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Toyota 7BPUE15 Service Manual

Serial no. 80,001 and up
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Table of Contents

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Service
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7BPUE15
Serial Numbers
80,001 and up

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Summary of Contents for Toyota 7BPUE15

  • Page 1 Service Manual 7BPUE15 Serial Numbers 80,001 and up...
  • Page 3 TOYOTA Service Manual High Orderpicker Level Model 80,001 and Serial No.
  • Page 4 Toyota Industrial 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 Industrial Equipment is not...
  • Page 6 37 SIB CE09-003 Adding Lift Limit with Bypass to 6BPU15 38 SIB DU09-002 Drive Unit Leakage 39 SIB CC09-002 Software Version 2.2 SIB BR09-002 6BPU15 Master Cylinder Installation SIB CC10-001 Flashware v4.2 for Class II and III Trucks 42 SIB CC10-002 v2.3 Software for 7BPUE15 Orderpicker...
  • Page 7 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCUHouse Valves; HTT-2005-08 - Solid State Handle on the Order Picker HTT-2005-10 - 7BPUE15 Continues Lifting a Few Inches After Releasing the Lift Knob HTT-2005-11 - 6BPU15 brake bleeding HTT-2005-12 - Reach and Straddle Truck Caster Adjustment 10 HTT-2006-02 - 6BPU15 &...
  • Page 8 42 HTT-2009-07 - Class II No Proportional Lowering 43 HTT-2009-08 - 7BNCU Lift Relief Pressure 44 HTT-2009-09 - 7BPUE15 with No Key-On B+ Volts, Class II "GATE" Code 45 HTT-2009-10 - Class II Wire Guidance - Losing Wire, BWI Light Coming On...
  • Page 9 Troubleshooting HTT-2011-09 - Class II C7 & C9 Configure Settings HTT-2011-10 - Class II 7BPUE15 Dual Mast Cable HTT-2011-11 - Class II 8B(D)RU Reach Cylinder Lock Nut Spec HTT-2011-12 - Class II Display Manager Card Replacement, Hyd Oil Maint and Diagnosing...

  • Page 10: Table Of Contents

    Toyota Orderpicker Model 7BPUE 15 Service Manual Table of Contents Table of Contents How to Use This Manual Map of the Manual Page Revision Page Safety Definitions Battery Safety 2-11 Tie-Down for Transport 2-13 Towing a Disabled Unit 2-14 Welding Safety...

  • Page 11: Table Of Contents

    Table of Contents Toyota Orderpicker Model 7BPUE15 Service Manual ......Traction Power Amplifier Fault Codes ......

  • Page 12: Table Of Contents

    Toyota Orderpicker Model 7BPUE 15 Service Manual Table of Contents Pallet Clamp 7 . 9 5 7-96 7-97 Wire Guidance System Overview 8 . 2 Install K t Components 8 . 3 Set-Up Procedure 8 . 9 8-12 Tests 8-35 General Troubleshooting 8 .
  • Page 13 Table of Contents Toyota Orderpicker Model 7BPUE15 Service Manual This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 14 This Toyota Orderpicker Model Service Manual Section How to Use Manual This Section 1. How to Use Manual 00700-CL222-05, 1 5 2005 March...

  • Page 15: How To Use This Manual

    Section 1 . How to Use This Manual Toyota Orderpicker Model 7BPUE15 Service Manual M a p the Manual of the Manual How To Use This Manual Table of Contents Safety Map of the Manual Manual Design Systems Overview Vehicle Specifications...

  • Page 16: Map Of The Manual

    This Section How to Use Manual Toyota Orderpicker Model Service Manual M a p of the Manual Component Alphabetical List of Procedures Component Procedures Component Location Wire Guidance Photos Appendix Lubrication Specification Chart Component Procedures by Lift Theory of Truck Systern...
  • Page 17 Section 1 . How to Use This Manual Toyota Orderpicker Model 7BPUE15 Service Manual Manual Design Once you're familiar with the symptoms Manual Design listed, you may instead simply find the symptom chart from the This Service Manual is designed with the...
  • Page 18 This Toyota Orderpicker Model 7BPUE Service Manual Section How to Use Manual Page Revision Page Page Revision Page This section is a record of all revised pages in this manual. Whenever a page is revised, this section is updated and included in the revision package.

