leakage To Frame Test Battery Charging Charging Process Hydrometer Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure Voltage Check Adding Water To Battery Guidelines Battery History Record Motors Motor Cleaning Brush Care Maintenance Schedule Motor Maintenance Inspection Chart Brush Replacement Motor Overheating Motor Test for Open Circuit Motor Open Circuit Test Procedure Short Circuit Test . Motors Short Circuit Test Armature Shorts Motor Grounds Test Grounds . General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

.

Service and Parts Manual Table of Contents

TOYOTA enQn

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Flush Grease Fitting Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Battery-Pak Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Bearing Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Control Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Head Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Cold Storage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Control Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Travel Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Horn. Lift/Lower Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pull Rod Bushings Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . 35 Carrier Frame Linkage and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Axle Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Hydraulic Oil Selection Changing Reservoir Fluid

Throttle Potentiometer Setting Example Battery Replacement Battery Wiring Hookup

.........................

47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Brake Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Linkage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Shoe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Service and Parts Manual Table of Contents

TOYOTA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

Lift/Lower Description Theory of Operation

......................................... ..................................... ...................................... ........................................... ................................. ......................

Electrical 54 Control Circuits 54 Power Wring 54 55 Lower Hydraulic and Electrical 55 56 Equipment Recommended for Normal Servicing Pump and Motor 57 Removal and Installation 57 Pump Motor Brush Removal 57 Relief Valve 59 Removing Solenoid Valve 59 Installing Solenoid Valve 59 59 Removing Pump and Motor Assembly 59 Removing Reservoir Removing the Pump 59 Installing the Pump 60 Installing the Reservoir 60 Check Valve 60 Cylinder Assembly Removal Installation 60 Cylinder Removal 60 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cylinder Disassembly 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Inspection Cylinder Assembly 62 63 Cylinder Installation Lift Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Troubleshooting 64 NoLift 64 Forks Do Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Forks Will Not Hold Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

..................................... ................................ ............................... ........................................ ................................. .................................. .......................... ................................... ...................................

.................................... ................................... ....................................... .......................... .....................................

.................................. .................................... ................................... ...................................... ..........................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Traction System Transistor Control (Motor Controller) Current Limiting Low Voltage Cutback Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Runaway Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Static Return to Neutral Protection Plugging Controller Keyswitch Input Controller Thumbwheel Throttle Inputs "Emergency Reverse" Plug Breaking Inhibit Traction System Adjustments Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer Adjustments Theory Preparing to Travel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

............................ ........................................ ................................ ......................... ....................... ............................... ................................ .........................................

....................................

68 69 69 69 69 69 69 70 70 70 71 71

Service and Parts Manual Table of Contents

TOYOTA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Diredionalfipeed Control Forward Directionalfipeed Control Reverse Emergency Reverse Contador Tip/Bar Replacement Troubleshooting Vehicle is dead . nothing operates No travel . horn and lift/lower operates OK No forward travel . forward contador does not energize No forward travel . forward contador closed No reverse travel . reverse contactor does not energize, forward travel operates No reverse travel . reverse contador closed No Emergency Reverse

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 . . . . . . . . . . . . . . . . . . . . . . . 76 . . . . . . . . . . . . . . . . . 77 . . . . . . . . . . . . . . . . . . . . . . 78 . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 . . . . . . . . . . . . . . . . . . . . . . . . 89 . . . . . . . . . . . . . . . . . . . . . . . . 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Low Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 High Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Manually Adjustable Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Programmer Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 StatusLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 0-5kR Throttle ("Type 3"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Plug Current in Over-Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 High Speed Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 Ramp Shap Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 Initial Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Programming and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Manual Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Current Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Plug Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Acceleration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Troubleshooting Wiring Inspection Procedure Miscellaneous Troubleshooting Battery Charger Electrical Testing Equipment Required lnstrudions Acceptable Charge Values Open Circuit Voltage Test Short Circuit Amperage Test Testing Components Diodes Capacitor Timer Overcharging Problems Charger and Battery not Properly Matched Defective Battery or Poor DC Connection Battery Charts

Service and Parts Manual Table of Contents

TOYOTA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 " . . . . . . . . . . . . . . . . . . . . . . 113 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Motor Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Maintenance Safety Cleaning Diagnostic History Diagnostics and Troubleshooting LED Diagnostics Programmer Diagnostics Programmer Operation Operating Modes Peace-of-mind Programming Programmer Self Test Programmer Menus Diagnostics and Special Diagnostics 'Menu

Service and Parts Manual List of illustrations

TOYOTA

....................... ................... ................... .................... ....................... ....................... ....................... ........................... .......................... ...................... .................... ........................ ...................... ...................... ........................... ................. ........................... ........................ ..................... .............................. ....................... ........................... ........................... .........................

Component Identification Component ldentification (Cont'd.)

Component ldentification (Cont'd.)

Standard Torque Data for Bolts Standard Decal Placement Bilingual Decal Placement Decimal Equivalent Chart Lubrication Points Hydraulic Fill Points Example of Cleaning Motor Measuring Brush Spring Tension Minimum Brush Lengths Motor Terminals and Circuits Flush Grease Fitting Adaptor Battery-Pack Lifter Bearing/Sealing Ring Installation Tool Control Head Unit Control Handle Removal Control Head . Exploded View Load Wheel Disassembly of Lower Link Drive Tire Removal Tire Hub Removal Wheel Hub Installation Drive Tire Installation Removing Drive Unit Drive Unit Installation Replacing Axle Seal Drive Unit Assembly Cover Removed Gear Removal Brake Lever Placement Battery Replacement Showing One Top Battery Swiveled Toward Forks Battery Wiring Hookup Brake Lever Adjustment Brake Interlock Switch Hydraulic Schematic . Lift Electrical Schematic . Lift Mode Hydraulic Schematic . Lower . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Lower Mode . . . . . . . . . . . . . . . . . . .

Hydraulic Motor, Pump. and Reservoir . . . . . . . . . . . . . . . . .

Lift Cylinder . Exploded View Lift Limit Switch Control System (Simplified) . . . . . . . . . . . . . . . . . . . . . . .

Motor Current Chart Adjustment Panel Travel Direction Reference Electrical Schematic . Forward Electrical Schematic . Reverse Electrical Schematic . Emergency Reverse Contactor . Exploded View Programmer and Motor Controller Motor Controller Connector Motor Controller Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

......................... .......................... ......................... .......................... .......................... ............................

.............................

......................... ......................... ........................ ......................... ....................... ....................

..................... ............................. .......................... ............................ ....................... ..................... ..................... ............... ....................... ................... ...................... ............................

Service and Parts Manual List of Illustrations

TOYOTA

............................. .......................... ............................. ............................. .......................... ............................ ..........................

16 Pin Connector 95 SK Throttle (Type 3 ) 96 96.1 Active Throttle Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2 Active Throttle 96.2 100 Manual Adjustments 103 LED Diagnostics Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 114 Hydraulic Schematic Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 115

vii

Service and Parts Manual S ~ e c i aService l Tools

Tool List

Description

00590-04661 -71

Diagnostic Service Tool (Programmer)

00590-04667-71

Pin Extractor

00590-04668-71

Pin Extractor

00590-04669-71

Pin Extractor

00590-04670-71

Pin Extractor

00590-04671 -71

Crimping Tool

00590-04672-71

Extraction Tool

00590-04673-71

Model 1 141 FasTest Accessory

00590-04674-71

Model 1142 Tester

00590-04675-71

Curtis Battery Book One

00590-04676-71

Bearing/Sealing Ring Installation Tool

00590-04677-71

Battery Pack Lifter

viii

TOYOTA

Service and Parts Manual

TOYOTA

General Information

Industrial vehicles may become hazardous if adequate maintenance is neglected.

Only trained technicians, using approved procedures, in adequate maintenance facilities should work on this or any other industrial vehicle.

General Maintenance Instructions

1 . Follow a scheduled lubrication, maintenance, and inspection schedule.

Maintenance Practices

2. Only qualified, authorized technicians are permitted to inspect, maintain, adiust, and repair this vehicle.

REMOVE RINGS, WATCHES, AND ALL JEWELRY BEFORE DOING ANY WORK ON

ACAUTlON

VEHICLE.

3. Before working on vehicle: a. Lower load handling mechanism completely to the floor. b. All controls must be in neutral. c. Release any trapped pressure in hydraulic systems. d. Block the wheels to prevent movement of the vehicle. e. Disconnect battery connector f. Elevate drive tire off floor.

USE EXTREME CARE WHENEVER THE VEHICLE IS JACKED UP FOR ANY REASON. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT VEHICLE DO NOT RELY ON JACKS.

-

g. Before working on load handler, support to prevent movement.

4. After working on vehicle, test all controls and functions to assure proper operation.

5. Work in a clean, dry, well ventilated area.

6. Avoid fire hazards. Have adequate fire fighting equipment in the maintenance area.

7. DO NOT use open flame or sparking devices around the battery. The gasses given off by the battery are highly explosive.

8. Use extreme caution when using flammable cleaning solutions.

,

More information pertaining to operating and maintenance procedures may be obtained from: American National Standards Institute 1430 Broadway New York, NY 1 0018 Ask for ANSI B56.1 - 1 988

Service and Parts Manual

TOYOTA

General Information Specifications 6HBW20 24 .

Model: Battery Voltage: Wheel: Drive: Load:

10.5 x 5"Rubber 3.25 x 5" Polyurethane 121 Install load wheels with at least 1 shim on each side and a maximum of V16' (1.58mm) end play.

-~

Transmission

80W-90W "DEXTRON I I V T F 0.8 Quart (0.75 liter) Torque drive tire retaining nut to 250 FT./LBS, (350Nm) (While rotating drive tire) Torque pivot bearing retaining nut to Zero (0) end play on pivot bearings while pivoting transmission.

Fluid: Standard Use Cold Storage .Fluid Capacity: Torque Requirement:

-

Hydraulic Lift/Lower System

Fluid: Standard Use Cold Storage

1OW-40W "Dextron I I V T F

Reservoir Capacity: Relief Valve Setting:

1 Quart (0.9 liters) 2600 psi f 50 psi (1 77 B a r f 3.4 bar)

Service and Parts Manual General Information

TOYOTA

Component Identification

Battery Discharge/Hour Meter

Key S u

Lift Butt01

, Directional/Speed

Control

Lower Button

Horn Button

Belly Button ~evbrseSwitch

Figure 63

Component Identification

Service and Parts Manual

TOYOTA

General Information Component Identification (Cont'd.)

'

Battery Charger Timer

' 1 120 VAC Power Cord (for the vehicle's battery charger)

Ban in C

Battery Charger

Figure 64

Component Identification (Cont'd.)

4

Service and Parts Manual

TOYOTA

General Information Forward Contactor

Reverse Contactor

15 Amp Fuse

Lift Cylinder

Battery Discharge/Hour Meter

Battery Connector ,

Motor Controller

Key Switch

Hydraulic Pump

Circuit 4 Breaker [CBl

Hydraulic Reservoir

Horn

/

Drive Unit

Lift Limit Cutoff Switch

Figure 65

Component Identification (Cont'd.)

Service and Parts Manual General Information Standard Torque Data For Bolts

Figure 66

Standard Torque Data for Bolts

6

TOYOTA

Service and Parts Manual General Information Conversion Table

TOYOTA

Service and Parts Manual

TOYOTA

General Information

The following pages show proper mounting and location of decals.

Decals

NOTE:

See the Parts Manual for decal description and ordering information.

"

a

:1

VlEW A

a 2.50' (6.35 cm)

1.2SD (3.17 cm)

4

VlEW A

Decals: 1. Emergency Disconnect 2. Caution-Bilingual 3. No Riding 4. Spec Plate U.S. 5. Pocket Manual 6. Warning 7. Cold Storage (located next to lift pump.)

Figure 61

Standard Decal Placement

Service and Parts Manual General Information

TOYOTA

Decals (Cont'd.)

NOTE:

-.-J' (6.35 i~m)

2.50' (6.35 cm)

See the Parts Manual for decal description and ordering information.

Decuk: 1. Emergency Disconnect-Bilingual 2. Caution-Bilingual 3. No Riding-Bilingual 4. Warning-Bilingual 5. Cold Stomge (located next to lift pump.)

6. Warning

xk

2.50' (6.35 cm) 2.50' (6.35 cm)

-4 11.25' (3.1 7 cm)

Figure 62

1

3

Bilingual Decal Placement

Service and Paris Manual General Information Decimal Equivalent

Chart

TOYOTA

Service and Parts Manual General Information Planned Maintenance (PM)

TOYOTA

Planned Maintenance is designed to reduce maior failures and costly downtime by scheduling periodic inspections, lubrication, adiustments, and testing on a schedule determined by use and application of your vehicle. A good PM program will alert you of the need for minor adiustments and repairs. This will greatly reduce the potential for a major failure in the future.

An effective program must include the following daily and periodic checks:

1. A daily inspection, prior to each shift, which will include a visual inspection for damage, leakage, fluid levels and safety items.

2. A scheduled monthly or 100 hour program based on your operating conditions performed according to the instructions in this manual.

Inspection Form

Daily and monthly inspection forms are an IMPORTANT part of your PM program.

They will provide you with the necessary details for keeping accurate records on the condition and service requirements of your vehicle. An inspection form is provided on page 15. Do not write on page. Make copies and use them.

PM Schedule and Procedure Daily lnspedion

The operator should be responsible for inspecting the condition of the vehicle at the beginning of each shift. The operator should note any problems and bring them to the attention of the proper maintenance personnel. Particular attention should be paid to the following items:

.

1 Drive tire.

2. Load wheels.

3. Battery charge and water level.

4. Controls, operation, and brakes.

Service and Parts Manual General Information Monthly PM Service (or 100 Hrs.)

TOYOTA

The regularly scheduled monthly PM service should be a comprehensive inspection and maintenance performed by qualified maintenance personnel. This service should include a detailed visual inspection, lubrication (where applicable), system and operational checks. The following list of items should be serviced.

1. Check battery charge and electrolyte level.

2. Visually inspect for leaks and damaged or missing parts.

3. Check all operating functions, brake interlock, travel, brake (adiust as needed), belly button reverse switch, and lift/lower.

4. Check hydraulic fluid level in the reservoir to be within 1 "(25.4mm) of filler plug with the forks lowered completely.

5. Check transmission oil level.

6. Lubricate all grease fittings.

7. lnsped power cables for loose connections and control wiring harness for damage.

8. Clean electrical components and motors using a compressed air nozzle meeting OSHA reduced velocity requirements.

9. lnsped contractor tips.

Semiannual Service (or 500 Hrs.)

At the semiannual service interval the following items should be performed in addition to the regular monthly PM service.

1. Clean battery and vehicle.

Annual PM Service (or 1000 Hrs.)

The annual scheduled service should include the monthly and semiannual service items, plus the following:

1. Drain, flush, and refill transmission gear case.

2. Drain, flush, and refill the hydraulic reservoir.

3. lnsped motor brushes.

Service and Parts Manual General Information Lubrication Points

Lubricate points shown monthly.

5

1. Load wheel axle 2. Pull rod, load wheel end (on cold storage package only) 3. Tmnsrnission pivot bearings (on cold storage package only) 4. Hydmulic lift cylinder rod end (on cold stomge package only) 5. Lift link (on cold domge package only) 6. Pull rod lift link end (on cold stomge package only)

Figure 67

Lubrication Points

TOYOTA

Service and Parts Manual General Information Fill Points

Tmnsmission

Tmnsmission Dmin Port

Figure 68

Fill Port

Hydraulic Fill Points

TOYOTA

Service and Parts Manual

TOYOTA

General Information

I

Out (20' to 70" F) (-6" to 21' C) application.

LUBE 'B' Hyd. Res- Rando Oil HD46 ervoir Oil for Hydraulic Standard Oil Mil-H(50" to 120" F) 176728 (1O0 to 49O C) applications.

See NOTE 1.

Pacemaker Nuto H46 Magnus A, 315 XD-20 Hydraulic Oil Mil-H460001B

URSATEX LUBE 'C' Drive Unit Gear Case for 1OW-30 below30"F(-1°C). 2166 Pump Motors w/oil cup, foot pedal, lift chains, etc. for above and below 30°F (-1" C).

C-6 1 0W30 Motor Oil Mil-H46152

baon Exira Motor Oil 1OW-30 API Service SE

Harmony 46-AW

Tellus T Oil-46

Trop-Artic Gulflube Shell All Season Motor Oil Rotella T Oil 15WMotor Oil X.H.D. 1OW-40 Mil- 10W-30 40 API Service SE L-46l52 CC and CD

LUBE 'D' Drive Unit Gear case for above 30°F (-1" C).

Multigear Lubricant EP 85W-90 Mil-L21058

Premium Gear Oil Gear Oil GX 80WMP90 Mil- 90 Mil-LL-21058 21 058

Philube SMP Gear Oil SAE 80W90 Mil-L2105C

Multipurpose Gear Lubricant 8OW-90

LUBE 'E' Drive Unit and Caster swivel, caster spring rod pivots, steer gear box, load wheels, uprights, reach arms, caster wheel bearings, etc., (above ond below 30°F [ - l oC]).

Regal AF8 2 Grease Mil-G18709A

HEP2 RONEX (above MP or 30°F only) UNIREX N2

Philube 1B and RB Grease

Gulfcrown Alvania Grease Grease No. 2 EP2

FLUID 'G' Brake Fluid SAE. (SAE J1 7 - O ~type F OR-3 or exceed). Do not use anything less than Dot 5.

LUBE 'H' AGMA #8 See NOTE 2.

DTE-15

Delco 400 Motor Oil 15W-40 API Service SE

Multron low-30 Mil-L46152 API Service SE

Spirax HD- Universal Gear EP 90 85W-90 Gear Mil-LLubricant 80W2105B 90 Mil-L21058 Avi-Motive Grease

Bearing Guard "LT"

Delvac Special 1OW-30 API Service SE

Mobilube HD 80W90

Mobil Grease 77

Dow Coming Silicone Brake Fluid or Equivalent

Honor Cyl. Oil 680

Cylesstic TK-680

Hector 630s Senet 186 Valvata J680

Cyl Oil 680X

LUBE 'J' Cold Temperature Synthetic Oil 30" to 85°F (-1" to 29" C) NOTE 1: Agway UF Hyd. Fluid is also approved. ' CLASS I ** CLASS II

Super Cyl. 600W SHC626

NOTE 2: Fiske Brothers Lubriplate CP-8 gear oil is also approved.

