Section 9. Theory of Operation

Toyota Orderpicker Model 7BPUE 15 Service Manual

Toyota Orderpicker Model 7BPUE15 Service Manual

Section 9. Theory of Operation

Figure 9- 13 (Cont.). Lower (Sheet 2 of 4)

00700-CL222-05, 1 5 March 2005

Figure 9-13 (Cont.). Lower (Sheet 4 of 4)

00700-CL222-05, 1 5 March 2005

24 " Limit Switch (56)

The 24 " limit switch is mounted to the carriage, and the switch rail is mounted on the truck frame 24 " (60.96 mm) from the bottom. The switch is closed until the carriage lifts high enough for the switch to run above the switch rail. When open, the switch limits travel speed to 3 rnph (4.8 kph). Travel speed is further limited to 1 rnph (1.6 kph) when steering is more than 5" from center.

If the truck is equipped with the High Performance option, travel speed is limited to 2.5 rnph (4 kph) when this switch is open and the steering angle is greater than 5" from center. There is no speed limit if the steering angle is less than 5".

150" Limit Switch (S29)

The 150 " limit switch is mounted to the mast behind the battery connector. This switch opens when the outer mast raises above it and the forks are 150 " off the floor. At this height, travel speed is limited to 1 rnph (1.6 kph), or disabled if the steering angle is more than 5" from center.

60" Limit Switch (57) (Optional)

The 60 " limit switch is included with the High Performance option.

This switch is mounted on the carriage and limits travel speed to 4.3 rnph (6.9 kph) when open, or 1 rnph (1.6 kph) if the steering angle is more than 5" from center.

120" Limit Switch (S29) (Optional)

The 120 " limit switch is included with the High Performance option.

This switch is mounted on the mast and limits travel speed to 2.5 rnph (4 kph) when open, or limits travel speed to 1 rnph (1.6 kph) if the steering angle is more than 5" from center.

180" Limit Switch (525)

(Optional)

The 180 " limit switch is included with the High Performance option.

This switch is mounted on the carriage and limits travel speed to 1 rnph (1.6 kph) when open, or disables travel if the steering angle is more than 5" from center.

Lift Limit Switch (524) (Optional)

The lift limit switch disables lift when open. This switch is mounted on the mast. It can be bypassed by pressing the optional lift limit bypass switch on the carriage.

Lift Limit Bypass Switch (551)

(Optional)

When the lift limit switch is open, pressing the lift limit bypass switch allows the truck to continue lifting.

Lower Limit Switch (560)

(Optional)

The lower limit switch disables lower when closed. It is mounted on the carriage and can be bypassed using the optional lower limit bypass switch on the carriage.

Pump Contactor

The pump contactor provides power to the lift motor and is closed during lift.

Load Holding Solenoid

The load holding solenoid is closed whenever there is no request to lower. When lower is requested, the solenoid opens. It closes when lower is no longer requested.

Pump Sense

The pump sense line monitors the status of the pump contactor at all times. If the pump contactor is closed when commanded open, an error code displays and the PC contactor opens. If the pump contactor is open when commanded closed, an error code displays.

CV- 1 Valve

This 5 psi (34.5 kPa) check valve makes sure that oil returning from the lift cylinders does not drive the lift pump and motor backward.

CV-2 Valve

This is the 100 psi (689.4 kPa) fork hang - up valve. If the pressure in the return line falls below 100 psi (689.4 kPa), the valve will close and not allow the carriage to lower.

Flow Control Valves

Each lift cylinder has a flow control valve at the bottom of the cylinder. If a lift hose fails, the flow in the side cylinders will be limited to 9 gpm (34 lpm) while the flow in the center cylinder will be limited to 1 1 gpm (41.6 lpm).

Oil Filter Check Valve

The oil filter is mounted to an adapter that incorporates a spring-loaded check valve. It provides a bypass around the filter in case the oil pressure in the return line is greater than what the filter can handle. Additionally, if the filter gets clogged, the oil will bypass the filter and return to the hydraulic reservoir.

REL-1 is the high pressure relief valve. It opens when lift pressure exceeds the pressure necessary to lift a full - rated load.