  • Page 19: Page Revision Page

    Section 1 . How to Use This Manual Toyota Orderpicker Model 7BPUE15 Service Manual Page Revision Page This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 20 This Toyota Orderpicker Model Service Manual Section How to Use Manual START Page START Page START Go to Section "Safety precautions? Go to Section 3 To examine "Systems Overview" specifications? Go to Section To do scheduled "Planned Maintenance" maintenance? Go to Section 5 "Troubleshooting"...
  • Page 21 Section 1 . How to Use This Manual Toyota Orderpicker Model 7BPUE15 Service Manual START Page Go to Section inspect, adjust, "Component Procedures" Go to Section 9 Y e s Go to Section A "Appendix Y e s Y e s...

  • Page 22: Safety

    Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety Section Safety 00700-CL222-05, 1 5 March 2005...

  • Page 23: Definitions

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 2. Safety Definitions Definitions Throughout this manual, you will see two kinds of safety reminders: Warning means a potentially hazardous situation exists which, not avoided, could result in death or serious injury.
  • Page 24 Section 2. Safety Toyota Orderpicker Model 7BPUE15 Service Manual General Safety General Safety Operate this truck only from the operator's position. When elevated, be sure to wear a safety belt attached to a secured tether. Do NOT operate or work on this truck unless...
  • Page 25 Section 2. Safety Toyota Orderpicker Model 7BPUE 15 Service Manual General Safety Do NOT use gasoline or other flammable liquids for cleaning parts. Follow the scheduled lubrication, maintenance and inspection steps. Clean u p any hydraulic fluid, oil or grease that has leaked or spilled on the floor.
  • Page 26 Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety General Safety Do NOT add to or modify this truck until you contact your authorized Toyota Dealer to receive written manufacturer approval. 00700-CL222-05, 1 5 March 2005...

  • Page 27: Battery Safety

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 2. Safety Battery Safety Battery Safety goggles or face shield, rubber gloves (with or without arm shields) and a rubber apron. As a battery is being charged, an explosive gas mixture forms within and around each cell.
  • Page 28 Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety Battery Safety Keep the charging area well-ventilated to avoid Keep plugs, terminals, cables and receptacles in hydrogen gas concentration. good condition to avoid shorts and sparks. Turn the key switch OFF before disconnecting the battery from the truck a t the battery connector.
  • Page 29 Section 2. Safety Toyota Orderpicker Model 7BPUE 15 Service Manual Battery Safety Never plug a battery charger into the truck's battery connector. Plug the battery charger only into the battery connector from the battery. Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual.
  • Page 30 Figure 2-3 shows the components of the Toyota (plastic bags, synthetic clothing, synthetic soles anti-static field service kit, part number on shoes, styrofoam coffee cups, etc.).
  • Page 31 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 2. Safety Static Safety Static-Dissipative Wrist Strap Work Surface Ground Cord Anti-Static Kit W i t h Wrist Strap a n d M a / Figure Wrist straps are available in quantities of 25, as part number 00590-04848-7 1.
  • Page 32 Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety Jacking Safety Jacking Safety Tractor Sometimes you may need to jack the truck up from the floor to perform maintenance Use care when jacking the tractor on procedures. When doing so, observe the proper wire-guided trucks.
  • Page 33 Section 2. Safety Toyota Orderpicker Model 7BPUE 15 Service Manual Jacking Safety Figure 1. Place the jack a t the designated jacking point. See Figure 2-5. 2. Jack the baseleg until you have enough clearance to replace the load wheel.