UPDATED

Service and Parts Manual Scheduled Maintenance

TOYOTA

Scheduled Maintenance The lead acid batteries furnish all power requirements of the vehicle. Most industrial batteries can be expected to function properly for more than five years. The following section contains essential battery maintenance information: cleaning leak test charging hydrometer check voltage check record keeping

Batteries

This information should extend battery life and increase vehicle efficiency.

WEAR EYE PROTECTION.

Battery Cleaning

Batteries in industrial vehicles pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. If cells are overfilled and electrolyte collects on the covers, the following process occurs:

Electrolyte Process

1. The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not evaporate.

2. This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This affects battery performance and vehicle operation.

3. The acid also causes corrosion of cell posts, nuts, connectors and the steel battery case.

Battery Cleaning Procedure

1. Mix 1 Ib. (.454 Kg) baking soda and 1 /2 gallon (1.9) of hot water.

2. Tighten the battery vent caps.

3. Use a brush with flexible bristles and apply the soda solution over the top of the battery. Leave the solution there until all "fining" stops, indicating that the acid has been neutralized.

4. Rinse thoroughly with clean water.

5. Blow battery case dry using compressed air [30 psi (207 kPa) max.].

NOTE:

Wet covers can be an indication of overfilling, leaky seals at posts or excessive gassing during charge. When observed, the cause should be determined and the adverse conditions corrected.

Service and Parts Manual Scheduled Maintenance Battery Electrical Leakage Test

TOYOTA

1. Disconnect the battery.

2. Use a voltmeter set on the 50 volt scale.

3. Attach meter leads: negative to vehicle frame, positive to battery positive.

4. The voltmeter should show no voltage or at most a 2-3 volt reading.

5. Attach meter leads: negative to battery negative, positive to vehicle frame.

6. The voltmeter should show no voltage or at most a 2-3 volt reading.

7.If there is more than a 2 to 3 volt reading in Steps 3 and 5, clean the battery rollers.

Battery Charging WHEN CHARGING BATTERIES, OBSERVE THE FOLLOWING PRECAUTIONS:

DO NOT SMOKE, USE OPEN FLAME, OR SPAR]<PRODUCING DEVICES NEAR THE BATTERIES. CHARGE IN A WELL-VENTILATEDAREA TO AVOID HYDROGEN GAS CONCENTRATION. KEEP BATTERIES CLEAN; CORROSION CAUSES GROUNDS AND THE POSSIBILITY OF SPARKS. CHARGE BATTERIES AT THE INDICATED RATES. KEEP PLUGS, TERMINALS, CABLES, AND RECEPTACLES IN GOOD CONDITION TO AVOID SHORTS AND SPARKS. NEVER LAY TOOLS ON TOP OF THE BATTERIES. WEAR PROTECTIVE CLOTHING AND ME PROTECTION WHEN HANDLING, CHECKING OR FILLING BATTERIES. NOTE:

Get the maximum use out of each battery by recharging the batteries only when they are effectively discharged. DO NOT routinely recharge batteries when they are only partially discharged; this will decrease battery life. At maximum recommended discharge, the specific gravity should read 1.1 50 or less.

Charging Process

To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge.

1. First, become familiar with the following: Charging rate, starting rate, and finish rate.

Time available for charge.

Variations in cell voltage.

Avoiding overheating, excessive gassing or overcharging.

2. Consult your battery manual for specific charging procedures.

Service and Parts Manual Scheduled Maintenance Hydrometer Use

NOTE:

TOYOTA

The hydrometer measures the specific gravity of the electrolyte. The specific gravity varies directly with the state-of-charge of a lead acid battery as follows:

Most industrial deep-cell discharge batteries are considered discharged when 20% of the charge remains (specific gravity of 1.1 40).

1. Insert the nozzle of the hydrometer into the battery cell and draw enough

Procedure

eledrolyte into the tube to permit the float to ride free.

2. Determine the specific gravity of the cell. See Chart above.

3. If there is insufficient electrolyte to obtain a hydrometer reading: add iust enough water to cover the battery plates. The eledrolyte level will rise during charge. Adding too much water before charging the battery will cause electrolyte to spill from the top of the cell.

Now charge the battery and take additional readings.

4. The specific gravity reading for each cell should be taken and recorded on the battery chart.

NOTE:

No amount of charging will increase battery capacity or raise the specific gravity above its fully charged level (1.280 to 1.300).

NOTE:

Water is added to the cell nftac the charging process is completed. Consult your battery manual for further information.

Voltage Check

Take a voltage check on each cell after performing the hydrometer check above.

Conned the leads of a Simpson Volt/Ohmmeter (VOM) or equivalent to the positive and negative terminals of each cell. VOM readings will vary with the state of charge:

1. Touch the voltmeter leads to the positive and negative terminals of each cell.

There should be a reading of at least two volts for each fully charged cell and a variance of no more than 0.2 volts between cells.

2. Record the voltage reading for each cell on the battery maintenance chart.

Service and Parts Manual

Scheduled Maintenance Adding Water To Battery

Guidelines

TOYOTA

Water must be added to battery cells periodically. Frequency and quantity depend on the water level above the plates and the amount of gassing during charge.

Use only approved or distilled water.

Add water aftac hydrometer and voltmeter readings are taken.

Add water nfter charging to minimize overfilling.

Always have plates entirely covered.

Keep outside of battery case clean and dry.

Battery Hidory Record

A battery record system is essential because battery failure can cause produdion slowdowns and increased battery operating costs. A properly supervised record system can deted and call attention to such operating irregularities as: Overcharging Undercharging Over discharging Excessive water consumption Excessive dirt and corrosion Worn out batteries Excessive current consumption of vehicles Records should be kept for each battery. Your battery supplier should be able to provide maintenance record sheets. Each report should contain: Battery number, type, serial number, and service data Specific gravity and voltage readings for each cell Temperature of the air and electrolyte Electrolyte Amperes Condition of connectors, covers, sealing compound and tray General cleanliness Number of total cycles Average specific gravity drop Watering frequency User comments and observations The battery is the energy source for the Model 6HBW20. Its condition should be of primary importance to the user to achieve maximum satisfactory service. Lack of proper battery maintenance will lead to reduced battery life and other component problems (i.e., motors, contactors, etc.).

Service and Parts Manual Scheduled Maintenance Motors

TOYOTA

The motors used in Toyota industrial vehicles are designed to operate with a minimum of maintenance. Sealed bearings are used in all motors thereby eliminating lubrication. Included in the motor section are the following maintenance procedures: motor cleaning brush care commutator care prevention of motor overheating open circuit test short circuit test These procedures, along with periodic inspection help to provide trouble-free motor performance.

Motor Cleaning

Periodic motor cleaning is essential to prevent overheating and electrical grounds.

To clean the motor properly, use the following procedure:

1. Wear safety glasses. Use clean, dry, low pressure air (30 psi (207 kPa) max.], to blow carbon dust and other foreign materials from: the motor housing brush holders commutator field and armature windings (if accessible)

Figure 10 Example of Cleaning Motor

NEVER USE A CHEMICAL SOLVENT TO CLEAN THE MOTOR AS IT WILL CARRY AcAuTloN CARBON DUST TO HARD TO CLEAN AREAS AND CAUSE SHORTS WITHIN THE MOTOR. WASHING WITH DETERGENTS REQUIRES COMPLETE DISASSEMBLY AND DRYING. THIS SHOULD ONLY BE ATTEMPTED BY AN AUTHORIZED MOTOR REPAIR SHOP.

Service and Parts Manual

TOYOTA

Scheduled Maintenance Brush Care

Brushes should be inspected for: Proper wear Signs of overheating Physical damage to brush holders Proper spring pressure/alignment Freedom of movement within brush holders.

Maintenance Schedule

Since the operating environment of motors varies widely, the following recommendations should be applied as actual conditions dictate. Several conditions to define before considering the following Maintenance Inspection Chart are: Type of Activity

Type of Service

Basically, an eight hour day of mostly indoor material handling.

Extended operating hours, or constant usage.

Dusty or Sandy Locations: i.e., cement plant, lumber or flour mills, coal dust or stone-crushing areas.

Normal Severe Extreme

High Temperature Areas: i.e., steel mills, foundries, etc.

Sudden Temperature Changes (continuous indoor-outdoor movement): i.e., refrigeration plant, etc.

Corrosive atmosphere: i.e., Chlorine

A

Motor Maintenance Inspection Chart Service Conditions

Inspection Fmquency (Opemting Time)

Normal

1000 Hours 3000 Hours 500 Hours As Required 250 Hours As Required By lnspection

Severe Extreme

,

Recommended Inspection

-

Periodic Routine Periodic Routine Periodic

Motor Location

Motor in Vehicle Motor Removed Motor in Vehicle Motor Removed Motor in Vehicle Motor Removed

Service and Parts Manual Scheduled Maintenance

TOYOTA

1. Position motors to provide easiest access to brushes.

Brush Care (Cont'd.)

2. lnsped the brushes in d l motors for:

Proper Wear - the brush surface should be polished and show even wear.

Overheating - overheating will be indicated if the brush shunts or brush springs are discolored.

-

Physical Damage lnsped the brush holders for damage. Make sure the holders are not loose on the end head or brush holder plate.

Spring Pressure/Alignment - check spring pressure as shown below.

Insufficient spring pressure will cause excessive arcing and reduced motor performance. Excessive spring pressure will result in premature wear of the commutator.

A brush spring that does not apply even pressure on the center of the brush will cause the brush to wear unevenly.

-

Freedom of Movement Check for correct clearance and freedom of brush movement within the holder. Be certain connections are clean and tight and that brush wires do not ground on motor frame or armature.

1. Place a paper strip between the brush face and commutator.

2. Hook the leather loop under the brush spring and attach to spring scale.

Note: If the brush spring has a loop at the brush, hook the spring scale directly into the spring.

3. Pull the spring scale on a line directly opposite the line of force exerted by the spring while applying a light pull on the paper strip. When the paper strip begins to move freely, the spring scale will be indicating the brush spring tension.

4. A spring tension of approximately 20 oz.

(568 g) for new brushes is acceptable.

Pull Paper in direction of rotation.

Figure 1 1

Measuring Brush Spring Tension

Service and Parts Manual Scheduled Maintenance Brush Replacement

TOYOTA

If any of the brushes require replacement, the complete brush set should be replaced. Do not replace just one or two brushes. Refer to the figure below for minimum brush lengths.

Drive

* Measurement of brush length refers to the "short" side dimension.

Figure 12

Minimum Brush Lengths

When ordering replacements refer to the motor serial number on the motor nameplate.

Do not substitute brushes. The brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear.

Where accessible, new brushes should be seated to the commutator curvature. This can be accomplished by wrapping a piece of 00 sandpaper around the commutator, seating the brush in the brush holder, and turning the armature. On smaller motors where space is limited, a brush seating stone may be used. QQ U use emery cloth to seat brushes.

After the brushes are seated, the dust should be blown out of the motor with dry compressed air 130 psi (207 kPa) max.]

Service and Parts Manual Scheduled Maintenance Motor Overheating

TOYOTA

Most motor overheating can be prevented by understanding the causes and preventions listed below:

Cause Insufficient ventilation due to ventilating hole blockage Dirty motor Defective bearings

Prevention Clean the ventilation holes with dry compressed air.

See motor cleaning on Page 21.

If the bearings are replaceable as a unit, replace them. If not, replace the motor.

Lifting excessive loads and stalling the motor Make sure the operator knows the vehicle limitations.

Replace or recharge the batteries.

Low battery voltage Open or short circuited armature or field Follow the test procedures in this manual. windings IF AN ELECTRICAL FAILURE OR AN EXTREME OVERLOAD OCCURS, ESPECIALLY IN A TOTALLY ENCLOSED MOTOR, PERSONNEL SHOULD NOT BREATHE THE FUMES WHICH HAVE BEEN GENERATED INSIDE THE MACHINE. THE HEAT OF THE FAILURE ARC OR OVERLOAD MAY GENERATE NOXIOUS FUMES BY BURNING OF THE INSULATION MATERIALS. ALL POWER SHOULD BE DISCONNECTED FROM THE MOTOR BEFORE ANY INVESTIGATION OF THE FAILURE IS ATTEMPTED. THE AREA AROUND THE MOTOR SHOULD BE WELL VENTILATED. PERSONNEL SHOULD NOT BREATHE THE TOXIC FUMES PRODUCED BY THE FAILURE. IF POSSIBLE, TIME SHOULD BE ALLOWED FORTHE MOTOR TO COOL AND FOR DILUTION OF THE FUMES WITH AIR.

Service and Parts Manual

TOYOTA

scheduled Maintenance

An open circuit is one in which the electrical circuit within the motor has been broken. This can be caused by:

Motor Test for Open Circuit

bad brushes or brush springs a broken wire in the field winding a loose or bad connection 1. Disconnect the motor from the vehicle circuit.

Motor Open Circuit Test Procedure

2. Use a milliohmmeter (preferably) or analog ohmmeter (Simpson 260, etc.), to measure continuity in the armature and field circuits at room temperature:

-Motor Traction Lift

Terminals A1 to A2 S1 to S2 AtoS

Analog (Voh Ohmmeter) .020 .030 Ohms 0.9 1.1 Ohms .020 .030 Ohms

-

-

-

3. Using a megohmmeter or analog ohmmeter, there should be N O continuity between the armature and the field terminals. The meter should register more than 100,000 ohms. (See Note:)

4. If the meter indicates an open circuit in the armature, check condition of the brushes before rejecting the motor.

NOTE:

The lift motor has only two external connections because the armature and field windings are connected internally. The above continuity check may be made between the two external terminals. If an open circuit is found, then the lift motor must be disassembled to check the field and armature circuits for continuity.

Tradion

Figure13

Motor Terminals and Circuits

Lift

Service and Parts Manual Scheduled Maintenance Short Circuit Test Motors

-

TOYOTA

A short circuited motor is one in which the insulation on the field or armature windings has broken down at two or more points. The breakdown creates a low resistance current path, allowing current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow. Location of the short determines its severity.

A shorted motor may be indicated by: slow or sluggish operation running faster than normal overheating blowing a power fuse

Short Circuit Test

1. Refer to the inspection report showing the motor current when the motor was new.

2. Duplicate the same vehicle conditions (loaded or unloaded) and measure the present current.

3. If the present current reading is 25% more than the original current value, a short circuit probably exists.

NOTE:

Armature Shorts

Excessive motor current can also be caused by abnormally high rolling resistance.

Such resistance may be caused by brake drag, defective wheel bearing(s), transmission problems. The devices driven by the motor should be inspected before replacing the motor.

A short circuit in the armature will cause heating which will probably result in burning of: the armature coil bandingwires commutator segments Visual inspection should show this condition.

Service and Parts Manual Scheduled Maintenance Motor Grounds Test

TOYOTA

In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused either by direct contad or through conductive foreign material.

The ground may be caused by: insulation breakdown brush leads touching the motor housing build-up of carbon dust or other materials.

1. Isolate the motor from the vehicle circuit.

2. Attach one lead of a megohmmeter (preferably), or an ohmmeter set to the highest resistance scale, to a motor terminal and the other lead to the motor housing. Be sure paint does not interfere with connections.

3. If the megohmmeter indicates a resistance of less than 100,000 ohms, the motor is grounded. Clean, repair or replace the motor as necessary.

Grounds - General

Another common cause of vehicle electrical problems is other grounding. Grounds can be caused by: accumulation of dirt breakdown of insulation bare wires Grounds can occur at numerous locations including: batteries motors contactors solenoid coils terminal strips switches

Procedure

1. Disconnect battery connector.

2. Connect one ohmmeter lead of a Simpson Model 260 (or equivalent) to the vehicle frame making sure of good contact with bare metal. Use R x 10,000 scale.

.3. Connect the other ohmmeter lead to each of the following points individually: Battery side of the 15 amp control fuse Negative side of several circuits

4. A reading of less than 1,000,000 ohms between any of the connections indicates that a ground exists.

5. Inspect circuit carefully to find the cause of the ground.

Service and Parts Manual Scheduled Maintenance

TOYOTA

Hydraulic

Oil Selection

Before adding or changing hydraulic fluid, determine the environment and usage of the vehicle. Refer to the Lubrication Equivalent chart on page 16 to make the proper oil/lubricant selection.

Changing Reservoir Fluid

1. Lower the forks all the way to the floor. Ensure that all hydraulic pressure is relieved.

2. Turn Key OFF. Disconnect battery.

3. Remove cover from power section.

4. Have a container capable of holding approximately 1 gallon (3.7 liters).

5. Remove the pump and motor assembly to drain the reservoir 6. Flush the reservoir with clean hydraulic fluid.

7. Refill reservoir with the proper grade of oil.

8. Reinstall the pump/motor assembly back into vehicle.

9. Operate the hydraulic system and check for leaks.

Service and Parts Manual Power Section

TOYOTA

Power Sedion Special Tools

Special tools may be purchased from your Dealer's Parts Department.

Flush Grease Fitting Adapter

Flush grease fittings are used throughout this unit. The adapter for greasing flush type fittings may be purchased locally. (See Figure 14)

Figure 14 Battery-Pak Lifter

This battery pak lifter is used to lift the battery pak from the unit. The battery pak lifter is available from your Dealer. (See Figure 15)

Figure 1 5

Bearing Installation Tool

Flush Grease Fitting Adaptor

Battery-Pack Lifter

This bearing installation tool is used to install both the bearing and sealing ring on the transmission drive shaft. The bearing installation tool is available from your Dealer. (See Figure 16.)

Figure 1 6

Bearing/Sealing Ring Installation Tool

Service and Parts Manual Power Section -

TOYOTA

Control Head Unit Removal and lnstallation

The control handle is designed so that some repairs can be made without removing the entire handle. A wiring harness plug in the top of the handle allows the head unit to be removed for bench repair. (See Figure 17.)

1 . Remove four Allen head cap screws from underneath hand guard.

Head Unit Removal

2. The head is now loose and may be removed from the handle after disconnecting wiring harness plug.

NOTE: Cold Storage Requirements

During reassembly of control handle, apply Lodite #222 as noted in Figure 17.

Prior to assembly of controller assembly to handle, do the following: Harness connectors: All plugs and connectors should have an ample amount of sealing compound applied where wires enter plugs or receptacles. The amount applied should be enough to prevent moisture from entering the connector. Disconnect connectors to apply compound both internally and externally.

Terminals: Apply an ample coating of sealing compound to each connection position after the harness is installed.

FHCS 1/4-20 x 1

FHCS 5/16-18 x 1

(See Note above.)

(See Note above.)

