Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual

Electric Motor Tests

3. YOU should observe the following measurements:

Motor

Probe Points

Short-circuited Armature or

Field Winding

1 Resistance 11 A short rirclriterl winding is one in which the

Drive Motor S1 to S2 0.9 to 1.5 1 (shunt) 1 ohms

S1 to S2 < 1 ohm

A1 to A2 < 1 ohm

A1 to S1; A1 to > 100,000 1 ohms

A2 toSl;A2 to > 100,000

A1 orA2 to > 100,000 Frame

Lift Motor < 1 ohm

A to Frame > 100,000 insulation on the field o; armature has broken down at two or more points. The breakdown creates a low resistance 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. The severity of the short circuit depends on its location.

A shorted motor may be indicated by:

Slow or sluggish operation

Running faster than normal (suggests a short in the field)

Steer Motor

A1 or A2 to > 100,000 Frame

4. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor.

5. If you find an open circuit in a series - wound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

Grounded Motor Test

Overheating

Blowing a power fuse

Burning of brush wires

Severe burning or discoloration on armature coil

Severe burning or discoloration on one or two commutator segments every 90" of rotation.

These symptoms can be caused by problems other than the motor itself:

Brake too tight or dragging

Wheel bearings too tight

Faulty transmission

Binding in a related pump, hose, or between the current - carrying conductors and solenoid valve the motor housing. This can be caused either by Load wheels not aligned properly direct contact or through conductive foreign

In a grounded motor, an electrical circuit exists

Rail guided with drive tire not aligned material. properly

The ground may be caused by:

Testing a motor for short - circuited windings

Insulation breakdown requires special equipment at a motor

Brush leads touching the motor housing

Buildup of carbon dust or other materials

To test for a grounded motor, see " Shorts to Frame Test" on page 5 - 4.

Battery Discharge Indicator (BDI)

Theory

Battery Discharge Indicator (BDI)is a feature that monitors and remembers the charge level of the battery connected to the lift truck and helps to prevent excessive discharging of that battery. Operating a lift truck using a discharged battery can damage both the battery and the electrical components of the lift truck.

At power-up, BDI tests the battery to determine if it is the same battery that was installed at power-down. If it is the same battery, it continues to monitor the battery for discharge and updates the Operator Display as required.

If a different battery is detected, BDI tests to determine the state-of-charge of the replacement battery. The replacement battery must meet both of the following criteria before the display will be reset and lift restored.

1. The replacement battery must have a charge level at least 50% different from the previously installed battery,

2. The charge value of the replacement battery must be greater than or equal to the configured BDI setting.

The criteria are determined in this way: a. Example 1: A battery in the lift truck is at 10% charge; the replacement battery is at 95%. With more than a 50% difference in the charge levels, BDI

1. BDI compares the charge of the battery that was connected to the lift truck with the new battery's charge. A charge difference of at least 50% between the two batteries resets BDI to show the state-of-charge of the replacement battery, that is, the measured state-of-charge of the replacement battery minus the remembered state-of-charge of the old battery must equal or exceed 50%. This reset can be higher or lower than the old battery.

Battery Discharge lndicator (BDI)

resets the Operator Display to show the replacement battery's charge.

b. Example 2: A battery in the lift truck is at 20% charge and lift cutout has not occurred. The replacement battery has a state-of-charge equal to 50%. Because the difference is only 30%, the display will remain at 20% until the replacement battery has discharged to 20%. Then the display will begin counting down.

c. Example 3: A battery in the lift truck is at 20% charge and lift cutout has occurred. The replacement battery has a state-of-charge equal to 50%. Because the difference is only 30%, the display will remain at 20% and lift cutout will remain in effect until a battery with a charge of at least 70% and a state-of-charge exceeding the configured BDI setting is installed in the lift truck.

2. BDI looks at the configured reset point. BDI reset is programmable from 55% to 100% of total battery charge and can be changed by entering the Configure Mode using the Superword. The new battery must be equal to or greater than the configured percent of charge before the BDI will change. Example - BDI configured at 95%. Plugging in a battery at anything below 95% charge will not change the Operator Display. Older batteries or applications providing inadequate charging time could require a lower configured value for BDI since older batteries might be unable to reach a higher percent charge. Therefore, some batteries could require BDI configured as low as 55% before lift cutout will reset and the Operator Display shows the charge of the replacement battery.

The following example describes installing a new battery when the Operator Display does not reset. Assume the following:

BDI configured at 95%, the battery connected is at 45% charge, and the new battery is at 92% charge.

Battery Discharge Indicator (BDI)

Since the new battery charge has not changed by at least 50% and the state - of - charge of the new battery is not greater than the BDI reset configured value, the Operator Display continues to show the old battery's charge of 45% (even though the new battery is at 92%). What occurs is that the Operator Display remains at 45% until the charge of the new battery declines to 45%. Then the display resumes its normal descent.