  • Page 34: Tie-Down For Transport

    Section 2. Safety Toyota Orderpicker Model 7BPUE15 Service Manual Tie-Down for Transport a. Install eye-bolts (3/4 in. [19 mm] thread Tie-Down for Transport size) in holes in the bumper. See Figure 2-6. b. Secure chain ti-on1 ye-bolts to vehicle 4. Strap truck ti-on1 Ijumpcr or guide roller to tloor of transport vehicle.

  • Page 35: Towing A Disabled Unit

    Section 2. Safety Toyota Orderpicker Model 7BPUE 15 Service Manual Towing a Disabled Unit Towing Disabled Unit release bolts provided. See Figure 2-8 and Figure 2-9. Steering is disabled while you are To safely tow a Toyota Orderpicker: towing, so you will need to manually 1.

  • Page 36: Welding Safety

    Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety Welding Safety Welding Safety Disconnect the battery before you attempt to inspect, service or repair the lift truck. Discharge residual charge in the traction power amplifier by pressing Flame cutting or welding on painted...
  • Page 37 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 2. Safety Welding Safety This page intentionally left blank 00700-CL222-05, 1 5 March 2005...

  • Page 38: Systems Overview

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 3. Systems Overview Section Systems Overview 00700-CL222-05, 15 March 2005...

  • Page 39: Vehicle Specification

    Alternate load capacity 3000 lbs. to 240-241" a. The Model 7BPUE15 is designed for level floor operation only. It is capable of being driven in a fully lowered, unloaded condition on a maximum 100 ft. long ramp with a maximum incline of 6%.
  • Page 40 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 3. Systems Overview Vehicle Specification Table Mast Specifications 88.5 2248 1 2 3 3124 5 2 8 3 4650 2 1 09 ( 2 -S t a g e ) 2 41 3...
  • Page 41 Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual Vehicle Specification 24"-28" (61 0-71 1 mm) Fork Adjustment (99 1 mm) min. OAW Platform Power Unit & Width Opening Safety Belt & Tether Extended 78.5" (1 994mm) Operator Compartment...

  • Page 42: General System Data

    Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual General System Data General System Data Chassis : Basic frame of the lift truck; E F INITI O N includes baselegs, bumper and Carriage mast. : Part of the truck that moves by EFI N ITI O N hydraulic force;...
  • Page 43 Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual General System Data Tractor : Holds the majority of electrical and EFINITI O N hydraulic components of the lift truck, including the power section and lift motor and pump. For the location of specific components, See "Component Locator Photos"...

  • Page 44: Installation Instructions

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 3. Systems Overview Installation lnstructions Installation Instructions : These instructions pertain to trucks that O TE are shipped horizontally on a cradle. 1. Remove long bolts from bumper plate (two bottom bolts).

  • Page 45: Wire Guidance

    Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual Wire Guidance Wire Guidance Wire guidance is a means to automatically steer the truck while traveling in a n aisle. I t offers precise steering a t full-speed travel in very narrow aisle (VNA) applications.

  • Page 46: Cold Storage

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 3. Systems Overview Cold Storage Cold Storage Cold storage is a factory-installed option that enables truck operation in temperatures of (-28.86" C) to 40" (4" C). On cold storage trucks, the electrical panel on the tractor is completely enclosed to contain heat.
  • Page 47 Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual Cold Storage COLD STORAGE CARRIAGE CONTROL HANDLE WIRES COLD STORAGE TRACTOR Figure Cold Storage Electrical Schematic 00700-CL222-05, 1 5 March 2005...

  • Page 48: Ul Label "Ee"

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 3. Systems Overview UL Label "EE" Label "EE" Underwriters Laboratories (UL) ratings indicate that specific criteria have been met by the manufacturer, and tested and documented by UL. "EE" designated trucks are electrically powered units that have, in addition to all of the requirements for "E"...