Figure 17

Control Head Unit

v/

Wri,

~ainessPlug

Service and Parts Manual

TOYOTA

Power Section Control Handle Removal

If removal of the entire control handle is needed, remove the control handle head first. (See previous page.) The wiring harness and return spring must be removed before removing the handle pivot pin.

1 . The handle return spring can be easily disconnected at the chain master link near the transmission case. Support the handle before removing the master link.

THE SPRING IS UNDER TENSION EVEN WHEN THE HANDLE IS FULLY RAISED. THE SPRING MAY FLY OUT OF THE HANDLE IF SUDDENLY RELEASED.

2. Remove clamps and pull wiring harness out bottom of handle. (To reinstall, use a piece of stiff wire to "FISHVhe harness back up through the handle.)

3. Remove motor side cover. Drive the roll pin out of handle pivot pin and slide the pivot pin out.

4. During reassembly, be certain that brake release cam is in the correct position before installing roll pin. (See page 52.)

Control Handle

Handle Return SpringI Allen Head Cap

9

Wire Harness Plug

Figure 18

Control Handle Removal

/

Wiring Harness

Service and Parts Manual Power Section Travel Control Switches

TOYOTA

The travel control switches are non-repairable and must be replaced if defective. To gain access to the control switches: (Refer to Figure 19.)

.

1 Remove the control head. (See page 31 .)

2. O n a bench, drive one roll pin out of either grip/butterfly lever.

3. Remove the grip and butterfly control (5). To remove the grip use a flat head screwdriver to pry off control stem.

4. Remove six flat head Allen head screws on the backside of the control head.

5. Separate the hand guard from the rest of the assembly.

6. Remove the bracket (6) holding the control switches (7) to the control head.

7. Replace the defective switch.

8. During reassembly, ensure that the spacers are installed in the location from which they were removed.

Horn, Lift/Lower Switches

To replace any one of these switches: (Refer to Figure 19.)

1. Remove four screws (9) holding the front cover. Lift cover (10) off.

2. Any of the three switches (8) can be inspected, tested, or replaced.

&Id

Figure 19

-

Contr.ol Head Exploded View

Load Wheel Repair and Replacement

The load wheel is a single wheel with ball bearings at each end. Removal is accomplished by:

1. Elevating the forks to expose the load wheels below the frame.

2. Raising the load wheels off the floor and supporting vehicle in a safe manner.

3. Driving the roll pin out of the axle shaft and removing axle.

NOTE:

When pressing bearings into the load wheel, the shielded side of the bearing goes to the outside.

Reinstall wheel and axle. Shims are used on each side of wheel between bearings and wheel fork to eliminate any end play on wheel bearings. DO NOT preload bearings. Drive in roll pin to lock axle in place.

NOTE:

The load wheels use a ball-bearing type load bearing. Use shims on the wheel axles to remove all end play, but DO NOT preload bearings. Split the total shim pack required and place on both sides of wheel to keep wheel centered in wheel fork.

Shield must face outward

Figure 20

Load Wheel

Service and Parts Manual Power Section Pull Rod Bushings Removal and Replacement

TOYOTA

To replace pull rods and/or bushings, it is easier to work with the vehicle upside down. Remove batteries before turning vehicle over. Some hydraulic oil may leak . . from the hydraulic reservoir.

1. Mend load wheel forks (15) and remove shaft (18) connecting wheel fork to pull rod (23). (See Figure 21.)

2. Remove pivot pin (22) by removing locking bolt (3).

3. With the lower links (26) out of the Lift frame channels, the links can be separated and pull rod (23) removed from link pin (25). Each link has one roll pin (20) attached at opposite ends. The link can be pulled apart without driving out any other roll pins.

4. Press new bushings (24) in pull rods (23).

5. Reassemble pull rods (23) on lower links (26) and press links together so they will fit in the frame channel.

6. Reinstall pivot shaft (22) and retaining bolt (3) in lower links.

7. Reconnect pull rod (23) to wheel fork (15).

8. Place vehicle upright and install the batteries. Conned battery. Test operation of lift frame. Check reservoir fluid level.

Figure 2 1

Carrier Frame Linkage and Bushings

Disassembly of Lower Link

The bushings (30) on the upper links (29) can be replaced by removing the links from one side at a time and pressing in new bushings (30).

To replace the lower link bushings, refer to the procedure above.

To separate lift and carrier frames, remove all electric connections and lift cylinder retainer plates from carrier frame before removing links. Remove linkages and lift the lift frame off carrier frame.

Service and Parts Manual Power Section Drive Wheel

TOYOTA

The drive wheel can be removed without removing the transmission by following these steps: Before starting disassembly of any parts, thoroughly clean outside of assembly with solvent or other non-corrosive cleaning fluid. Air dry all parts.

Removal

1. Disconnect the battery, block vehide with drive tire off floor (about 1 inch) (25.4mm).

2. Remove nut holding drive tire to drive axle.

3. Remove drive tire by hand or if necessary use three bolts from side cover over drive tire and thread in hub to push drive tire off drive axle. (See Figure 22.)

Figure 22

Drive Tire Removal

4. Press drive tire from wheel hub. (See Figure 23.)

Figure 23

Tire Hub Removal

Service and Parts Manual Power Section

TOYOTA

Drive Wheel (Cont'd.)

1. Press drive tire onto wheel hub. (See Figure 24.)

lnstallation

If the new tire does not press on with a minimum of 5 tons pressure, replace the hub.

2. Install drive tire. The drive tire retaining nut should be torqued to 250 ft./lb (350Nm). (See Figure 25.)

Press hub into tire thisdirection 5 to 15 ton press fit.

cl

Figure 24

Wheel Hub Installation

Torque to

250 Ft. Lbs. (350Nm)

Figure 25

Drive Tire Installation

37

Service and Parts Manual

TOYOTA

Power Section Drive Unit

1. Disconnect the batteries and remove from vehicle. Block vehide with drive tire off floor (about 1 inch) (25.4mm). Refer to Figure 26.

Removal

2. Remove sheet metal cover and plastic cover from vehicle.

3. Disconnect control wiring harness and power cables from electrical panel.

4. Remove control arm (9).

5. Remove pivot bearing retaining nut (1).

TRANSMISSION ASSEMBLY MAY FALL FREE FROM MOUNTING AFTER NUT IS REMOVED.

6.Remove transmission assembly (10) by lowering through mounting bracket.

7. Remove control wiring harness and power cable through transmission pivot mount.

2$a \ I

Figure 26

Removing Drive Unit

Remove Batterias

/

Service and Parts Manual

TOYOTA

Power Section Drive Unit (Cont'd).

Refer to Figure 26 on previous page.

Installation

1 . lnstall bearing cups (3) in frame (4).

2. lnstall nilos ring (7) over pivot tube on top of transmission assembly and install bearing cone (6).

3. Pull control wiring harness and power cables up through transmission pivot mount.

4. Install drive unit assembly through mounting bracket. lnstall bearing cone (3) and nilos ring (2).

5. (See Figure 27) While tightening the steering locking nut, rotate drive unit to simulate steering action. Continue tightening nut until nut is snug and drive unit will not rotate. Back nut off 1/4 turn and move steering. If steering feels free, lock nut with Lodite #242. If steering still feels snug, back nvt off another 1/4 turn before applying Lodite.

6. lnstall control arm (9).

7. Reconnect harness.

8. Lower vehicle.

9. lnstall and conned batteries.

10. Turn key switch "0N"and test operation of vehicle.

1 1. lnstall sheet metal cover and plastic cover on vehicle.

Steering Locking Nut APPb Loctite #242

View A-A

.19"

TYP

Figure 27

Drive Unit Installation

Service and Parts Manual Power Section Axle Seal Removal

TOYOTA

The drive axle seal can be replaced without removing the gear case cover by following these steps: Before starting disassembly of any parts, thoroughly clean outside of assembly with solvent or other non-corrosive cleaning fluid. Air dry all parts.

1. Drain transmission oil.

2. Disconnect the battery, block vehide with drive tire off floor (about 1 inch) (25.4mm).

3. Remove side cover over drive tire.

4. Remove nut holding drive tire to drive axle (43).

5. Remove drive tire (40) by hand or, if wheel is stubborn, use three bolts from side cover over drive tire and thread in hub to push drive tire off drive axle.

6. Remove axle seal (39) with seal ~ u l l e or r pry out with pry bar. Take care not to damage sealing surface or mounting bore.

Installation

1. Install new oil seal.

2. Install drive tire. The drive tire retaining nut should be torqued to 250 R./lbs.

(350Nm).

3. Install side cover over drive tire. Torque bolts to 35 ft./lbs. (49Nm).

4. Refill transmission case with proper grade of new oil.

Figure 28

Replacing Axle Seal

Service and Parts Manual

Power Section

TOYOTA

Drive Unit Assembly

Notes: 1. Apply L o d e X242 and toque to 35 ft./lbs. (49 Nm).

2. Toque to 30 ft./lbs. (42 Nm) dry.

ITEM

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

BRAKEIMOTOR ASSY. ROD-BRAKE WELD CLEVIS-END STEPPED PIN-CLEVIS PIN-COTTER 1/16 X .75 SPRING ANCHOR-BOLT ANCHOR-PIVOT LEVER-BRAKE SCREW-SHOULDER3/8-16 X 1.62 BUSHING-FLANGED NUT 1/4-20 CAM FOLLOWER MIT 1/4-28 SCREW-SCH 3/8-16 X 1.OO WASHER-LOCK 3/8 NUT 1/4-28 TRANSMISSION O-RING

VlEW A - A

Figure 29

Drive Unit Assembly

TOP VlEW

Service and Parts Manual

TOYOTA

Power Section Drive Unit Disassembly

After draining gear case lubricant, thoroughly clean outside with solvent or other non-corrosive cleaning fluid. Air dry all parts, and proceed with disassembly of transmission as follows:

1. Remove gear case cover.

Figure 30

Cover Removed

2. Block transmission with gear case side down. Allow room for gears to drop between blocks.

Cluster Gear

Qx@

\

Figure 31

Drive Geor/Axle

Gear Removal

3. Press drive axle through collar and bearing. Drive gear/axle and cluster gear will come out together.

4. Remove old bearings and races from gears and case. Clean transmission case.

Service and Parts Manual Power Section Assembly

TOYOTA

Heat bearing cone on bearing heater to facilitate installation.

1. lnstall new bearings on cluster gear.

2. lnstall new bearing cone on drive axle.

3 . lnstall new bearing cups in transmission case.

4. Position transmission on work bench with gear case side up. Place drive axle and cluster gear in case as a unit with gears meshed. Because of gear size and bearing tolerances, the gear set and bearings cannot be installed separately.

5. Use Loctite #515 'gasket eliminator" on mating surface and install drive unit side covers. Be sure that two dowel pins are in case to position cover. Torque cover bolts to 30 ft./lbs. (42Nm).

6. Reposition transmission case so that it rests on gear case cover.

7. Temporarily install drive motor in transmission case using only two bolts to hold motor in place.

8. lnstall outer drive axle bearing cone and retaining collar: A. Place bearing cone over shaft. Use a standard 1 " X 14 nut and bearing installation tool, to push bearing on drive axle. At this time the bearing will not seat on shoulder of drive axle. Remove nut and pusher.

B. lnstall drive axle seal in transmission case.

C. lnstall collar on drive axle. Use bearing installation tool and nut to press collar on shaft. This should also press bearing down to seat on shoulder. Turn axle shafi while torquing nut to 250 ft./lbs (350Nm.) Control the drive axle turning by holding brake lever on drive motor.

9 . Reinstall drive unit into frame. The drive motor will have to be removed in order to route electric cables and control wiring through pivot tube. Liberally grease top and bottom bearing cones on pivot bearing. Bottom cup of pivot bearing is a slip fit in mounting frame. Be certain that bearing cup has not fallen out of frame.

10. Torque pivot bearing retaining nut. See Drive Unit Installation section of this manual on page 39.

1 1. lnstall the control handle.

SHOCK HAZARD! DISCONNECT BATTERY BEFORE DOING ANY WORK ON/OR AROUND CONTACTOR PANEL ASSEMBLY.

Service and Parts Manual Power Section

TOYOTA

Drive Motor

1. Disconnect the battery, block unit from moving and.remove side cover over tire.

See NOTE:

Removal

NOTE:

While it is not absolutely necessary to remove the drive tire to remove the drive motor, it makes removing/installing the motor a lot easier with the tire off.

2. To remove the drive tire, use a 1 1/2"ssacket.

3. Disconnect brake interlock switch and remove mounting bracket from case.

4. Remove the spring from the brake.

5. Disconnect the clevis connecting the linkage to the brake assembly.

6. Disconnect power cables from drive motor, noting their proper position.

7. Using a 5/16 Allen wrench, remove four (4) mounting bolts (motor will be loose when bolts are removed).

8. Drive motor can now be removed from the drive unit.

Drive Motor Brush Replacement

To replace the brushes, the drive motor will have to be removed from the drive unit.

Refer to removal procedure.

1. Remove any shields around motor end cover to expose brushes.

2. Lift spring off brush, pull brush out of holder.

3. Remove screw holding brush lead and remove brush from motor.

4. Reverse steps for assembly.

Drive Motor Disassembly

1. Remove locknut and pinion gear from motor armature shaft.

2. Remove locknut and brake drum from other end of motor armature shaft.

By lifting one brake shoe of the brake assembly at a time, the mounting bolts can be removed without disassembling the brake assembly.

3. Remove and discard old O-ring.

4. Remove four screws holding brush end bell to field housing.

5. Separate end bell from field housing. The armature will come out with end bell.

6. To remove end.bell from armature, remove snap ring that holds bearing in end bell. If needed, press off bearing and replace.

Service and Parts Manual Power Sedion

TOYOTA

Drive Motor Installation

The drive motor can be reinstalled without removing the gear case cover by following these steps:

1. Thoroughly clean all parts with solvent or other non-corrosive deaning fluid. Air dry all parts. The O-ring on drive end of motor should be replaced at this time with a new O-ring.

The drive motor should be installed in a dirt-free area.

2. lnstall brake assembly by lifting one brake shoe at a time and installing mounting bolts.

Location of activating lever should be positioned as shown in Figure 32.

Figure 32

Brake Lever Placement

3. lnstall brake drum on armature shaft over the key.

4. lnstall pinion gear on drive motor over the key and tighten locknut. Place a wrench on both locknuts and tighten nut to 75 ft./lbs (105Nm).

5. lnstall new O-ring on motor drive end.

Always make sure that the O-ring has been lubricated with petroleum jelly before installing.

When re-installing the drive motor the power cables must be kept to the back side of the gear housing or the motor will not go into the gear case.

6. Slide drive motor in gear case and work it around until the motor lines up with cluster gear.

7. Install the four (4) motor mounting bolts and torque to 35 ft./lbs (49Nm).

8. Conned the power cables to their proper terminal.

9. lnstall brake interlock switch mounting and conned wires.

(Continued next page)

Service and Parts Manual Power Section Drive Motor Installation (Cont'd.)

TOYOTA

10. Install brake linkage and stretch spring across mounts.

1 1. Install drive tire, if removed. Torque nut to 250 ft./lbs. (350 Nm).

1 2. Install the side cover over drive tire. Torque to 35 ft./lbs (49Nm).

13. Remove blocks, conned battery and test operation of unit.

Service and Parts Manual Power Section

TOYOTA

Controller Assembly Throttle Potentiometer Setting

1. Disconnect the handle harness at the bottom end of the handle prior to adjustment. This will insure that feedback, from other circuitry in the vehicle, will not effect the V.O.M. readings.

2. Conned a V.O.M. to pins VR-1 and VR-3. The resistance measurement should be 13,000 +/- 1,300 ohms. Disconnect meter.

3. In order to electrically center the potentiometer, the Directional/Speed Control Handle must be in the neutral position. Use an Allen wrench (3/32") to loosen the screw on the gear located on the shaft of the potentiometer.

4. Conned the V.O.M. to pins VR-2 and VR-4. Measure the potentiometer resistance while rotating the potentiometer shaft until the V.O.M. reads as close to 0 ohms as possible.

Tighten the Allen screw and proceed to Step #5. Secure the Allen screw using Lodite. A paint dot on the shaft and on the bushing should line up for reference.

5. With the V.O.M. still connected to pins VR-2 and VR-4, verify that the forward and reverse throttle positions are equal. Rotate the Directionalfipeed Control Handle fully in both directions. Record the maximum resistance value in both cases. In either direction the resistance value should be 5,000 +/- 500 ohms when equalized.

Since this value is variable, it is important that in both directions the resistance value is equalized to within 200 ohms maximum.

MAXIMUM VARIATION EXAMPLE Handle Position Resistance [Ohms) 5,000 Fully Clockwise 5,200 Fully Counterclockwise

6. To determine the ideal maximum potentiometer position, add the previously recorded readings in Step #5 and divide that result in half. (See example below.)

Loosen the potentiometer nut (1/2 turn) so that the potentiometer will move in the bracket with finger force applied.

Example

5,000 ohms C.W.

+ 5,200 ohms C.C.W. = 10,200 ohms

10,200 + 2 = 5,100 ohms (ideal resistance setting)

7. Rotate the throttle control fully in one direction and hold. Move the potentiometer body until the ideal maximum resistance value is obtained. Once the potentiometer is electrically centered, tighten the potentiometer nut securely to prevent the pot from moving in the bracket. Repeat Step #5.

Service and Parts Manual Power Section

TOYOTA

(See Figure 33)

Battery Replacement

THE BATTERY PACK MUST BE BOLTED TO THE VEHICLE FRAME BEFORE ROTATING THE UPPER BATTERIES. THE BAllERY PACK WILL TIP OVER IF NOT SECURED. THIS COULD CAUSE INJURY OR ACID SPILL. 1. Turn key switch off and remove key.

2. Disconnect battery connector.

3. Remove battery cover.

4. To gain access to the lower 2 batteries, lift up slightly on one of the top battery frames.

5. As the frame is lifted, swing the battery toward the center of the forks.

6. Cables may now be disconnected from the battery terminals and batteries may be serviced/replaced as required.

NOTE:

See Figure 34 and the decal on the battery frame for proper battery hookup.

Top battery swiveled toward forks

Figure 33

Battery Replacement Showing One Top Battery Swiveled Toward Forks

Service and Parts Manual Power Section Battery Wiring Hookup

Legend: 1. Connector Assembly 2. Cable Tie 3. Cable 4. Grommet 5. Terminal Boot 6. Nut 7. Flat Washer 8. Grommet 9. Battery

Figure 34

Battery Wiring Hookup

TOYOTA

Service and Parts Manual Brake Brake

TOYOTA

The brake in the vehicle is a spring applied and mechanically released design. The brake has a drum mounted on the drive motor armature shaft. This design gives excellent braking and long life since the drum and shoes are protected from dirt and other abrasive materials. Braking is accomplished by a spring-loaded cam arm.