One final example. Assume the following: BDI configured at 95%, the battery connected is at 65% charge, and the new battery is at 20% charge.

Again, the change in charge is not at least 50% and the new battery is not above the configured BDI level. The Operator Display continues to show 65%, but then descends rapidly as the lift truck operates until the Operator Display shows the original charge of 20%. Once the display shows 20%, it resumes a normal descent.

Setting Battery State-of-Charge Cutout

1. Fill, charge, and install a battery that is typical of the batteries normally used in this application.

2. Have a customer operator use the lift truck in normal application until cutout occurs.

3. Permit the battery to cool and stabilize for at least two hours.

4. Before filling the battery, either take specific gravity readings or measure open circuit voltage of the battery cells.

5. Compare the measurements with the battery manufacturer's recommendations for maximum discharge.

6. Adjust the cutout value as needed and repeat the previous steps until battery cutout occurs at the desired discharge level.

Contactors

Contactors

Testing Resistance

Visually inspect the contactor for any signs of burning or physical damage.

1. Turn key switch OFF and disconnect battery connector.

2. Disconnect two wires marked X and Y contactor.

3. Connect one lead of ohmmeter to X contactor lead and one to the Y contactor lead.

4. The reading should be between 20 and 40 ohms. If resistance is outside that range, replace contactor.

Examine the fuse for signs of overheating, discoloration, cracking, or other physical damage. You should be able to see if the fuse is blown through the fuse window. Replace the fuse if you find damage.

To test a fuse, remove it or isolate it from the electrical circuit. Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse.

Use an ohmmeter set to Rxl scale and measure the resistance across the fuse. The resistance should be less than 1 ohm.

Hydraulic Troubleshooting Guidelines

Hydraulic Troubleshooting Guidelines

After elevating the carriage for troubleshooting, be sure to use blocks to secure the carriage. Use extreme care when blocking the mast for any reason. Never remove a block when it is supporting the mast.

Lower the carriage fully.

Stabilize the top of the mast with an overhead chain hoist.

When you measure voltage at solenoids, make sure hydraulic lines and components are fully installed.

Whenever possible, keep the key switch OFF and the battery connector disconnected.

Cap open hydraulic lines to prevent contamination.

Definitions

Continuity

A continuous and uninterrupted path between two or more locations in an electrical circuit, typically having a resistance of less than 1 ohm.

Deadman Switches

The switches in the truck that must be closed to allow truck operation. The Orderpicker Model 7BPUE15 has two deadman switches under the deadman pedal. Both switches must be functional for the truck to travel, lift or steer. Stepping on the pedal on the operator platform activates these switches. The deadman function acts to protect against travel while the brake is applied.

M3 and M4 Accel Rate

The time necessary to reach full output (PWM) from zero output in M3 or M4 (high speed, PMC-3 on) mode. See Table 5 - 7 on page 5 - 24.

M3 and M4 Max Speed

Maximum speed (PWM duty factor) in M3 or M4 (high speed) mode.

Mode Select Inputs

The traction power amplifier is capable of four modes of operation that are determined by two mode select inputs (MM1 and MM2) from the steer/tractor manager. See Table 5 - 4 on page 5 - 22.

Neutral Braking

The plugging force applied to the drive motor by the power amplifier when the throttle is in neutral with the deadman switches closed.

Open Circuit

Definitions

Overtemperature (Traction Power Amplifier)

Overtemperature of the traction power amplifier is 85" C (185" F) and above. Overheating is unusual, but can occur if the traction power amplifier is installed incorrectly or overloaded. At overtemperature the drive current limit is linearly decreased from full set current down to zero. Plug current is not reduced by any thermal conditions to allow full plugging strength at all times.

Pulse Width Modulation

Pulse Width Modulation (PWM),also called " chopping, " controls the speed of the motor by switching the battery voltage to the motor on and off very quickly.

Short Circuit or "Short"

A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit.

Example: Two insulated wires are physically next to each other and the insulation has been worn off each of the wires. Because the conductors inside each wire are now touching each other, there is a short circuit.

Example: A power cable from the battery to a junction post in the truck has had the insulation worn away. Because the wire conductors are touching the tractor frame, there is a short circuit of the battery cable.

Undertemperature

When the amplifier is operating at less than -25" C (-13" F), the current limit is cut back resulting in reduced travel speed and acceleration.