  • Page 49: Special Tools

    Section 3. Systems Overview Toyota Orderpicker Model 7BPUE 15 Service Manual Special Tools Special Tools BDI (Battery Discharge Indicator) cutout threshold Options Learn throttle Diagnostics For operating instructions, See "PC Loader Program" on page 10-2. Ram Service Tools Use these tools when repacking the side cylinders or center cylinder.

  • Page 50: Planned Maintenance

    Section Planned Maintenance Toyota Orderpicker Model Service Manual 4. Planned Maintenance Section 00700-CL222-05, 1 5 2005 March...

  • Page 51: Maintenance Guidelines

    Toyota Orderpicker Model 7BPUE15 Service Manual Section Planned Maintenance Maintenance Guidelines Maintenance Guidelines Interval 1 Daily or Eight Hours Moderate Usage: Every 6 Months or 500 Interval 2 A planned maintenance program is Hours recommended to enable: Severe Usage: Every 3 Months or 250...

  • Page 52: Interval 1

    Toyota Orderpicker Model Service Manual Section Planned Maintenance Interval Interval 1 Battery Check cleanliness and exterior condition. Check the charge. Check the connector. Make sure all powered functions are shut down when disconnected. Gates must be properly installed and securely locked in place.

  • Page 53: Interval 2

    Section Planned Maintenance Toyota Orderpicker Model 7BPUE15 Service Manual Interval 2 Interval Check the weight stamped on the battery in the truck Page 3-2 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.
  • Page 54 Toyota Orderpicker Model Service Manual Section Planned Maintenance Interval Hardware Check the tightness of all wire and cable connections. This can be done by trying to move the connection with your hand. Check for loose hardware for major truck components (steer...
  • Page 55 Section Planned Maintenance Toyota Orderpicker Model 7BPUE15 Service Manual Interval 2 do not reflect a normal wear pattern, the chance of intermittent error codes caused by shorts between maintenance intervals. It will also extend the life of cables and harnesses.
  • Page 56 Toyota Orderpicker Model 7BPUE 15 Service Manual Section Planned Maintenance Interval 2 4- 1 . Figure Bottom of Battery Compartment 00700-CL222-05, 1 5 March 2005...

  • Page 57: Interval 3

    Section Planned Maintenance Toyota Orderpicker Model 7BPUE15 Service Manual Interval 3 Interval Hardware Tighten or replace any loose, broken or missing hardware. Drive Unit Change the fluid in the drive unit. Page Hydraulic System Replace the hydraulic fluid and filter.

  • Page 59: Troubleshooting

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual How to Use This Chapter How to Use This Chapter This chapter contains a set of general troubleshooting guidelines, a troubleshooting task flow, and a set of troubleshooting tables for symptoms not accompanied by a fault code.

  • Page 60: Electrical Troubleshooting Guidelines

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Electrical Troubleshooting Guidelines Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. See "Battery Exterior Cleaning" on page 7-33. Check the electrolyte level and state of charge.
  • Page 61 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Shorts to Frame Test Shorts to Frame Test Then test for shorts between electrical components and the truck frame. "Shorts to frame" is a n industry term for To test for shorts to frame: unintentional current leakage paths between 1.

  • Page 62: Shorts To Frame Test

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Shorts to Frame Test DO NOT continue until this condition is fuses and motor terminals. Begin corrected. Your meter may be damaged if measuring a t the highest ampere scale you proceed before correcting this and work toward the lowest.
  • Page 63 Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Shorts to Frame Test Shorts to Frame Test With battery connector Turn the key switch disconnected, measure OFF and disconnect leakage current from battery the battery case to battery B+ and to connector.
  • Page 64 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Shorts to Frame Test Do NOT With battery connector continue until disconnected (or resistance measures measure resistance from greater than truck frame to truck B+, 1000 ohms, or to truck B-...
  • Page 65 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Troubleshooting Wiring Problems move a harness, cut a cable tie, or remove the Troubleshooting Wiring wire from a bracket. Note carefully the location Problems of the wire and all protective or securing attachments before moving the harness.