The cam forces the brake shoes against the brake drum. This provides braking any time the handle is in the static position (i.e., fully raised or fully lowered).

The brake is released as follows:

1. The control arm is moved from either the full vertical or full horizontal position.

2. Moving the control arm moves the cam arm on the brake assembly.

3. As the cam arm moves, it rotates the brake cam.

4. Tension springs between the brake shoe assemblies pull the brake shoes away from the brake drum.

Brake Adjustment

1. Disconnect battery, block drive wheel off floor and remove drive motor cover.

2. Fully raise the control handle and remove the brake application spring. This will allow the brakes to release.

3. Lower the control handle to the operating position so that brake linkage is on top of operating cam.

4. Adjust clevis so that the pin just goes in the brake lever.

5. Reinstall spring and test braking ability. Vehicle should stop in its own length. If brakes are inadequate, then shorten the linkage on clevis to get adequate braking. Do not allow the brakes to drag when handle is in operating position.

The brake drum may be removed and the operating cam arm moved one "splineVo compensate for brake shoe wear.

Cam Arm

Cam

SECTlON A-A

Cam Arm

LA Locate lever as shown on spline of brake assembly.

Figure 35

Brake Lever Adjustment

50

Brake Interlock Switch

The brake interlock switch is located under the drive motor cover. It is activated by the brake arm. Its purpose is to disconnect electrical power to the drive motor when the brake is applied (handle is fully up or down) by opening the control circuit. To adjust the interlock switch:

1. Disconnect battery, block drive wheel off floor and remove drive motor cover.

2. Leave the brake *ON"(handle up).

3. Loosen the two (2) screws holding interlock switch on bracket and slide switch left, away from brake arm as far as possible.

4 Slide switch to the right until switch clicks (snaps). Next move an additional 1/52" (.79mm) and tighten screws.

5. Check that brake arm makes solid contact with the interlock switch lever.

6. Check that switch clicks (snaps) near middle of the cam arm movement. Brake interlock switch should actuate within 1 O0 of handle movement from the full up or full down position.

7. lnstall drive motor cover and torque to 35 ff ./lbs (49Nm).

8. Remove blocks, conned battery and test operation of unit.

Figure 36

Brake Linkage Removal

Brake lnterlock Switch

1. Disconnect battery and block vehicle with drive tire "OFF" floor (about 1 inch) (25.4rnrn).

'2. Remove side cover over drive tire.

3. Loosen brake interlock switch and slide switch away from cam of brake arm.

4. Disconnect main spring and brake linkage at clevis and remove entire lever from case.

Brake Linkage Installation

1. Thoroughly clean all parts with solvent or other non-corrosive cleaning fluid. Air dry all parts.

2. Install brake linkage and stretch spring across mounting.

3. Adjust brake linkage and brake interlock switch.

4. Install the side cover over drive tire. Torque to 35 ft./lbs (49Nm).

5. Remove blocks, conned battery and test operation of unit.

Service and Parts Manual Brake Brake Shoe Removal and Installation

TOYOTA

1. Disconnect battery and block vehicle with drive tire 'OFF floor (about 1 inch) (25.4mm).

2. Remove side cover over drive tire.

3. Disconned main spring of brake.

4. Move control handle to 'BRAKE-RELEASED"p0sition and disconnect clevis from brake lever.

5. Loosen nut and remove brake drum.

6. Remove springs and remove brake shoes.

During reassembly the brake lever should be checked to see that it is set at 60°, (See Figure 35), and that brake drum nut is torqued to 75 ft./lbs. (105Nm).

Adiust brake linkage and brake interlock switch (See page 51).

Service and Parts Manual

TOYOTA

The hydraulic pump assembly consists of a positive displacement rotary gear pump with reservoir mounted to an adapter. A DC electric motor is mounted on the opposite side of the pump adapter. An adjustable relief valve, check valve and a solenoid operated release valve are located within the adapter.

Description

Theory of Operation Lift Hydraulic

With the battery connected and the key switch turned On, closing the lift switch energizes the lift pump motor contador causing the following to occur:

1 . The lift pump draws fluid through the 100 mesh screen in the reservoir.

2. As the pump rotates, oil is forced out the pressure port. Oil cannot return to the reservoir because of the closed pressure relief valve and closed lowering solenoid valve.

3. Pressurized oil continues to flow to the lift cylinder, causing the piston to extend.

4. Releasing the lift switch de-energizes the lift pump motor contador, shutting the lift motor Off. The solenoid valve and the check valve near the lift pump hold the lift cylinder in the extended position.

Flow Control

Cylinder

Legend:

I = LOW Pressurn

= High Pressurn

Figure 37

Hydraulic Schematic - Lift

Service and Parts Manual

TOYOTA

Lift (Cont'd.)

Electrical Control Circuits

With the battery connected and the key switch turned On, depressing the lift button causes the following:

1 . Battery potential goes through: 1 5 amp control fuse key switch closed lift switch closed lift limit interlock switch through lift contador coil back to battery negative

2. This causes the lift pump contactor coil to energize, closing the lift pump contactor tips.

Power Wiring

3. When the lift pump contador tips close, battery potential flows from B+ to: closed lift pump contador tips lift motor battery negative

4. The lift motor runs turning the lift pump.

5. When the forks reach the maximum elevated height, the lift limit interlock switch opens preventing further lift.

Figure 38

-

Electrical Schematic Lift Mode

54

Service and Parts Manual

TOYOTA

Lift/Lower Lower Hydraulic and Electrical

With the forks elevated, the normally closed solenoid valve and the check valve built in to the lift pump prevent hydraulic fluid from returning to the reservoir. Depressing the lowering switch:

1. Supplies battery potential to the lowering solenoid coil, energizing it.

2. This repositions the solenoid valve, allowing oil to go back to the reservoir. The forks lower.

Legend:

Flow' Con11pol

Figure 39

.

Resetrvoir ...

Hydraulic Schematic - Lower

Service and Pads Manual

Equipment Recommended for Normal Servicing

TOYOTA

Recommended tools/supplies for servicing the lift/lower system include:

1/2' Allen wrench (pipe plugs).

Screwdriver (relief valve adjustment).

1' Opening adjustable crescent wrench and/or open end wrenches.

11/I& solenoid operated release valve.

12 point socket (pump screw).

1 /4' socket (reservoir screw).

0-3000 PSI (20,682 kPa) pressure gauge with 1/4' NPT end.

3/8"nipple and 3/8* tee (fittings to install pressure gauge).

Ball peen hammer.

1/4"dia. drive pin punch (for seating relief valve).

Clean fluid for the hydraulic system (for preparing O-rings for assembly).

Proper care and cleanliness should be observed in servicing so as to insure the oil does not become contaminated. Did or other foreign material can be drawn into the pump. This may damage the pump which could cause failure of the pump assembly.

Service and Parts Manual Lift/Lower

TOYOTA

Pump and Motor The hydraulic pump and motor assembly must be removed from the vehicle in order to separate the pump from the motor. The lift frame must be fully lowered before removing pump.

Removal and Installation

1. Lower lifting frame to release pressure in system.

2. Disconnect battery, remove access covers, and key switch mounting bracket.

3. Disconnect and cap hydraulic hose. Disconnect electrical cables. Disconnect solenoid control.

4. Unbolt pump and motor mounting bracket and remove assembly.

5. Remove motor-end cover for access to the bolts that hold motor to pump adapter.

6. Remove the mounting bolts and separate motor from pump adapter.

Pump Motor Brush Removal

The brushes are accessible under the pump motor end cover and can be replaced without separating the motor and pump. Lift the brush spring and pull brush from holder, unscrew lead and remove brush. Check that new brushes are properly seated during installation. (Refer to page 24.)

Legend: 1. Motor 24 VDC 2. Adapter Block (W/Check Valve) 3. Reservoir 4. Solenoid Release Va ke/Coil 5. Flow Control Valve Q GPM) 6. Adjustable Relief Valve 7. Pump 8. Fill Elbow 9. Vent Plug (W/40 Micron Fiher) 10. Solenoid Start Switch

-

Figure 41

Hydraulic Motor, Pump, and Reservoir

Service and Parts Manual

Hydraulic Pump Repair

TOYOTA

If hydraulic pump assembly does not operate properly, the following preliminary checks should be made:

1. Proper oil level: 2. All electrical connections tight.

3. Battery fully charged.

After the preliminary check is accomplished, install a 0-3000 PSI (20,684 kPa) pressure gauge in the pressure line near the 3/8" NPTF outlet port in the adapter. The installation of the pressure gauge is required to insure proper observation of what is occurring in the unit during troubleshooting. Attach a jumper wire across the terminals of the Lift Limit Switch. Start the pump and raise the cylinder to its upper limit stops to develop maximum pressure of the unit. The pressure gauge should be reading the set pressure of the relief valve. Remove pressure on the system by actuating the lower switch.

The normal problems that may occur with the lift system have been grouped under three headings: Failure to (A) Raise (B) Hold (C) Lower the load. One or more of the listed sources may be causing improper operation. Refer to the proper heading (i.e., relief valve) for detailed instructions or disassembly. Check and adjust the parts to remedy the problem. (Refer to page 59 for A, B and C below).

A. Pump operates, but will only develop low pressure or slow lift: I. Relief valve seat scored, foreign particles under ball or relief valve out of adjustment.

2. Dirt in solenoid valve.

3. Pump worn - replace pump.

B. Pump develops pressure, but will not hold load: 1 . Dirt in solenoid valve.

2. Relief valve seat scored, foreign particles under ball or relief valve out of adjustment.

C. Forks will not lower:

1 . No electrical contact to solenoid valve.

2. Lower switch or associated wiring may be bad.

3. Solenoid coil in solenoid valve coil is open.

4. Relief valve set too high causing pressure to go beyond the unloading limit of the solenoid release valve.

Service and Parts Manual Lift/Lower

TOYOTA

Hydraulic Pump Repair (Cont'd.)

Relief Valve

Remove hex cap on relief valve. If relief valve is causing the low pressure condition, the pressure can be increased by screwing in the adjusting screw. Recycle the pump and note pressure gauge reading. Be sure the final adjustment on the screw is at least 1/2 turn from bottoming position. If the problem is not remedied by the relief valve adiustment, remove adiustment screw and spring and ball. Valve seat should be clean and not scored. Replace spring and ball in cavity. Insert 1/4" drive pin punch down through spring coils and hold ball against valve seat. Tap gently on drive pin punch with ball peen hammer to seat the ball. Reassemble the relief valve parts. Adjust relief valve and recycle the pump per above. Do not operate motor/pump at relief valve setting any longer than is necessary (no longer then 10 seconds at any one period).

Removing Solenoid Valve

Clean surface around valve before starting. This will prevent foreign matter from falling into the cavity. Disconnect wires from terminals on coil, loosen and remove nut. Remove coil. Using wrench on flat surface, loosen and remove tube sub-assembly unit. Remove, inspect and clean or replace strainer as required.

Installing Solenoid Valve

Clean and inspect valve cavity to be sure it is free of all foreign matter.

ACAUT'oN

D O NOT BEND OR APPLY PRESSURE TO CENTER STUD OR HOLD CARTRIDGE BODY ANY PLACE BUT ON FLAT SIDES OF SUB-ASSEMBLY. Be sure O-ring and Teflon ring are in place. Apply a small amount of clean grease to both rings. Be sure strainer is in place. Screw sub-assembly in place and tighten to a maximum of 35 ft./lt=s. (49 Nm) for die cast metal. Assemble coil on spool assembly and tighten nut to a maximum of 5 ft./lbs. (7Nm). Conned wires to terminals on coil.

Removing Pump and Motor Assembly

It is necessary to remove the reservoir for access to the pump.

Removing Reservoir

1. Drain reservoir of oil.

2. Remove the pump/motor assembly from the vehicle.

3. Set pump/motor assembly with reservoir end up.

4. Remove four 1/4" screws holding reservoir

5. Tap reservoir lightly to loosen. Wiggle the reservoir sideways while pulling up at the same time.

Removing the Pump

Remove pump inlet tube. Rtmmove (4) four screws holding pump to adapter. Lift pump off.

Service and Parts Manual

lnstalling the Pump

TOYOTA

Lubricate O-ring lightly and install on pump pilot. Align splines on motor drive and pump shaft. Gently push pump pilot in adapter.

When pump is flush with adapter, pump and motor are connected. Replace four (4) screws, torque to 10-12 ft./lb. (1 4- 1 6Nm). Check strainer for clogging. Wash in suitable solvent, blow out with air hose from inside out. Insert inlet tube in pump.

Installing the Reservoir

1. Examine the inside leading edge of reservoir for any burrs or nicks that may cut O-ring during installation. Wipe the inside of the reservoir clean.

2. Lubricate the O-ring with hydraulic oil in the groove on adapter.

3. Start the reservoir over the flange on the adapter up to the O-ring. Make sure it is aligned with the holes properly as well as not cocked.

4. Rest a block of wood on the back of the reservoir and strike it squarely in the center of the reservoir end. The reservoir should move into position.

5. Install four (4) screws in position and tighten to snug condition.

Check Valve

Remove check valve from adapter. Remove 1/2-20 hex plug from valve body.

Check that the ball is not pitted or scored. Valve seat is to be clean and not scored.

If necessary, seat ball per instructions in relief valve section. After the unit is reassembled, it is necessary to bleed the pressure line of all air. This is done by loosening, (do not remove or loosen too much), the outlet pressure port fitting and turning the lift motor On until oil seeps thru the fitting.

Cylinder Assembly Removal Installation

The lift cylinder is a positive displacement type cylinder; all seals are at the head end of tube. The piston end of rod has only a bearing for guidance.

Scheduled maintenance involves inspecting cylinder and hydraulic connections for leaks, tightness of the mounting retainers, and cleanliness around sealing area of rod.

DO NOT dismantle the cylinder unnecessarily. If a loss of performance occurs, the system as a whole must be investigated before assuming that the cylinder is at fault.

Cylinder Removal

1. Raise and block lifting frame of vehicle. Release pressure in cylinder by activating lowering switch.

2. Disconnect and remove battery from unit to prevent accidental operation.

3. Remove electrical access cover, plastic cover, and key switch mounting bracket.

4. Remove four (4) mounting bolts and two (2) retainers at base of cylinder.

Service and Parts Manual

TOYOTA

Hydraulic Cylinder Cylinder Removal (Cont'd.)

5. Thoroughly clean outside of cylinder before removing hydraulic hose. Cap and plug open fittings.

HOT OIL UNDER PRESSURE M A Y BE PRESENT. BE CERTAIN VEHICLE IS SAFELY BLOCKED AND PRESSURE IS RELEASED. 6. Remove lock bolt from retaining pin at top of cylinder assembly and remove pin.

Some spillage of hydraulic oil may occur.

7. Place on a clean bench for disassembly.

Cylinder Disassembly

1. Thoroughly clean outside of cylinder assembly.

2. Pull rod (1) out until end of rod and snap ring (2) can be seen through inlet port.

3. Insert screwdriver in inlet port and slide snap ring in deep groove in rod assembly.

4. Remove rod assembly from barrel assembly (5).

5. Remove wiper (3) and seal (4) from inside diameter of barrel assembly.

Replace wiper seal, seal and lock ring as new items. These parts are included in the seal repair kit available for this cylinder.

4

Inlet Port

Figure 42

Inspection

Lift Cylinder - Exploded View

1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

2. lnspect inside surface of barrel assembly for excessive wear or scoring.

3. Inspect outside surface of rod for nicks, scratches or scoring.

Service and Park Manual Lift/Lower Cylinder Assembly

TOYOTA

Refer to Figure 42.

1. All parts should be cleaned and dried thoroughly. Metal parts should be lightly oiled prior to reassembly.

2. Install new seal (4) in inside diameter of barrel. Install new wiper seal (3) with lips facing inward to bottom of barrel.

3. lnstall new lock ring (2) in deep groove of rod end.

4. Oil outside of piston rod (1) and carefully insert rod in barrel assembly.

5. Push rod in barrel assembly (5) until snap ring (2) can be seen through port.

6. By using screwdriver through port, pop snap ring (2) in lock position.

7. Extend rod (1) to full out position to make sure snap ring is locked in place.

1. In order to prevent air from filling the cylinder, install the cylinder with rod

Cylinder Installation

retracted.

2. lnstall upper mounting pin first and lock in place with locking bolt.

3. Install and conned battery to unit.

4. Connect hydraulic hose and use the pump to extend the cylinder.

5. Install four (4) mounting bolts and two (2) retainers at base of cylinder.

6. Raise and unblock lifting frame of unit.

7. Test operation of cylinder and look for leakage around fitting and cylinder rod.

8. Check reservoir fluid level.

9. lnstall key switch mounting bracket, plastic cover, and electrical access cover.

Lift Limit Switch

The lift limit switch turns the hydraulic pump/motor "OFF" when the fully raised position has been reached. This is to prevent loading of the pump motor running at relief pressure after maximum cylinder travel has been reached. (See Figure 43.)

When activated, the lift limit switch cuts "OFF" control power to the lift solenoid. This turns the hydraulic pump/motor "OFF". Adjustment of the switch is made by:

1. Raising the forks until they reach their fully raised position.

2. Adjusting the switch to activate when the forks are 1/2" to 1" (1 2.7mm-25.4mm) from fully raised position.

Normally Closed

Figure 43

Lift Limit Switch

Common Normally Open

Service and Parts Manual

TOYOTA

Lift/Lower Troubleshooting

Condition: Pump/motor runs, but still no lift.

No Lift Lowering solenoid stuck open

1

rYes

Clear and/or replace

r

Clear and/or replace

Yes

Load check valve open

Check pressure Set relief to 2,600 psi (+/- 50 psi)/l7,924 Kpa (+/-344 Kpa)

Relief valve set too low

Yes No flow or pressure from Pump

Check flow 1.lgpm (4.1 6 Ipm) at 2,000 psi (13,788 kPa) (24 volt)

Condition: Lift contactor closed, lift motor does not run.

No Lift Measure voltage at:

1

Pump motor field coil terminal B t volts

N~

Are contador tips OK?

/ Yes

I

I Yes

I

Check wiring continuity from B+ to pump motor fields

Pump motor field coil terminal B+ volts

Replace wire from motor to battery negative

Continued next poge.