Electrical Connector Locator Chart

Electrical Connector Locator Chart

(Spare digital)

Mast limit switches, lift limit switches

Steer feedback encoder

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Connector

JPT7

JPT8

JPTS

JPTlO

JPTl 1

JPT12

PS1

JS1

JT1

JPW 1

JPW2

Function or Routing

(Spare digital)

Steer power head

Mast cable 1 (signals)

Mast cable 1 (power)

Traction power amplifier

Power and drivers

Steer/power head connector

Filter card and steer controller interface

MULTI (Memory Update Link and Test Interface)

Filter card connector to load sensor

Filter card connector to tractor sensor

Location

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Steer/tractor manager

Guidance manager

Steer/tractor manager

Guidance manager

Guidance manager

Programmable Maintenance Tool

Programmable Maintenance Tool

Diagnostic History

You can use the Programmable Maintenance Figure

The optional Programmable Maintenance Tool (PMT) (P/N 00590 - 4998 1 - 71) allows you to test and diagnose the traction power amplifier in this lift truck.

The PMT is powered by the host amplifier through the four - pin connector on the amplifier. See Figure 5 - 5.

When the PMT is first plugged into the amplifier, the PMT displays the amplifier's model number, date of manufacture, and software revision code. Following this initial display, the PMT displays a prompt for further instruction.

NOTE: Follow the prompt at the top of the PMT screen, not the blinking icon, to choose the correct setting.

Tool to access the diagnostic history file of the traction power amplifier.

The PMT will read out all the faults that the amplifier 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 error.

For example, an overtemperature fault may be caused by operator habit or overloading.

NOTE: Each fault is listed only once, regardless of the number of times it occurred.

Access

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

2. Remove the tractor cover.

3. Connect the PMT to the traction power amplifier.

4. Connect the battery and turn the key switch ON.

5. Hold the more info key, and press the diagnostics key.

Programmable Maintenance Tool

Clear

After you have diagnosed and corrected the problem, you should clear the diagnostic history file. This allows the traction power amplifier to accumulate a new file of faults. By checking the new history file at a later date, you can easily determine whether the problem was completely fixed.

1. Hold the more info key, and press the program key. Release both keys after you enter the Special Program mode.

2. Scroll through the mode using the scroll display keys until "CLEAR DIAG HIST" is the top line in the display.

3. Press the more info key again. The PMT will prompt you to acknowledge or cancel.

4. Press the value up key to clear the diagnostic history. Press the value down key to cancel.

Test Mode

This section shows you different modes you can use on the PMT to troubleshoot this lift truck.

Access

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

2. Remove the tractor cover.

3. Connect the PMT to the traction power amplifier.

4. Connect the battery and turn the key switch ON.

5. Press the test key on the PMT.

6. Scroll through the line items using either scroll display key. When the item you want is the top line on the display, press the more info key for a full screen display.

Explanation

Throttle reading, in percent of full: 1- 100%

Motor field current, in amps: 6-20A

Motor armature open, in amps: 80-300A

Motor field applied duty cycle, as %: 0- 100%

Motor armature applied duty cycle: 0 - 100%

Battery voltage across the internal capacitors: 20-25V

Heatsink temperature, in "C: 22-70" C

Forward switch: on/off

Reverse switch: on/off

Mode Select 1 (MM1):on/off. See Table 5 - 4.

Mode Select 2 (MM2):on/off. See Table 5 - 4.

Interlock switch (deadman): on

PC drive (output): on/off

Auxiliary driver (not used): on/off

NOTE: The traction power amplifier is capable

(MM1 and MM2) from the steer/tractor of four modes of operation that are manager. See Table 5 - 4. determined by two mode select inputs

Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual

Programmable Maintenance Tool

it is replace the TPA. If it shows being activated, fork-first travel would allow a full speed of 6.0 MPH. The throttle percent input will be varied

The table below lists messages you may see displayed when the PMT is operating in either the Diagnostic Mode or the Diagnostic History. The messages are listed in alphabetical order for easy reference.

Display

ANTI-TIEDOWN

CONT COIL/FLD SHORT

CURRENT SHUNT FAULT

FIELD OPEN

HW FAILSAFE

LOW BA?TERY VOLTAGE

M- SHORTED

Explanation

Mode 1 select switch closed at start - up

Contactor driver overcurrent or field winding short

Current sensor error

Motor field winding open

Hardware fail-safe activated

Battery voltage too low (<16 volts)

M- shorted to B-

Display

NO KNOWN FAULTS

OVERVOLTAGE

THERMAL CUTBACK

THROTTLE FAULT 1

No known faults

Explanation

Battery voltage too high (>45volts)

Thermal cutback due to over/under temperature

Throttle wiper input fault

Special Program Mode

The chart below shows you line items in the Special Program Mode.

Access

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

2. Remove the tractor cover.

3. Connect the PMT to the traction power amplifier.

4. Connect the battery and turn the key switch ON.

5. Press and hold the more info key; press the program key.

6. Scroll through the line items using either scroll display key until the item you want to change is the top line on the display. See Table 5 - 6 on page 5 - 23.

7. Press either change value key until you reach the value you want.

Load programming settings

SETTINGS+ CONTRAST Adjust display contrast ADJUSTMENT Display PMT information