  • Page 66: Troubleshooting Wiring Problems

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Troubleshooting Wiring Problems Use the "Electrical Connector Locator Chart" on page 5-18 to locate electrical connectors on the truck. Inspection Whenever working on the truck, use care around wiring harnesses.

  • Page 67: Switches (General)

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Switches (General) Switches (General) the switch assembly and can only be seen if the switch is disassembled.) Examine the switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace the switch if you see such damage.
  • Page 68 Section Troubleshooting Toyota Orderpicker Model Service Manual Electric Motor Tests permanent magnet steer motor uses Electric Motor Tests permanent magnets a s fields and has only two external connections. : Field connections may be labeled S. O TE Shunt-wound motor field connections...

  • Page 69: Electric Motor Tests

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Electric Motor Tests Short-circuited Armature or 3. Y measurements: Field Winding Drive Motor 0.9 to 1.5 insulation on the field o ; armature has broken (shunt) o h m s down a t two or more points.
  • Page 70 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Battery Discharge lndicator (BDI) Battery Discharge resets the Operator Display to show the replacement battery's charge. Indicator (BDI) b. Example 2: battery in the lift truck is at 20% charge and lift cutout has not occurred.

  • Page 71: Battery Discharge Indicator (Bdi)

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Battery Discharge Indicator (BDI) Since the new battery charge has not changed by a t least 50% and the state-of-charge of the new battery is not greater than the BDI reset...

  • Page 72: Contactors

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Contactors Contactors Testing Resistance Visually inspect the contactor for any signs of Examine the fuse for signs of overheating, burning or physical damage. discoloration, cracking, or other physical damage. You should be able to see if the fuse is 1.

  • Page 73: Hydraulic Troubleshooting Guidelines

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual 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.
  • Page 74 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Definitions Definitions Overtemperature (Traction Power Amplifier) Continuity Overtemperature of the traction power amplifier is 85" C (185" F) and above. Overheating is A continuous and uninterrupted path between unusual, but can occur if the traction power two or more locations in a n electrical circuit, amplifier is installed incorrectly or overloaded.
  • Page 75 Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Electrical Connector Locator Chart Electrical Connector Locator Chart (Spare digital) Mast limit switches, lift limit switches Steer feedback encoder Table Electrical Connector locator Chart 00700-CL222-05, 1 5 March 2005...

  • Page 76: Electrical Connector Locator Chart

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Electrical Connector Locator Chart Connector Function or Routing Location JPT7 (Spare digital) Steer power head Mast cable 1 (signals) Mast cable 1 (power) Traction power amplifier Power and drivers PS 1...
  • Page 77 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Programmable Maintenance Tool Programmable Maintenance Tool Connection for to Traction Power A m p Figure Diagnostic History You can use the Programmable Maintenance Tool to access the diagnostic history file of the...

  • Page 78: Programmable Maintenance Tool

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Programmable Maintenance Tool Test Mode Clear After you have diagnosed and corrected the This section shows you different modes you can problem, you should clear the diagnostic use on the PMT to troubleshoot this lift truck.
  • Page 79 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Programmable Maintenance Tool 5-4: Table Modes of Operation 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...
  • Page 80 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Programmable Maintenance Tool Table Diagnostics and Special Diagnostics list Display Explanation NO KNOWN FAULTS No known faults OVERVOLTAGE Battery voltage too high THERMAL CUTBACK Thermal cutback due to over/under temperature...
  • Page 81 Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Programmable Maintenance Tool Programming 7. Press either change value key until the setting you want is displayed. The parameter is now set a t the value you You can change certain parameters using the selected.
  • Page 82 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Drive Unit Troubleshooting Guide Drive Unit Troubleshooting Guide Oil leaks Damaged sealing rings Replace sealing rings, bearing shims, and drive shaft bearings Worn or damaged drive shaft Replace sealing rings, bearing shims, drive...