1

Repair pump motor

Repair/Replace contador

Service and Parts Manual Lifi/t/Lower

TOYOTA

Condition: Key switch closed

No Lift Check voltage at:

Check continuity from key switch to raise

lNON0 switch

Raise switch B+ volts

No Lift

Condition: Key switch closed, raise switch closed

,LReplace raise switch

Raise switch B+ volts

Check continuity from raise switch to lift limit switch

Lift limit switch B+ volts

No Lift

Condition: Key switch closed, raise switch closed, lift limit switch closed

Normally open terminal of lift limit switch B+ volts

Replace lift limit switch I

Yes

1 Raise contador coil B+ volts

Check continuity from lift limit switch to raise coil

Service and Parts Manual

TOYOTA

Condition: Key switch closed

Forks Do Not Lower

Check voltage at:

- - I No

Lowering switch B+ volts

1

Check continuity of wire 6 to keyswitch

yes

Close lowering switch Wire 4 on lowering switch B+ volts

1%

Replace switch

I

Check continuity of wire 4 from lowering switch to solenoid

Yes

I

Wtre 4 on lowering solenoid B+ volts Yes

Wire 13 on lowering solenoid B+ volts

Forks Do Not Lower

Replace negative wire to solenoid

Condition: Electrical system OK.

Yes Lowering valve stuck closed

Yes

i

Is solenoid coil OK?

Clear and/or replace

Replace Solenoid Coil

Check for mechanical failure.

Forks Will Not Hold Load Lowering valve stuck oped=.

Load check valve open

Clear and/or replace

1 L Clear . and/or replace

1%-

-

Replace solenoid coil

Service and Parts Manual Traction System

TOYOTA

Traction System

This vehicle uses a transistorized speed control.

Transistor Control (Motor Controller)

The transistor control system electronically controls drive motor power and can be varied from full OFF to full O N without speed steps or increments. The heart of this control system is the Transistor Control Power Module.

The Power Module is basically a high-power semiconductor switch. An array of MOSFET power transistors are connected in parallel and control the current through the motor windings.

The transistors are connected in series with the battery and the motor. When the transistors are on, the current through the motor builds up, the stored energy causes the motor current to continue to flow through the internal freewheel diode. The transistors are turned on and off at the rate of up to 15,000 times per second by the internal control circuitry. The ratio of on and off times is varied by the input from the throttle potentiometer. This technique is called pulse width modulation.

Figure 44 Control System (Simplified)

Service and Parts Manual Traction System

TOYOTA

Transistor Control (Cont'd.)

As shown in Figure 45, the motor current ramps up and down as the power FET's turn on and off. The average current (which determines the motor torque) is being controlled by the ratio of the on and off times. In this way, smooth, stepless control of the power delivered to the motor is achieved with very low power loss in the control components.

Current Limiting

The controller limits motor current to a preset maximum. This current limit protects the controller from damage. Damage would result if the current were limited only by motor demand. The current limit also reduces stress placed on the motor, drive train, motor controller, and battery. Motor, battery efficiency and service life are improved by eliminating high current surges during vehicle operation.

Figure 45

Motor Current Chart

Low Voltage Cutback

The controller prevents operation at very low battery voltages. The control circuitry requires a minimum voltage to function properly. Performance is gradually reduced if the battery voltage falls below approximately 16 volts. By reducing the output to the motor, battery voltage can recover. A balance is achieved where the battery is allowed to supply as much current as it can without falling below 16 volts.

Thermal Protection

When internal temperature of the motor controller exceeds 165°F (73"C), and the controller is overloaded, current limit will be gradually reduced in a linear fashion. This will generally allow continued vehicle operation, but at a reduced performance level.

When the controller cools down, full current limit and performance will automatically return. This action is not damaging to the controller; however, if thermal cutback occurs often, the vehicle may not be suited for the particular application.

Service and Parts Manual Traction System

TOYOTA

Runaway Protection

The controller has a feature which shuts off the output in the event of an open circuit fault in the throttle system or the control module which could otherwise result in uncontrolled operation. The throttle configuration is a 13,000 ohm pot going from zero ohms in neutral (when referencing the pot wiper to the fixed center tip of the pot), to 5000 ohms for full on in either direction. Broken pot wiring, connections or pots which fail open would normally give a full on signal. The controller detects any throttle inputs of more than 7000 ohms as a fault and shuts off the output preventing a runaway condition. The controller will return to normal operation when the fault is repaired.

Static Return to Neutral Protection

The controller has circuitry to sense a "high" (non-zero) throttle at the time the keyswitch is turned on and inhibits the output until the throttle is released and re-applied. This safety feature prevents the vehicle from being turned on with the throttle engaged, requiring the operator to start smoothly from zero throttle. It also protects against sudden starts caused by problems in the throttle linkage (e.g., bent parts, broken return spring, etc.), which might give a partial or full throttle signal to the controller even with the throttle released.

Plugging

When the series wound drive motor field is reversed while the vehicle is moving, a form of electrical braking called "plugging" occurs which may be used to slow the vehicle down. When the motor is reversed, with the throttle engaged (by reversing the field connections) the armature ads as a generator. Current from the armature flows through a "plugging diode" built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plugging torque proportionately based on throttle position. The vehicle slows smoothly to a stop, then automatically accelerates in the other direction. The plugging current is factory set, but may be adiusted in the field.

Controller Keyswitch Input

The controller keyswitch input is used to turn the controller on and off. The controller's main power connections (B+ and B- busses) are kept "live" at all times.

Most of the internal circuitry is powered down when the keyswitch is turned off.

Controller Thumbwheel Throttle Inputs

The throttle inputs are used to input speed selection to the controller

The throttle input must go from zero ohms at neutral to 5000 ohms in each direction (actual values may vary, but they must be equalized +/- 100 ohms). Actual start point is approximately 300 ohms, and full on is achieved at 4.3k ohms).

"Emergency Reverse" Plug Breaking Inhibit

In normal operation, when reversing vehicle direction, the controller goes through a "plugging" mode. A variable pulse rate (throttle controlled) is input to the drive motor (the field connection is also reversed), initiating a gradual decrease in speed to zero then reversing direction.

An "emergency reverse" condition requires a quicker response. This causes the controller to bypass the normal plugging mode of operation and immediately ramp up to full speed in the reverse direction as long as the Emergency Reverse switch is activated. This action commands a maximum forks-first travel speed command to the motor controller.

Service and Parts Manual Traction System

TOYOTA

Traction System Adiustments

Adjustment Panel

The adjustment panel is located on top of the controller, under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, and also contains a connector for the handheld programmer and a status LED.

MAIN

?LUG

CURRWlLIYIr

ACCEL.

CREE?

SPEEOLIMtt

1

Figure 46

Potentiometer Adjustments

Adjustment Panel

For detailed information on potentiometer adjustments turn to page 100 "Manual Adjustments."

Service and Parts Manual Traction System

TOYOTA

The following operational modes will be covered in this section:

Theory

Travel Forward Reverse Emergency Reverse Preparing to Travel

Moving the travel/brake control down from the vertical position: (Refer to Figure 48.)

1. Closes the broke switch.

2. Starts the hour meter.

REVERSE (FORKS FIRST)

Figure 47

Travel Direction Reference

Service and Parts Manual Traction Svstem Directional/Speed Control Forward

TOYOTA

As the twistgrip/butterfly control (diredional/speed control) is rotated in the forward direction from neutral the following occurs: (Refer to Figure 48.)

1. The first few degrees of control handle movement closes the forward directional switch which in turn closes the forward contactor.

The resistance of throttle potentiometer (directional/speed control pot) changes as the twistgrip/butterfly lever is rotated. When the lever is in the neutral position, the resistance is zero ohms between the wiper and the center tap (VR4). As the lever is rotated in either direction, resistance increases to a maximum of approximately 5.OK ohms.

2. The throttle potentiometer in the control handle (see page 93): controls throttle input to the motor controller at P I 2. controls output from the motor controller (P3) to the forward contactor.

.

-

= Positive = Negative - . = Signal Voltage

r - - - - - - -

Figure 48

Electrical Schematic - Forward

72

This schematic is for theory of operation only. Refer to the electrical schematic at the back of this monual when tmubleshooting or performing maintenance.

Service and Parts Manual

TOYOTA

Tradion System Directional/Speed Control Reverse

As the twistgrip/butterfly control (directional/speed control) is rotated i n the rearward direction from neutral the following occurs: (Refer to Figure 49.)

1. The first few degrees of control handle movement doses the reverse diredional switch which in turn doses the reverse directional contador.

The resistance of throttle potentiometer (directional/speed control pot) changes as the twistgrip/butterfly lever is rotated. When the lever is in the neutral position, the resistance is zero ohms between the wiper and the center tap (VR4). As the lever is rotated in either direction, resistance increases to a maximum of approximately 5.OK ohms.

2. The throttle potentiometer in the control handle: controls throttle input to the motor controller at PI 1. controls output from the motor controller (P2) to the reverse contactor.

.

.

..

= Positive = Negative = Signal Voltage

Figure 49

Electrical Schematic - Reverse

"

this manual when troubleshooting or performing maintenance.

Service and Parts Manual Traction System Emergency Reverse

TOYOTA

If the emergency reverse switch is closed, when traveling tractor first (belly button switch), the control system will provide an immediate, rapid acceleration in the reverse (forks first) direction.

When traveling in the forward direction, if the emergency reverse switch is activated: (See Figure 50.)

1. The forward contactor coil is de-energized.

2. The emergency reverse switch closes which applies B+ to P I 3 of the motor controller. This allows a higher plugging current limit.

3. The reverse contactor coil is energized.

4. A full reverse signal is sent to the motor controller regardless of throttle input, and remains in that condition until the emergency reverse switch is released.

Once the emergency reverse switch is activated, the motor controller locks out the forward contactor by opening the negative circuit (internally). To reset the vehicle for normal travel, the handle must either be set to the full vertical or full horizontal position. Turning the keyswitch OFF and then ON will also reset the control module.

Figure 50

Electrical Schematic - Emergency Reverse

this manual when troubleshooting or performing maintenance.

Service and Parts Manual Traction Svstem

1. Contactor tips are the only serviceable part of contactors. The bars should be replaced when tips have worn through the silver contact in any area.

Contactor Tip/Bar Replacement

2. Disconnect Battery.

3. Disconnect buss bars (15) from contactors.

4. Remove screws, (16) holding contactor cover (4) in place.

5. Remove cover (4), being careful not to drop springs (5).

6. Install new bars (9, 14) and tips (6).

7. Install cover (4) with springs (5) in correct place.

8. Install and tighten screws (10).

9. Conned buss bars (15).

7

TOYOTA

8

Figure 51

Contactor - Exploded View

Service and Parts Manual Traction Svstem

Reference Motor Controller "Diagnostics and Troubleshooting" on page 103 when troubleshooting.

Troubleshooting Vehicle is dead nothing operates Check for voltage at:

Positive side of control fuse B+ volts

.-I

No

Check connection to battery

/ Yes 1

No Replace fuse

Negative side of control fuse B+ volts

1

Yes

Positive side of keyswitch B+ volts

I

(With keyswitch closed) Negative side of key switch B+ volts

-%1

Check wire from fuse to keyswitch

i

Replace keyswitch

I Yes

1

Check wiring from key switch to B-

No travel - horn and lift/lower operates OK

Condition: Key switch closed

Check for voltage at: No Check wire from key switch to brake switch

Positive side of brake switch B+ volts

I

i

Yes

I (With brake switch closed) negative side of brake switch B+ volts

1

TOYOTA

Replace brake switch

Yes

B+ side of the belly button reverse switch

No

-.,

Check wire between brake switch and B+ side of

1 belly button reverse switch

Yes

B- side of the belly button reverse switch

No

Replace belly button reverse switch

I

B+ side of travel con:rci switch

No

Check wiring between travel control switch and

/ belly button reverse switch

Yes Replace travel control switch

Service and Parts Manual Traction System No forward travel forward contador does not energize

TOYOTA

Condition: Key switch closed, brake switch closed

Check for voltage at: Normally open terminal of belly button reverse switch B+ volts

I k Replace belly button reverse switch

Check wire from belly button reverse to travel control switch

Common of travel control switch B+ volts

(With forward switch ilosed) travel control switch B+ volts

1

Yes

(With forward switch closed) Forward contactor coil B+ volts

1

Replace travel control switch

Ik.

Check wire from travel control switch to coil

Yes

Forward contador coil B+ volts

Check continuity of negative wire from No

Replace forward contador coil

Service and Parts Manual

TOYOTA

Traction System

-

No forward travel forward contador closed

Condition: Key switch closed, forward contactor energizes.

Check voltage at: Wire to normally open side of forward contador tips B+ volts

Is B+ on either side of circuit breaker

I-.

N~

Reset/Replace circuit breaker

I

Yes Check wiring for continuity between circuit breaker and forward contador.

Yes

OK?

I

Check continuity of wire from normally open forward contador tips to drive motor A2

A2 on drive motor armature B+ volts I

i

Drive motor terminal A1 B+ volts

I

No

Repair drive motor

I Yes Check continuity of wires from resistors from

Reverse contador tips normally closed side for B+ volts

A1 to normally closed reverse contador tips

1 Yes Check continuity of wiring from S2 to the normally closed side of the contador

Drive motor terminal S2 volts

I Drive motor terminal S1 volts

Replace negative wire from S1 to battery negative

1%

Repair drive motor

Replace tips or repair contador

Repair/Replace wiring

Service and Parts Manual

TOYOTA

Traction System No reverse travel reverse contactor does not energize, forward travel operates

Condition: Key switch closed, brake switch closed

Check voltage at:

Travel control switch terminal 1 for B+ volts

L-l

Check for continuity from travel control switch to belly button reverse switch

I L .

Replace travel control switch

1 Yes (With reverse switch closed) terminal 2 at travel control switch for B+ volts

1

Yes

I (With reverse switch closed) reverse contador coil for B+ volts

Check continuity of wire

1

(With

reverse switch closed)

reverse for B+ volts

No

Replace negative wire from coil

N~ Replace coil

Service and Parts Manual

TOYOTA

Traction System No reverse travel reverse contador closed

Condition: Key switch closed, reverse contactor energizes.

Check voltage at: Is B+ on either side of circuit breaker?

Wire to normally open side of reverse contador tips B+ volts

l E s Resetflepbce circuit breaker

Check wiring for continuity between circuit breaker andreverse contador. OK?

1 5 .

Repair/Replace wiring

Normally open reverse contador tips to Test resistors and check wiring from reverse contodor tips to A1

A1 on the drive motor ohms

I Yes

1

------1

No

Repair drive motor

A2 on drive motor ormature ohms

I Yes

I

Forward contodor tips normally closed side for B+ volts

1

F-

Check continuity of wiring from A2 to normolly closed tips of the forward contador

Yes

Normally closed forward contador tips to diive motor S2 ohms

Check continuity of wiring from forward contador normally closed tips to S2

Yes

!

Replace tips or repoir contodor

yes

1 S1 drive motor terminal ohms

I

Yes

Replace wire from S1 to battery negative

IK.Repair drive motor

k I

Repair/Replace wiring

Service and Parts Manual Traction Svstem N o Emergency Reverse

Condition: Key switch closed, brake switch closed

Close reverse switch; check voltage at: Normally open terminal of reverser switch B+ volts

No

Replace reverse switch

Yes

Reverse contador B+ volts

5Check for open diodes

TOYOTA

Service and Parts Manual Troubleshooting Troubleshooting

TOYOTA

It is important when you troubleshoot vehicle problems to: Use a logical, commonsense approach.

Begin with the simplest solution and work towards the most complex.

The following will aid in developing a logical and systematic troubleshooting procedure.

1. Verify the problems by: Obtaining as much information as you can about the problem.

Determining, if possible, what the vehicle's performance was before the problem began.

Reviewing any records which should have been kept about the truck's performance.

Operating the vehicle yourself to verify the problem.

. Locate the truck problem area by: Opening the compartment covers and visually inspecting the systems, then referring to the electrical and mechanical maintenance sections for general information which may save you time.

Determining if the problem is in the control circuit or the power circuit if there i s no obvious physical problem.

. Establish a logical testing sequence by: Using the appropriate schematic diagram(s). Begin at the power source and establish a sequence of testing points to locate the problem. Use the schematic(~) in conjunction with the appropriate flow diagram.

Establishing test points which indicate that all components between any new test point and the power source are good.

Avoiding haphazard checking which provides inconclusive results.

4. Use the troubleshooting flow diagrams by: Consulting the list of vehicle problems.

Following the appropriate flow diagram from the beginning to where the probable cause is isolated.

5. Identify the cause of the problem by: Checking for improper vehicle usage.

Bringing the problem to the service manager's attention to avoid repetition of the cause.

6. Correct the problem by: Repairing or replacing defective components following instructions in the Maintenance section of this manual.

Complying with appropriate safety procedures.

Continued next page.

Service and Parts Manual Troubleshooting

TOYOTA

WHENEVER A TROUBLESHOOTING PROCEDURE REQUIRES CLOSING KEYSWITCH S1, THE VEHICLE MUST BE BLOCKED. THIS WILL AVOID ACCIDENTS CAUSED BY UNEXPECTED VEHICLE TRAVEL.

ACAUTlON

DISCONNECT POWER WHEN CHECKING ELECTRICAL CIRCUITS OR COMPONENTS WITH AN OHMMETER. CURRENT CAN DAMAGE THE METER! 7. Save time and trouble; look for simple causes first.

Visually inspect all wiring and electrical components for: Loose connections or connectors Loose or broken terminals Damaged terminal blocks or strips Broken wiring and shorted conditions (especially close to metal edges or surfaces) Use an ohmmeter to check for wiring continuity.

Service and Parts Manual Troubleshooting Wiring Inspection Procedure

TOYOTA

1. Check that fuses are not blown, terminals and connedions are properly connected, contadors actuate normally, and contad tips are not worn.

2. If the problem has not been found, use the following procedure: a. Check insulation resistance; it should be more than 1 megohm (measure on a R x 100 ohm range). Check only with a volt-ohmmeter. Place negative lead:

(-) of the meter to the chassis and... (+) to the live parts and vice versa.

Refer to pages 114 and 115 for schematics.

3. Use the Troubleshooting Flow Charts by: Determining in which system the problem occurs.

Referring to that system within this manual.

Consulting the list of problems at the end of the specific system section.

Following any applicable charts from beginning to isolation of problem.

