Section 4. Planned Maintenance
Toyota Orderpicker Model 7BPUE15 Service Manual
Interval 2
Interval 2 Moderate Usage: E v e r y 6 M o n t h s o r 500 Hours; S e v e r e Usage: E v e r y 3 M o n t h s o r 250 H o u r s Refer to
What to d o Check the weight stamped on the battery in the truck against the minimum and maximum allowable weights on the specification plate for the truck. Report any trucks that are running with batteries under the minimum or over the maximum allowable weight.
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Inspect the battery connector and all leads for damage and cuts in protective coatings. Shorts to the truck frame will cause electronic component failure or intermittent electrical failures. Check the brake for proper stopping distance. The truck should stop within 8 to 10 feet if brake is applied while the truck is loaded, traveling tractor-first a t full speed. Visually inspect the friction plate (rotor disk) with the brake released. Minimum thickness of the pad and steel backing plate is 1 /4 in. (6 mm).
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Inspect the contactor tips for burnt or pitted surfaces. Failure to replace the tips may cause surfaces to weld together, causing unscheduled downtime.
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Check the plunger for smooth operation with no binding. If binding occurs, the truck may exhibit intermittent fault codes.
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Operate the lift/lower function. Verify the response is smooth and both speeds work. Operate the travel function. Verify the full range of acceleration is smooth and responsive. Make sure the plugging is functioning properly. Look for any play in the center position of the lift or travel. If there is free play, replace the return springs. Check for proper fluid level in the drive unit. If the fluid level is low, investigate for leaks and determine the cause.
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Inspect all power cables for nicks or cuts. Give special attention to those cables that are not stationary, for example, cables to the drive motor. Inspect the over-the-mast cable for chafing or wear. Replace any cable that is damaged or shows signs of excessive heat. Failure to do so will cause intermittent system shutdowns and/or electronic failures.
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00700-CL222-05, 1 5 March 2005