4. Identify the cause of the problem by: Checking for careless or improper operating procedures and if found, bringing the problem to the service manager's attention to avoid repetition of the cause.

5. Correct the problem by: Repairing or replacing defective components and following instructions in this manual.

USE EXTREME CARE WHENEVER THE VEHICLE IS JACKED UP FOR ANY REASON. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT VEHICLE. DO NOT RELY ON JACKS.

Service and Parts Manual Troubleshootinn

TOYOTA

Miscellaneous Troubleshooting

1. No reverse when reverse switch is closed a. Open diode in reverse circuit

2. Circuit breaker opens up a. Excessive amp draw on pump or drive motor

b. Brake dragging

-

c. Overloaded pressure relief set too high

3. Heaters burn out a. Thermostat shorted

4. Hourmeter operates only with either forward, reverse or lift a. Open diode in hourmeter circuit

5. Forward closes with either reverse or lift a. Shorted diode in hourmeter circuit

6. Reverse closes with either forward or lift a. Shorted diode in hourmeter circuit

7. Lift closes with either forward or reverse a. Shorted diode in hourmeter circuit

Service and Parts Manual Troubleshooting Battery Charger

TOYOTA

The battery charger incorporates a very simple and reliable design which makes troubleshooting relatively easy. The repair procedure involves testing the output of the charger and then testing individual components. The test procedures follow a logical sequence of electrical flow throughout the circuit. Only standard hand tools and an AC/DC voR/ohmmeter are required. A battery hydrometer is also recommended.

BEFORE CHECKING CHARGER, DISCONNECT AC POWER SUPPLY, UNPLUG BATTERIES, AND DISCHARGE CAPACITOR WlTH AN INSULATED SCREWDRIVER ALL TESTS SHOULD BE MADE WITH DCTREME CAUTION WHEN A TEST CALLS FOR THE POWER TO BE "0N"AT THE CHARGER Electrical Testing Equipment Required

Common hand tools.

1. AC/DC volt/ohmmeter.

2. Battery connector with to loop (use on charger only).

3. Battery hydrometer.

+ -

Instructions

Check condition of battery (check each cell).

Acceptable Charge Values

Specific gravity-before and after charging.

1. Discharged battery - 1.1 80 2. Fully charged battery 1.280

-

Any cell that varies by more than 20 points from any other cell indicates a suspect battery.

B. Volts per cell, open circuit - before and after charging.

1. Discharged battery - 1 .9 v/cell 2. Fully charged 2.2 v/cell

-

C. Charging rate - DC amps - at start and finish of charge cycle.

(See Chart I on page 90.)

D. Charging rate at battery - DC volts - at start and finish of cycle.

(See Chart II on page 90.)

Service and Parts Manual Troubleshooting Battery Charger (Cont'd..)

TOYOTA

Visually inspect charger with all power disconnected.

A. Inspect AC power supply arcuit breaker, wall outlet, plug, and cord.

B. lnspect charger for physical damage.

C. lnspect internally for loose or discolored connections and wires damaged due to overheating.

D. lnspect transformer coils for obvious discrepancies.

E. lnspect the charger internal AC power fuse -should be 10 amp rated.

If the AC power fuse is blown it could indicate a shorted diode on the DC output circuit.

Testing the DC output circuit.

If the AC power fuse blows or the DC 1X circuit breaker trips, check for reverse polarity of the battery connection.

Open Circuit Voltage Test

With the batteries disconnected and the charger turned on, the DC output voltage should be 1 b9 times the rated DC voltage.

See Chart Ill on page 90.

Short Circuit Amperage Test

With the charger output battery connector short circuited (positive to negative jumper connedor plugged into charger output connedor), and the charger turned on, the DC output amps should be 80% of the normal DC amps.

See Chart IV on page 90.

I. With the charger in the "off position, conned AC power cord to appropriate AC power supply. Conned the battery connector with the

+ to - loop to the charger.

2. Turn the battery charger On and note the amp gauge reading. It should be as stated on Chart IV on page 90.Leave the charger on for five minutes while watching the amp gauge. The amp gauge should remain steady. This verifies the condition of the circuit breaker and any loose connections.

3. Turn the charger off before disconnecting the iumper connector.

Service and Parts Manual Troubleshooting

TOYOTA

Battery Charger (Cont'd.)

Testing Components.

BEFORE CHECKING COMPONENTS; DISCONNECT AC POWER SUPPLY, UNPLUG BATTERIES, AND DISCHARGE CAPACITOR WlTH AN INSUIATED SCREWDRIVER. ALL TESTS SHOULD BE MADE WlTH THE CHARGER DISCONNECTED UNLESS OTHERWISE STATED. USE EXTREME CAUTION WHEN A TEST CALLS F O R THE POWER TO BE '0N"AT THE CHARGER. Diodes

1. Discharge Capacitor.

2. A quick test for shorted diodes may be made by connecting the leads of an ohmmeter to the charger battery connector terminals and testing for continuity in each direction. If the test shows open, the DC circuit breaker may be open. To bypass an open DC circuit breaker, conned the test leads to the positive and negative lugs behind the circuit breaker, reverse the ohmmeter probes. A shorted diode will show continuity in both directions. You will have to test the diodes individually as described below to determine which diode is faulty.

3. Disconnect the diode flexible leads to isolate the diodes from the circuit.

4. Use the ohmmeter to test the continuity of each diode in both directions. A shorted diode will show continuity in both directions and an open diode will show no continuity in either direction. A good diode will show continuity in only one direction.

5. Reconnect diode leads in charger.

Capacitor

1. Discharge capacitor.

FAILURE TO DISCHARGE CAPACITOR MAY RESULT IN INJURY OR DEATH.

2. Disconnect capacitor leads.

3. Set ohmmeter R x 1 0,000 scale and conned ohmmeter leads to terminals on capacitor. When needle (or display) quits moving, reverse leads. On a good capacitor, the needle will deflect to the right (low resistance) and then deflect back to the left (high resistance) each time the meter leads are reversed. O n a shorted capacitor the needle will deflect to the right (low resistance) and remain there. On an open capacitor the needle will not deflect (stationary display).

4. Reconnect capacitor leads in the charger (Continuedon next page)

Service and Parts Manual Troubleshootina

TOYOTA

Battery Charger (Cont'd.)

Testing Components (Cont'd.)

5. Set AC voltmeter on a scale to read at least 500 volts AC. Conned meter leads to the capacitor terminals.

A. A shorted capacitor will indicate 0 volts AC. B. An open capacitor will indicate about 300 volts or 20 volts AC. This is the same as the capacitor transformer winding voltage without a capacitor connected in circuit.

+ -

6. Turn on charger power.

Timer

The timer can be tested by rotating the timer knob clockwise to the one (I)hour mark. With the AC power connected, the charger should turn off in one (I) hour.

Overcharging Problems

Most charging problems can be remedied by following the previous procedures; however, overcharging problems may not be the fault of the charger. Often times overcharging is caused by faulty batteries or poor connections. The following items should be checked to resolve problems of overcharging or failure of charging amps to taper down.

Charger and Battery not Properly Matched

1. Check the specifications on both batteries and the charger.

A. This battery pack was designed for a specific size and type of battery. If another battery has been installed, be certain that it is comparable to the original batteries. Automotive-type batteries will not function properly in this application.

2. Excessive battery temperatures cause suppressed battery voltage.

A. Allow battery to cool.

Defective Battery or Poor DC Connection

Check the battery voltage while the charger rate is controlled by the battery state of charge. This will adjust the output to the proper level if the battery is in good condition. If the voltage does not come up to finish rate, this may indicate a bad cell within a battery or a marginal DC connection between the battery and the charger.

Carefully inspect the connections for excessive heat. Test all the battery cell voltages and specific gravity.

Service and Parts Manual Troubleshooting

TOYOTA

Battery Charger (Cont'd.)

Battery Charts Chart I

Chart II

Chart Ill

1

System voltage

24 volts

Battery Charger Output Open circuit output voltage

I

36 volts

Chart IV

I

System vohage

24 volts

Battery Charger Output Shorl circuit output amps

approx. 12 amps

1

Service and Parts Manual ContoHer Description

TOYOTA

The microprocessor-based logic section combined with a proven MOSFET power section gives the motor controller high power and advanced features in a simple, compact package. The optional handheld programmer enables the user to set parameters, conduct tests, and obtain diagnostic information quickly and easily.

Figure 52

Programmer and Motor Controller

The controller offers superior operator control of the vehicle's motor drive speed.

The key features of the controller include: Infinitely variable drive and plug brake control Power MOSFET design providing high efficiency (for reduced motor and battery losses) and silent operation Connections made by solid copper power busses with a polarized Molex connector for control signals Solid, well-protected construction with an aluminum mounting plate and iniection-molded cover Thermal protection and compensation circuitry provides under-temperature cutback, constant current limit, and linear rollback in over-temperaturethus preventing sudden power loss regardless of thermal conditions Over voltage and under voltage protection Intelligent hand held programmer (optional) provides a full set of parameter and function settings

Service and Parts Manual Contoller Description (Cont'd.)

.

TOYOTA

Diagnostic and test information for the controller and other system components readily available both on-board and through the programmer On-board potentiometers allow direct manual adjustment of acceleration rate, creep speed, low speed, plug current, and main current limit (without programmer) Circuitry and software detects faults in the throttle circuit, MOSFET drive circuit, MOSFET transistors, contactor drivers, and contactors ensuring that the controller meets ECC fault detect requirements Input sequencing options include neutral start and static return to off (SRO) Microprocessor-controw contactor sequencing provides true arcless contactor switching Smooth, controlled plug braking with either variable (throttle-dependent)or fixed plug current limit Programmable low-speed input for true two-speed operation Emergency reverse (belly button switch) with a single input Anti-rollback provides full power for starting on ramps Simple contactor and switch wiring, with coil drivers monitored for shorts and open circuits thus ensuring fail-safe operation

Service and Parts Manual

TOYOTA

Contotter

Four tin-plated copper bus bars are provided for the high current connections to the battery and motor:

High Current

Figure 54

Motor Controller

Cables are fastened to the bus bars by M8 (5/16) bolts. When tightening the bolts, two opposing wrenches should be used to prevent bending the bus bars and putting undue strain on the internal connections.

Adjustment Panel

The adjustment panel is located on top of the controller, under a sliding protective cover. The panel provides access to a set of adjustable potentiometers, and also contains a connector for the handheld programmer and a status LED.

0

1

'

2

0ff'044 MAIN

'

1

2

od'-'%3 0ffCo~4 PLUG

0

Manually Adjustable Potentiometers

2

'

0fFC0'4 ACCEL.

CURREIJILIYIT

Figure 55

1

1

0.('-'$3

2

0FFCo'4 CREEP

LOW

SPEED L I M I T

Adjustment Panel

Three screwdriver-adjustable potentiometers ("'trimpots")allow manual adjustment of plug and main current limit and acceleration rate. To adjust any of these parameters electronically with the programmer, its pot must be set to "off."

(See page 101 for values.)

Note:

For adjustment of potentiometers, refer to page 100.

Note:

Creep and Low Speed Limit adjustment are disabled.

Programmer Connedor

An RJ11 modular connector is provided for the handheld programmer. The mating connector is supplied with the programmer.

Status LED

The LED displays flashing codes to indicate various faults; the codes are listed on page 103 of this manual.

Service and Parts Manual

TOYOTA

Contoller Power Wiring

The field is wired between B+ and A2 and the armature is wired between M- and the A2 terminal. The internal plug diode used in the controller is connected between M- and A2. Therefore, the armature and field positions cannot be interchanged.

Reversing contactors are used to switch either the armature or the field.

Control Wiring

Wiring for the input switches and contadors is shown in Figure 56 (see detail below).

The main contador is normally conneded directly to the controller. Optionally, the main contactor can be switched directly by the key switch or brake, leaving pin P4 unconnected.

KEYSWITCH

/

I

SPEED

1

FORWARD

I

Bg.E

NOT USED; PI

RHEOSTAT (5 U)

Figure 56

nlan

EMERGENCY - ;R E

EMERGENCY REVERSE CWCK OUTPUT

I I /

I

R-RSE

i

MAIN COWACTOR

REVERSE COHTACTOR

16 Pin Connector

The field is wired between B+ and A2 and the armature between M- and A2. The internal plug diode in the controller is connected between M- and A2; therefore, the armature and field positions cannot be interchanged.

Service and Parts Manual

TOYOTA

ContoHer

The 0-5kR throttle (''Type 3" in the programming menu) is a 2-wire resistive throttle that connects between the 5kS2- 010- 5kQ pin (P8) and the Pot Low pin (P7), as shown in Figure 57. Zero speed corresponds to Of2 and full speed corresponds to 5kR.

0-5kS2 Throttle (''Type 3")

Broken wire protection is provided by the controller sensing the current flow from the 0-5kR input through the pot and into the Pot Low pin. If the Pot Low inpui current falls below 0.1 mA, a throttle fault is generated and the controller is disabled.

Note:

The Pot Low pin (P7) must not be tied to ground.

PI Pot l o w NOTE Cterminal 10 kn pot wired for04/62 wipwag Opefation

Figure 57

5kR Throttle (Type 3)

Service and Parts Manual Controller

TOYOTA

Plug Current in Over-Temperature

Plug current is no longer reduced when the controller is in over-temperature. Main drive current is still gradually reduced when the controller's internal temperature exceeds 8 5 ' ~ . It is reduced to zero current at 9 5 ' ~ . Plug current will be maintained at approximately its programmed value during over-temperature to provide full vehicle braking under all thermal conditions.

High Speed Parameter

The programmable parameter "High Speedn sets the maximum PWM duty cycle in high speed mode. This parameter is only programmable from the Programmer and can be used to set the overall maximum output of the controller in high speed mode. The programmable range of High Speed is from 40% to 100% and is independent of Low Speed.

In the examples listed below, the term "maximum speed-efers to either High Speed or Low Speed when in the respective speed mode. "00% maximum speed"means High Speed is set to 100%, if operating in high speed mode, or low Speed is set to 100%, if operating in low speed mode.

Ramp Shape Parameter

"Ramp shape"is a new programmable parameter that determines the static throttle map of the controller. There are eleven different preprogrammed ramp shapes to choose from. They are labeled 20% to 70% in 5% steps. The ramp shape number refers to the PWM output at half throttle as a percentage of its range.

For example, if maximum speed is 100% and creep speed is 0%, a ramp shape of 50% will give 50% output at half throttle. This corresponds to a linear response. A graph of various ramp shapes with maximum speed of 100% and creep speed of 0%is shown in Figure 57.1.

Changing either maximum speed or creep speed changes the output range of the controller. Ramp shape output will always be a percent of that range.

Figure 57.1 Ramp Shapes with Maximum Speed

Service and Pads Manual Controller

TOYOTA

A graph showing ramp shapes with creep speed of 10%(range is 100% -1 0%=90%) is shown in Figure 57.2. A graph showing ramp shape with maximum speed of 60% and creep speed of 10% (range is 60% -1 0%=50%)is shown in Figure 57.3. When operating the controller with a reduced 'Maximum speed", the throttle is rescaled to provide the output range over the full active throttle travel.

Reduced maximum speed does not merely truncate the output.

Figure 57.2 Ramp Shapes with Creep Speed of 10%

Figure 57.3 Ramp Shape with Maximum Speed-60%

Service and Parts Manual Contoller Initial Check

TOYOTA

Before operating the vehicle, carefully complete the following check procedure. If you find a problem during these checks, refer to the diagnostics and troubleshooting section on page 103 for further information.

The initial check-out can be conducted with or without the hand held programmer.

The check-out procedure is easier with a programmer. Otherwise, observe the Status LED for codes.

ACAUT'oN

PUT THE VEHICLE UP ON BLOCKS TO GET THE DRIVE WHEEL OFF THE GROUND BEFORE BEGINNING THESE TESTS. TURN THE KEY SWITCH OFF AND MAKE SURE THAT THE BRAKE IS APPLIED (BRAKE SWITCH OPEN), THE THROTTLE IS IN NEUTRAL. DO NOT STAND, OR ALLOW ANYONE ELSE TO STAND, DIRECTLY IN FRONT OF OR BEHIND THE VEHICLE DURING THE TESTS.

1. Slide open the cover on the top of the controller. The cover is not removable; be careful not to force it. If a programmer is available, connect it to the programmer connector.

2. Turn the key switch on. The programmer should "power up" with an initial display, and the controller's Status LED should begin steadily blinking a single flash. If neither happens, check for continuity in the key switch circuit and controller ground.

3. If you are using a programmer, put it into the diagnostic mode by pressing the diagnostics key. The display should indicate "No Faults Found".

Release the brake (close the brake switch). The LED should continue blinking a single flash and the programmer should continue to indicate no faults. If there is a problem, the LED will flash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, look up the LED diagnostic code on page 103. (Diagnostics and Troubleshooting).

When the problem has been corrected, it may be necessary to cycle the brake in order to clear the fault code.

4. With the brake released, operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the forward/reverse switches, forward/reverse contactors, and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Page 103.

5. If you are using a programmer, put it into the test mode by pressing the test key.

Scroll down to observe the status of the forward, reverse, brake, emergency reverse, and throttle switch. Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer.

(Continued on next page)

Service and Parts Manual Contoller Initial Check (Cont'd.)

TOYOTA

6. Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good top speed.

7. Test the plug braking of the vehicle. Verify that the plug braking is as desired.

8. Verify that all options, such as high pedal disable (HPD), static return to off (SRO), and anti-tie down, are as desired.

9. Check to see whether the emergency reverse (belly button) feature is working correctly. Verify that the circuit is operational by momentarily disconnecting one of the emergency reverse wires. The vehicle should be disabled and a fault indicated.

10. When you have completed the check-out procedure, be sure to close the protective sliding cover.

Service and Parts Manual Contoller

TOYOTA

Programming and Adjustment

The high speed main current limit, high speed plug current limit and acceleration rate can be changed either electronically, using the hand held programmer, or manually, using the screwdriver-adiustable potentiometers.

Programming

To change a parameter using the programmer, press the PROGRAM key, and scroll down the Program Menu until the desired parameter is the top line of the display.

Press the appropriate CHANGE VALUE key ("+"or "-") until the desired number is reached. The parameter is now set at the desired value. All programming occurs in real time. In other words, the parameters can be changed while the vehicle is in operation.

The upper and lower limits of parameters are set at the factory. Some parameters have dependencies on other parameters. When the programmer is being used to adjust a parameter and a limit is reached, the display will stop changing. To see why the display has stopped changing, press the MORE INFO key. If the limit is related to another parameter, that information will be displayed; changing the value of the related parameter may allow the original parameter to be adiusted further.

Otherwise, the display simply says "Max Limit" or Win Limit."

If a programmer is connected when a parameter is adjusted manually, the effect of the manual change can be seen in the programmer display. To adjust one of these parameters with the programmer, its pot must be set to the "off' position on the adjustment panel. If you attempt to use the programmer to adjust a parameter whose pot is nnt set to the "off' position, its value will not change. You will also note that the LEDs in the corners of both the change value keys do not light up. This is another indication the parameter is in the manual mode. If you press the MORE INFO key, the programmer will display the following message: "Protected by controller, can't program"..

Service and Parts Manual Contoller

TOYOTA

Three parameters, high speed main current limit, high speed plug current limit and acceleration rate can be adjusted manually with a small insulated screwdriver. The potentiometers are accessed through holes on the adjustment panel, located under the sliding protective cover on top of the controller. (Creep and low speed limit adjustments are disabled.)

Manual Adjustments

Figure 58

Manual Adjustments

The pot's relative position indicates the approximate value over the allowable range.

For example: if the main current limit range is 20 to 250 amperes, position "0" corresponds to 20 amperes, and position "4" to 250 amperes. Setting the pot halfway (at position "2") corresponds to approximately 135 amperes.

The main and plug current limit pots affect only the high speed mode of operation.

The low speed settings of main and plug current limit can only be changed by the programmer. If the high speed input is not connected, or if anti-tiedown is activated, the current limit pots will have no effect on operation as the controller is operating in low speed mode.

Initial adjustments are made at the factory. However, should adjustment become necessary, or if a new control system has been installed, use the following procedure.

1. Use a small insulated screwdriver to adjust the potentiometer.

2. Set each potentiometer per the following procedures.

Current Limit Setting

ACAUTION

DO NOT JACK VEHICLE UP DURING CURRENT LIMIT ADJUSTMENT. RESTRAIN VEHICLE SECURELY TO PREVENT MOVEMENT. A HEAVY LOAD ON THE FORKS IS RECOMMENDED SO THE DRIVE WHEEL DOES NOT SPIN. To properly adjust the current limit, the battery must be a minimum of 24 volts or greater and have a specific gravity of at least 1.260. The drive motor must be relatively cool (at room temperature). (See potentiometer adjustment table on the next page.)

1. Conned an amp meter (300 amps full scale minimum) in series with the negative M line on the controller. A clamp-on ammeter is sufficient for this measurement.

2. Insure that the handle is in the upright position and the brake is on.

Service and Parts Manual Contoller Current Limit Setting (Cont'd.)

10

TOYOTA

3. Using extreme caution, bypass the brake interlock switch using jumper wire between terminals.

The brake interlock switch is located near the brake drum. (See Page 51.)

5. Move the Directional/Speed control to full speed (against stops), and observe the current reading on the meter.

Note:

It may be possible to field adjust the current limit pots below the programmed low speed current limit settings. Should this occur, less power would be delivered in high speed mode than in low speed mode.

6. Adjust Current Limit pot as necessary to match specifications. (Refer to the potentiometer adjustment table below.) Turning the pot clockwise will increase the current limit while turning the pot counterclockwise will decrease the current limit. (Current to be measured in the M- line with shunt or clamp on meter.)

DO NOT HOLD THE POWER O N LONGER THAN 15 SECONDS. FOR EVERY 15 ACAUTION SECONDS THAT THE MOTOR IS ON, ALLOW 30 SECONDS FOR THE MOTOR TO COOL BEFORE RETESTING.

Plug Current Adiustment

Adiust for desired amount of deceleration force.

Acceleration Adjustment

1. Adjust potentiometer as required to increase or decrease the rate at which the vehicle accelerates. (See table below)

2. Test and readjust as required.

For an increased acceleration rate, turn the potentiometer clockwise. For a decreased acceleration rate, turn the potentiometer counterclockwise.

Note:

Creep and Low Speed Limit adjustments are disabled.

Service and Parts Manual Contoller Maintenance

TOYOTA

There are no user-serviceable parts inside the controller. No attempt should be made to open the controller. Opening the controller may damage it and will void the warranty.

However, it is recommended that the controller exterior be cleaned periodically, and if a handheld programmer is available, this periodic cleaning provides a good opportunity to check the controller's diagnostic history file.

Safety

The controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated wrenches.

Cleaning

Although the controller requires virtually no maintenance, the following minor maintenance is recommended in certain applications.

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B- terminals.

3. Remove any dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

4. Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

Diagnostic History

The handheld programmer can be used to access the controller's diagnostic history file. Connect the programmer, press the MORE INFO key, and then while continuing to hold the MORE INFO key press the DIAGNOSTICS key. The programmer will read out all the faults that the controller has experienced since the last time the diagnostic history file was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator errors. Faults such as contactor faults may be the result of loose wires; contactor wiring should be carefully checked out. Faults such as HPD or overtemperature may be caused by operator habits or by overloading.

After a problem has been diagnosed and corrected, clearing the diagnostic history file is advisable. This allows the controller to accumulate a new file of faults. By checking the new diagnostic history file at a later date, you can readily determine whether the problem was indeed completely fixed.

To clear the diagnostic history file, go to the Special Program Menu (by pressing and holding the MORE INFO key, and then pressing the program key), scroll through the menu until "Clear Diagnostic History" is the top line in the display, and then press MORE INFO again. The programmer will prompt you to acknowledge or cancel. See page 106 of this manual for more detail on programmer operation.

Service and Parts Manual

TOYOTA

ContoHer Diagnostics and Troubleshooting

LED Diagnostics MAIN

CLUO

ACCEL.

CURRENT L I M I T

Figure 59

CREEP

LOW

SPEED L I M I T

LED Diagnostics

During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second. If the controller detects a fault, a 2-digit code (see Table 1) is flashed continuously until the fault is corrected. For example, code "3,2"welded direction *contactor appears as:

Note:

Only one fault is indicated at a time, and faults are not queued up. Operational fault such as a fault in SRO sequencing are cleared by cycling the brake or keyswitch.

Service and Parts Manual Contoiler Programmer Diagnostics

TOYOTA

With a programmer, diagnostics and troubleshooting are more direct than with the LED alone. The programmer presents complete diagnostic information in plain language codes to decipher. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu.

The following 4-step process is generally used for diagnosing and troubleshooting an inoperative vehicle:

(1) visually inspect the vehicle for obvious problems; (2) diagnose the problem, using the programmer; (3) test the circuitry with the programmer; and (4) correct the problem. Repeat the last three steps as necessary until the vehicle is operational.

Example:

A vehicle that does not operate in "forward" is being repaired.

Step 1: Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose connections.

Step 2: Connect the programmer, put it in diagnostic mode, and read the displayed fault information. In this example, the display shows "No Faults Present," indicating that the controller has not detected anything out of the norm.

Step 3: Put the programmer in test mode, and observe the status of the inputs and outputs in the forward direction. In this example, the display shows that the forward switch did not close when "forward" was selected, which means the problem is either in the forward switch or the switch wiring.

Step 4: Check or replace the forward switch and wiring and repeat the test. If the programmer shows the forward switch closing and the vehicle now drives normally, the problem has been corrected.

Refer to the troubleshooting chart (Table 2), next page, for suggestions covering a wide range of possible faults.

Service and Parts Manual

Contolier TABLE 2

PROGRAMMER EXPLANATION LED CODE LCD DISPLAY hardware fail-safe error 1,2 HW FAIL-SAFE

1,3

M-FAULT

TOYOTA

Troubleshooting Chart

POSSIBLE CAUSE

M- output shorted

1. Controller defective.

2. Invalid throttle type selected.

1. M- output shorted to ground.

SRO fault

3. Direction contador not closing fod enough.

4. Internal motor short to ground.

1. Improper sequence of KSI, brake, and direction inputs.

0-5kQ or wiper fault

2. Wrong SRO type selected.

3. Brake or direction switch circuit open.

4. Sequencing Delay too short.

1. Throttle input wire open.

2. Direction contador not closing.

1,4

SRO

2,l

THROTTLE FAULT 1

-

2. Throttle input wire shorted to ground or B+.

3. Throttle pot defective.

4. Wrong throttle type selected.

2,2

BB WIRING CHECK

emerg. rev, wiring fault

1. BB wire open.

2. BB check wire open.

2,3

HPD

HPD sequencing fault

1. Improper seq.. of KSI, brake, throttle inputs.

Pot Low broken or shorted

3. Misadiusted throttle pot.

1. Pot Low wire open.

3. Wrong throttle type selected.

1. Direction contador coil shorted.

2,4

2. Wrong HPD type selected.

THROTTLE FAULT 2

2. Pot Low wire shorted.

3,1

CONT DRVR OC

driver output overcurrent

3,2

DIR CONT WELDED

welded direction contador

3,4

MISSING CONTACTOR

missing contador or shunt

1. Direction contador did not close.

2. Direction contador stuck closed.

1. Direction contador coil open.

low battery voltage

3. Shunt field open.

4. Wire to shunt or direction contactor open.

1. Battery voltage <16 volts.

4,1

2. Shunt field shorted.

LOW BATTERY VOLTAGE

2. Direction contador missing.

2. Corroded battery terminal

4,2

OVERVOLTAGE

overvoltage

4,3

THERMAL CUTBACK

over-/under-temp. cutback

3. Loose battery or controller terminal.

1. Battery voltage >45 volts.

2. Vehicle operating with charger attached.

1. Temperature > 8 5 ' ~or <-25'~.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

-

Service and Parts Manual

TOYOTA

Contoller Programmer Operation

The optional handheld programmer allows you to program, test and diagnose the motor controller. The programmer is powered by the host controller, via an RJ11 modular connector located in the adjustment panel on top of the controller.

When the programmer is first plugged into the controller, the brake switch must be open (brake applied) until the programmer has acquired all the controller parameters. When this step has been completed, the programmer displays the controller's model number, date of manufacture and software revision code.

Following this initial display, the programmer displays a prompt for further instructions.

The LED in the corner of the key lights up to identify the mode of operation

-

-

A 4-line LCD display is presented in this window

Choose the Program, Test, or Diagnostics Mode with one of these three keys

Scroll the 4-line display (up and down) with these two keys Change value (+ or -) of the selected items with these two keys

-

Figure 60

Get more information about selected items with this key. Also, use this key in combination with other keys to put the programmer in special modes.

Programmer

The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the PROGRAM or the DIAGNOSTICS key, the MORE INFO key selects the Special Program mode or the Special Diagnostics mode.

Service and Parts Manual

TOYOTA

Contoller Programmer Operation (Cont'd.)

The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode.

When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of programmer operation. For example, if the TEST key is pressed, the LED at the corner of the key indicates that the programmer is now in the Test mode, and the Test Menu is displayed.

Four lines of a menu are displayed at a time. The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window. The selected item is always the top line. (In the Program mode, the selected item is highlighted by a flashing arrow.) To modify a parameter or obtain more information about it, it must be scrolled to the top position in the display window.

To scroll up and down within a menu, use the two SCROLL DISPLAY arrow keys.

The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down.

When a key is held down, the scrolling speed increases the longer the key is held.

SCROLL DISPLAY

A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This sample display is from the Program Menu:

Scroll bar

PLUG C/L US PLUG C/L MR REV C/L US EMR REV C/L

100 80 140 80

Selected item

Service and Parts Manual Contoller

TOYOTA

The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item. Like the SCROLL DISPLAY arrow keys, the change value arrow keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows rapid changing of any parameter.

CHANGE VALUE

An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible. When the value of a parameter is being increased, CHANGE VALUE key is on until you reach the maximum value the LED on the for that parameter. When the LED goes off, you cannot increase the value.

"+"

The MORE INFO key has three functions: (1) to display more information about the selected item, (2) to access the Special Program and Special Diagnostics modes (when used together with the program and diagnostics keys), and (3) to initiate certain commands (such as the Self Test).

"More information" is available in all of the programmer operating modes. After using the MORE INFO key to display additional information about the selected item, press the MORE INFO key again to return to the original list.

Operating Modes:

Program, test, diagnostics, special program, special diagnostics

In the program mode, accessed by pressing the PROGRAM key, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item at the top of the display, with the flashing arrow can be changed, using the CHANGE VALUE keys (+ and -).

PROGRAM

The LEDs on these keys indicate whether there is still room for change. That is, when key no longer the upper limit of a parameter's range is reached, the LED on the lights up, indicating that the present value cannot be increased; when the lower limit is reached, the LED on the "-" key no longer lights up.

"+"

The MORE INFO key, when used in the Program mode, displays a bar graph along with the minimum and maximum values possible for the selected parameter.

Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the additional information is being displayed (see example below).

Sdded pcrcmeta

MAIN LIMIT

U nits

Bcr gcph Winimum vdue.

AMPS

I MIN 20

100 MAX 250

-

Set value

-

Maximum value

Service and Parts Manual Contoller Operating Modes (Cont'd.)

TOYOTA

Some parameters on some controllers have dependencies on other parameters. This means that the available settings for one parameter may be dependent on the limits of another parameter. For example, your controller may not allow the main current limit to be set below some other current limit, such as the emergency reverse current limit. In this example, if you attempt to reduce the main current limit below that of emergency reverse, a message will be displayed indicating that the minimum main current limit is dependent on the emergency reverse current limit.

The Program Menu is presented at the end of this section.

m TEST

In the Test mode, accessed by pressing the TEST key, real-time information is displayed about the status of the inputs, outputs, and controller temperature. For example, when the status of the forward switch is displayed, it should read "On/Off/On/Off/On/Off" as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list; it only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, and also for troubleshooting should problems occur.

The MORE INFO key, when used in the Test mode, causes additional information to be displayed about the selected item (top line in the window).

The Test Menu is presented at the end of this section.

In the Diagnostics mode, accessed by pressing the DIAGNOSTICS key, currently active faults detected by the controller are displayed.

lu)

The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item.

DIAGNOSTICS

A list of the abbreviations used in the Diagnostics display is included at the end of this section.

MORE INF O

TE S T

The Special program mode allows you to perform a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the programmer memory, load the controller settings from the programmer into a controller, clear the controller's diagnostic history, adjust the contrast of the programmer's LCD display, select the language to be displayed by the programmer, and display basic information (model number, etc.) about the controller and the programmer.

To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the programmer is in Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display.

Service and Parts Manual Contoller

TOYOTA

The MORE INFO key is used initially to access the Special Program mode, and once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select "Contrast Adjustment" by scrolling until this item is at the top of the screen, and then press MORE INFO to find out how to make the adiustment.

Programming (Cont'd.)

Note:

The Special Program Menu is presented at the end of this section.

In the "Special Diagnostics" mode, the controller's diagnostic history file is displayed.

This field includes a list of all faults observed and recorded by the controller since the history was last cleared. Each fault is listed in the diagnostic history file only once, regardless of the number of times it occurred.

MORE INFO

TEST

Note:

The maximum and minimum temperatures recorded by the controller are included in the Test Menu.

To access Special Diagnostics, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key will light, just as when the programmer is in Diagnostics mode. The brake must be applied (brake switch open) in order to access the diagnostic history file.

DIAGNOSTICS

The MORE INFO key, when used within the Special Diagnostics mode, causes additional information to be displayed about the selected item.

To clear the diagnostic history file, put the programmer into the Special Program mode, select "Clear Diagnostic History," and press the MORE INFO key for instructions. Clearing the diagnostic history file also resets the maximum/minimum temperatures in the Test Menu.

Service and Parts Manual Contoller

TOYOTA

Peace-of-mind Programming

Each time the programmer is connected to the controller, it acquires all the controller's parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select "Revert to Previous Settings"by scrolling it to the top of the display window, press the MORE INFO key, and follow the instructions displayed. Any inadvertent changing of parameters can be "undone" using this procedure even if you can't remember what the previous settings were as long as the programmer has not been unplugged and power has not been removed from the controller.

Programmer Self Test

You can test the programmer by displaying two special test screens. Press the MORE INFO key while the programmer is powering up. During the Self Test, you can toggle between the two test screens by pressing the SCROLL DISPLAY keys. The first screen turns on every LCD element, and the second screen displays all the characters used in the various menus. As part of the Self Test, you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the Self Test, unplug the programmer or turn off the controller, and then re-power it without holding the MORE INFO key.

L l l l l l l i l l l l i l l

111111mmm11111 111111m1111111 111m1111111m11

1111IlI111111I 1II11l11111111

-

A SCROLL DISPLAY

Service and Parts Manual

TOYOTA

Contoller Programmer Menus

The Program, Test, and Special Program Menus are presented here. The abbreviations used in the Diagnostics and Special Diagnostics displays are also listed.

I~roamrnMenu pirplciY

1Parameter

MAIN C/L

Main Current Limit

VS MAIN C/L

Low Speed Main Current Limit

PLUG C A

Plug Current Limit

VS PLUG C/L

Low Speed Plug Current Limit

I

-IEMR REV C/L 1Emergency Reverse Current Limit I - VS EMR REV C/L ILow Speed Emergency Reverse C A I

Factow Settina

60 350

I

I

RAMP C/L

I ram^ Start Current Limit

VS RAMP C/L

Low Speed Ramp Current Limit

ACCEL. RATE

Acceleration Rate in Seconds

1.o

THROllLE TYPE

Throttle Type (See Manual)

3

CREEP SPEED

Creep Speed in Percent of Full Throttle

10

ILOW SPEED

ILow Speed in Percent of Full Throttle I

VARIABLE PLUG

]Throttle Variable or Fixed Plug

HIGH PEDAL DIS

I High Pedal Disable Wes or No)

- SRO - ANTI-TIEDOWN QUICK START

Static Return to Off Type (See Manual)

60

I no

n

ON ON

1

Anti-Tie down On or Off

OFF

Quick Start Throttle Factor

3.0

* N O T ADJUSTABLE

- N O T SEEN

I

250 250 60

250 7nn 200

-IEMR REV SPEED IEmergency Reverse Speed in Percent I - ISEQUENCING DLY 1 Sequencina Delay in Seconds I

1

1 1 1

I

Service and Parts Manual Contoller

TOYOTA

Menu (Cont'd.)

Diagnostics and Special Diagnostics "Menu"

This is not a menu as such, but simply a list of the possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes.

With handle down and throttle indexed both ways.

Service and Parts Manual -

TOYOTA

Hydraulic Schematic

Lift Cylinder

/

Reservoir

Figure 1

Hydraulic Schematic

Service and Parts Manual 8

,

Electrical Schematic

TOYOTA

Service and Parts Manual Appendix Motor Controller Specifications

TOYOTA

Service and Parts Manual Glossary

Iann Acceleration/deceleration rate

TOYOTA

..

Descntlon The acceleration rate (the time required for the controller to increase from 0%to 100% duty factor) is adjustable manually (via the appropriate trimpot on top of the controller) or electronically (via the handheld programmer). The deceleration rate is fixed, and cannot be adjusted. The shape of the acceleration/deceleration curves is controlled by the dynamic throttle response, which is linear. (see Ramp start) Before enabling high speed operation, the anti-tiedown function checks that the high speed switch (HSS) has been released after the last cycling of the brake switch. This feature discourages operators from taping or otherwise "tying down"the high speed switch. If high speed mode is already selected before the brake is released, the controller remains in low speed mode until the HSS is released and pressed again.

Arcless contador switching

The controller output duty factor is quickly reduced to zero any time a direction is de-selected, so that the controller current will be reduced to zero the direction contactor drops out.

befors

Brake

The brake must be released (brake input "high") for the controller to operate. This is a safety interlock used on most material handling vehicles.

Contador drivers and circuits

The controller can accommodate up to four external contactors: forward, reverse, main, and shunt. Some vehicles may have no main contactor, or the main contactor may be wired directly to the KSI or brake signal, bypassing the controller.

Creep speed at first throttle

Creep speed is activated when a direction is first selected. The output maintains creep speed until the fhrottle is rotated out of the throttle deadband (typically 10% of throttle). Creep speed is adjustable from 0 to 25% of the controller duty factor; the adjustment can be made manually (via the appropriate trimpot on top of the controller) or electronically (via the handheld programmer).

Current limiting

Current limiting reduces the PWM output to the power section until the motor current falls below the set limit level. Reduction of output is done smoothly. The current limit depends on the operating mode; for example, the limit is typically higher in high speed than in slow speed. The high speed main and plug braking current limits are adjustable manually (via the appropriate trimpots on top of the controller). Additional current limits are Settable electronically (via the handheld programmer).

Disable recovery

(see Fault recovery)

Emergency reverse

Emergency reverse is activated when the brake is released, KSI is activated, and the emergency reverse switch (the BB, or "belly button' switch) is pressed. After the BB switch is released, normal controller operation is not resumed until neutral (no direction) is selected or until the brake is cycled (brake, then brake release). However, repeatedly pressing the BB switch will reactivate the emergency reverse function each time.

Service and Parts Manual Glossary

lkm Fault detection

..

TOYOTA

Pescn~tton An internal micro controller automatically maintains surveillance over the functioning of the controller. When a fault is detected, the appropriate fault code is signaled via the LED, externally visible on top of the controller. The diagnostic codes flashed by the LED are listed on page 103. contador coil open / shorted driver (F/R and shunt contadors) contador driver overcurrent / contador coil short contador welded emergency reverse circuit check overvoltage cutoff power supply out of range (internal) M- fault memory checks upon start-up throttle fault undervoltage cutback watchdog (external) watchdog (internal)

Fault recording

Fault events are recorded in the controller's memory. Multiple occurrences of the same fault are recorded as one occurrence. The fault event list can be loaded into the programmer for read-out. The Special Diagnostics mode provides access to the controller's diagnostic history the entire fault event list created since the diagnostic history was last cleared. The Diagnostics mode, on the other hand, provides information about only the currently active faults.

Fault recovery (including recovery from disable)

Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation.

The only exceptions are these: fault recovery anti-tiedown release and reapply HSS contador overcurrent when condition clears BB re-applied or brake cycled emergency reverse lower throttle to below HPD threshold HPD when battery voltage drops below overvoltage overvoltage when proper sequence is followed SRO thermal cutback when temperature changes throttle fault clears when condition gone undervoltage when battery voltage rises above undervoltage

High-pedal-disable (HPD)

The HPD feature prevents the vehicle from being started while the throttle is applied. The controller can be programmed to have HPD based on either brake input or KSI.

Brake-type HPD

To start the vehicle, the controller must receive a brake input (brake released) before receiving a throttle input. Controller operation will be disabled immediately if pedal demand (throttle input) is greater than 25% duty fador at the time the brake is released (brake input "high"). Normal controller operation is regained by reducing the throttle demand to less than 25%.

An alternative version, which can be set with the handheld programmer, provides a variable delay before setting the disable. If the brake is applied while the throttle is applied above the HPD threshold (25%), HPD is not activated if the brake is then released before the delay time elapses.

Service and Parts Manual Glossary

Zarm KSI-type HPD

..

TOYOTA

Pescnptm The HPD feature can be activated by KSI input instead of brake input, if preferred. To start the vehicle, the controller must receive a KSiiqut before receiving a throttle input.

High speed

High speed operation is selected by means of the high speed switch (HSS).

HSS allows the controller output to reach 100% output. If HSS is Mf selected, the maximum output is the low speed setting (which can also be set to 100%). If the anti-tiedown feature is active, HSS must be re-selected after braking.

KSI

KSI (Key Switch Input) provides power to the logic board, and initializes and starts diagnostics. In combination with the brake input, KSI enables all logic functions.

Some vehicles may have no key switch (KSI simply tied to B+) or may have the key permanently turned on.

LED

An LED (located on top of the controller, under the slidipg protective cover) flashes a code if a fault is detected by the controller. The fault codes are listed in Table 1. The fault code will continue to flash until the fault condition has been cleared during active fault detection. This will typically happen after cycling KSI for power-up fault conditions, and cycling the brake for faults detected during operation.

Low speed

Low speed operation allows less than the full speed range available. The user can adjust the maximum duty factor in low speed manually (via the appropriate trimpot on top of the controller) or electronically (via the handheld programmer). The throttle input to the controller is rescaled to use the whole range of throttle movement in order to obtain 0% to full low speed output (or creep speed to full low speed output), regardless of its setting.

If high speed is not selected, the controller operates by default in low speed; when the controller returns to low speed it automatically changes the main current limit, the emergency reverse current limit, the plug current limit, and the ramp start current limit to their low speed values.

These low speed values can only be set by the programmer. The manually adjusted pots have no effect on low speed current limits.

Overtemperature

At overtemperature (from 8S°C to 95OC), the current limit is linearly decreased from full set current down to zero. The operating PWM frequency is shifted to 1.5 kHz when the controller is operating in the overtemperature range.

Overvoltage cutoff

Overvoltage resets the microprocessor, kills the PWM, and opens the contactors, thereby shutting down the controller.

Overvoltage can result during battery charging or from an improperly wired controller. Controller operation resumes when the voltage is brought within the acceptable range. The cutoff voltage and re-enable voltage are percentages of the battery voltage, and are set at the factory.

Service and Parts Manual Glossary

..

TOYOTA

Innn

Pe=ll!bn

Plug braking

Plug braking takes place when a series motor is driven electrically in a direction opposite from the direction it is turning. The controller controls the current to obtain smooth and controlled plug braking torque. During plug braking, the maximum current limit is automatically changed to the plug current limit, and the PWM frequency is changed to 1.5 kHz. NOTE: Plug current limit on the controller controls the current. The armature current in plug mode will be higher than the current.

There are two types of plug braking control: fixed and variable. The fixed plug current limit is set to a fixed level. The variable plug current limit varies the current limit to correspond to the throttle position.

The high speed plug current limit is adjustable manually (via the appropriate trimpot located on top of the controller) or electronically (via the handheld programmer).

Upon receiving a quick throttle demand from neutral, the controller will attempt to exceed normal acceleration momentarily in order to overcome inertia. The "quick-start"a1gorithm is applied each time the vehicle passes through neutral and is not in plug mode. If the vehicle is in plug, the quick-start function is disabled, allowing normal plug braking to occur.

Ramp start (anti-rollback)

The ramp start feature allows the vehicle to be started with a higher plug current limit to prevent rolling downhill. Ramp start increases the plug current limit for the s & & j dlrect~ono h . When the opposite direction is selected, ramp start will be canceled and a 3-step sequence must be followed to re-activate it: 1. select a diredion for more than 1 second, 2. return to neutral, and 3. re-select the same direction.

Once the vehicle is operating in ramp start mode, it will continue to do so until the opposite diredion is selected for more than one second.

When the brake is first released, the ramp start current limit level will be obtained when either direction is selected in plug braking mode. In ramp start mode, either direction selected will allow the ramp start current limit level. This condition remains until the other direction is selected for more than one second. The new direction then becomes the decision diredion, and the 3-step ramp start sequence is required to regain the ramp start current limit level in plug.

The ramp start current limit is adjustable electronically via the handheld programmer.

. .

Reset

Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation; see "fault recovev for exceptions.

Shunt field control

The shunt of a compound motor can be directly controlled by using the shunt winding driver (if the current requirement meets the contactor driver specifications). The shunt is adivated while a direction is selected, as long as the controller is not in plua brakina mode. A programmable delay is available for the shunt drive. This delays the shunt turn-on until some time after the reversing contactors have shuttled.

Service and Parts Manual Glossary

Ienn Static-return-to-off (SRO)

TOYOTA

..

Descwhm The SRO feature prevents the vehicle from being started when 'in gear.'

SRO checks the sequencing of brake input of KSI nad brake input relative to a direction input. The brake input must come on before a direction is selected. If a direction is selected before or simultaneously (within 5 0 msec) with the brake input, the controller is disabled. There are two types of SRO: SRO relative to brake input alone (Type '1' in the programming menu), and SRO relative to both KSI & brake input (Type "2"). The handheld programmer can be used to set the controller to operate with either of these types of SRO, or with no SRO. If your controller is wired so that both KSI and brake input are required (SRO Type T'), the following sequence must be followed to enable the controller: step 1, KSI on; step 2, brake released (brake input "high"); and step 3, direction selected. The interval between steps 1 and 2 is the same as between steps 2 and 3; that is, KSI input must precede brake input by at lead 50 msec. Once the controller is operational, turning off either KSI or the brake causes the controller to turn off; re-enabling the controller requires the 3-step sequence.

Temperature compensation for current limits

Full temperature compensation provides constant current limits throughout the normal operating range (heatsink temperatures of -25C to +85C). The temperature sensor is also used to calculate and display the heatsink temperature on the handheld programmer.

Temperature extreme current-limit cutback

(See Overtemperature, Underternperahre)

Temperature extreme data storage

The maximum and minimum temperatures read at the heatsink at any time during powering of the controller are stored in the controller's memory.

These values (which can be accessed via the programmer's Test Menu) are cleared each time the controller's diagnostic history is cleared.

Throttle map

is shaped to The throttle map (duty factor as a function of throttle ~ositiorl) provide the proper feel for the many types of vehicles that use the controller. The throttle map enables the controller to provide smooth (rather than "iumpy")low speed control.

Throttle response

is shaped The dynamic throttle response (duty factor as a function of b) by the acceleration rate setting. Dynamic throttle response is linear. The newest throttle input is mapped to the throttle map, and the controller then automatically accelerates (or decelerates) through a straight line until the new throttle demand is obtained.

Throttle types

The controller accepts a variety of throttle inputs, through various combinations of its four throttle input pins. The most commonly used throttles (including 5Kn-0 and 0-51Cn pots, 3-wire pots, 4-terminal wig/wags, 0-5V, and the Curtis ET-101 electronic throttle) can be hooked up without additional programming. Additional throttle types can also be accommodated; please contact the service center nearest you.

Throttle full range produces 0-1 00% duty factor at the controller output (unless limited by other conditions). Throttle fault detect is performed on the throttle input signals and virtually eliminates the possibility of runaway operation. Adjustments and settings are independent of throttle type.

However, throttle fault conditions will vary by throttle type.

Service and Parts Manual Glossary

Isum Undertemperature

Undervoltage cutback

TOYOTA

..

Descrlpfrnn When the controller is operating at less than -2S°C, the current limit is cut back to approximately one-half of the set current. The operating PWM frequency is shifted to 1.5 kHz when the controller is operating at undertemperature.

Undervoltage protection automatically disables the controller output if battery voltage is detected below the undervoltage point at start-up, or when the battery voltage is pulled below the undervoltage point by an external load. The undervoltage cutback point is set in ROM, and is not adjustable. During normal operation, the controller duty factor will be reduced when the batteries discharge down to less than the undervoltage level. If the motor current is such that the batteries are being pulled below the minimum point, the duty factor will be reduced until the battery voltage recovers to the minimum level. In this way the controller regulates the duty factor around the point which maintains the minimum allowed battery voltage.

Even if the voltage continues to drop below the undervoltage level to a severe undervoltage condition (due to battery drain or external load), the controller continues to behave in a predictable fashion, with its output disabled.

Watchdog (external, internal) The external watchdog timer guards against a complete failure of the microprocessor, which would incapacitate the i d watchdog timer. This independent system check on the microprocessor meets the EEC's requirement for backup fault detection.

The external watchdog timer safety circuit shuts down the controller (and the microprocessor) if the software fails to generate a periodic external pulse train. This pulse train can only be created if the microprocessor is operating. If not periodically reset, the watchdog timer times out after 150 msec and turns off the controller. The external watchdog also directly disengages all contactors and directly shuts down the PWM drive to the MOSFETs. It can only be reset by cycling KSI. The internal watchdog timer must be reset periodically by correct sequential execution of the software. If not reset, the internal timer times out and the microprocessor is 'warm booted."This causes the microprocessor to shut down its outputs (thus shutting down the controller) and attempt to restart.

PWM

Pulse width modulation (PWM), also called "chopping," is the technique that permits silent, stepless operation.

Service and Parts Manual Alphabetical Index

Advanced Transistor Control Controller Keyswitch Input - 69 Controller Thumbwheel Throttle Inputs - 6 9 Current Limiting - 68 Emergency Reverse Plug Breaking Inhibit - 69 Low Voltage Cutback - 68 Plugging - 69 Runaway Protection - 69 Static Return to Neutral Protection - 6 9 Thermal Protection - 68 Axle Seal lnstallation - 40 Removal 4 0

-

TOYOTA

Carrier Frame Linkage and Bushings - 35 Cold Storage Requirements Control Head Unit - 31 Component Identification - 3 Contactor - 75 Tip/Bar Replacement - 75 Control Handle Removal 32 Control Head Unit - 31 Cold Storage Requirements - 3 1 Removal and lnstallation - 31 Travel Control Switches 33 Controller Assembly - 47 Conversion Table 7

-

-

-

Battery Battery Charging - 1 8 Battery Charts - 9 0 Battery Cleaning - 17 Battery History Record Keeping - 20 Battery Leakage to Frame Test - 1 8 Battery Replacement - 48 Battery Voltage Check - 19 Wring Hookup - 49 Battery Charger - 86 Acceptable values - 86 Capacitor - 88 Diodes - 88 Electrical Testing - 86 Open Circuit Voltage Test - 87 Overcharging Problems - 89 Short Circuit Amperage Test - 87 Timer - 89 Battery Pak Lifter - 3 0 Bearing lnstallation Tool - 30 Brake - 50,. 51., 52 Adjustment - 50 Interlock Switch - 51 Linkage lnstallation - 51 Linkage Removal - 51 Brake Shoe Removal and lnstallation - 52

Daily Inspection - 1 1 Decal Placement - 8 Decimal Equivalent Chart - 10 Drive Motor - 44, 45 Brush Removal - 44 Disassembly - 44 lnstallation - 45 Removal - 44 Drive Unit - 42 Assembly - 43 Disassembly - 42 Removal - 38 Drive Unit Assembly - 41 Drive Wheel - 36 lnstallation - 37 Removal - 36

Electrical System Adjustments - 70 Acceleration Adjustment - 101 Current Limit Setting - 100 Plug Current Adjustment 101 Potentiometer Adjustments 70

-

-

Service and Parts Manual Alphabetical Index

-

Fill Points 14 Flush Grease Fitting Adapter - 30

Glossary

- 11 7

TOYOTA

Maintenance 100 Hours 12 500 Hours 12 1 000 Hours 12 Fill Points - 14 General Practices 1 Lubrication Points 13 Schedule 16 Motor Controller Adjustment Panel - 70, 94 Adjustments, Manual 100 Cleaning - 102 Cloning 109 Control Wiring 95 Diagnostic History - 1 02 Diagnostics and Troubleshooting Initial Check - 97 LED Code Chart 103 LED Diagnostics 103 Low Current 93 Maintenance 102 Overview - 91,92 Potentiometers 94 Power Wiring - 95 Programmer Connector - 94 Programming - 99 Safety 102 Specifications 116 Status LED - 94 Throttle - 96 Troubleshooting Chart - 105 Motors Brush Care 22 Brush Replacement 24 Cleaning 21 Grounds Test - 28 Maintenance Schedule - 22 Open Circuit Test 26 Overheating - 25 Short Circuit Test - 27

-

-

-

-

Hydraulic Changing Reservoir Fluid - 29 Check Valve 60 Hydraulic Cylinder - 60 Oil Selection - 29 Pump 59 Pump and Motor - 57 Pump Installation - 60 Pump Removal - 59 Pump Removal/lnstallation - 57 Relief Valve - 69 Reservoir lnstallation - 60 Reservoir Removal - 59 Solenoid Operated Release Valve - 59 Hydraulic Cylinder Disassembly - 6 1 Inspection 61 Installation 63 Removal - 60 Hydraulic Pump Repair - 58 Servicing Equipment - 56

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Lifi Lower - 53 Lifi/Lower Electrical - 54 Hydraulic - 53 Theory of Operation - 53 Load Wheel Repair and Replacement 34 Lower Hydraulic and Electrical - 55 Lubrication Points - 14

-

-

- 1 03

Service and Parts Manual Alphabetical Index

Planned Maintenance (PM) - 1 1 Programmer Diagnostics - 1 03, 1 04 Diagnostics Menu 1 1 3 Menus 1 12 Operating Modes - 108 Operation - 106 Self Test - 1 1 1 Pull Rod Bushings Removal and Replacement - 35 Pump Motor 57 Brush Removal - 57

-

-

-

Reservoir - 59

Specifications - 2 Switches Horn - 33 Lift/Lower - 33 Travel Control - 33

TOYOTA

Throttle Potentiometer Setting - 47 Torque Data 6 Travel Control Switches - 33 Troubleshooting 64 Forks Will Not Hold Load 66 Miscellaneous - 85 No Emergency Reverse - 81 No Lift 64 No Lower 66 No Travel, Other Systems OK - 76 Travel Problems - 77 Vehicle Is Dead, Nothing Operates Wiring Inspection Procedure - 84

-

-

-

-

-

- 76