  • Page 83: Drive Unit Troubleshooting Guide

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Drive Unit Troubleshooting Guide This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 84 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Troubleshooting Flowcharts Troubleshooting Flowcharts T S 1: START TROUBLESHOOTING Message or Fault Code displayed? listed in symptom tables in Follow symptom table directions in Section 5 Chart GEN-1 00700-CL222-05, 1 5 March 2005...

  • Page 85: Troubleshooting Flowcharts

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Troubleshooting Flowcharts Gather as much information as you Eliminate unlikely What is the problem? can about causes. Where did it happen? When did it happen? Select and prioritize What functions are affected? the most likely causes.
  • Page 86 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Troubleshooting Flowcharts Operate the truck a s it Make sure ALL wires, was being operated when hoses, and cables that the problem occurred. you removed have been Verify the problem does re-attached correctly.
  • Page 87 Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Troubleshooting Flowcharts This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 88 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Symptom Tables: Hydraulic Functions Symptom Tables: Hydraulic Functions : If you determine that a component O TE failed as a result of hydraulic fluid contamination, replace the failed component and flush, fill, and bleed the hydraulic system.

  • Page 89: Symptom Tables: Hydraulic Functions

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Symptom Tables: Hydraulic Functions Unable to Pick Up a Load; Lift Pump Runs; Travel OK check cutout adjustment: Allow battery to set unused for two hours. Check SG and compare to battery manufacturer's recommendations.

  • Page 90: Symptom Tables: Travel Functions

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting Symptom Tables: Travel Functions Symptom Tables: Travel Functions Slow or Sluggish Acceleration 1. Allow battery to set unused for two hours. Check SG and compare to battery manufacturer's recommendations. OK; No Fault Codes Slow Travel;...

  • Page 91: Symptom Tables: Electrical Symptoms

    Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual Symptom Tables: Electrical Symptoms Symptom Tables: Electrical Symptoms Electrical Motors Motor Overheating Dead Lift Truck Display is Dark; Lift Truck is not Operational 00700-CL222-05, 1 5 March 2005...

  • Page 92: Codes And Tests

    Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Section Codes and Tests 00700-CL222-05, 1 5 March 2005...

  • Page 93: Operator Display Messages

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 6. Codes and Tests Operator Display Messages Table Each steering 6- 1. indicator message is explained in Messages The operator display has two sections, the All LEDs scroll in Drive unit position is steering indicator and the battery indicator.
  • Page 94 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Operator Display Messages The battery indicator will always show the mode displayed. Once these codes are resolved, the next highest codes are displayed until they are with the highest priority that is active. For example, a n Info Display message will override resolved.

  • Page 95: Maintenance Mode

    Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Maintenance Mode Maintenance Mode Wait for the BDI display to clear. A clear display indicates the first digit was accepted. Maintenance mode allows you to test individual : You must enter the second digit within 3 circuits of switches and inputs while the lift seconds of entering the first digit.
  • Page 96 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Maintenance Mode Lower limit (S60); see Note on previous : This test will not work if you step on the O TE Auto manual (S61) 2. Rotate the steering wheel.

  • Page 97: Traction Power Amplifier Fault Codes

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 6. Codes and Tests Traction Power Amplifier Fault Codes An internal microcontroller automatically checks the function of the traction power Fault Codes amplifier. When this microcontroller detects a fault, it signals the appropriate fault code...
  • Page 98 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code LED Solid On T P A Code LED Solid On Corrective Actions and Checks T P A Code Heartbeat Corrective Actions and Checks None. System functioning properly.
  • Page 99 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual TPA Code 1,1 Code 1,l Corrective Actions and Checks Code 1 , 2 Corrective Actions and Checks Replace the 00700-CL222-05, 1 5 March 2005...
  • Page 100 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests TPA Code 1,3 TPA Code 1,3 Corrective Actions and Checks TPA Code 00700-CL222-05, 1 5 March 2005...
  • Page 101 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual TPA Code 2,6 Corrective Actions and Checks Full speed request Step 2 Replace STM approx. 4.25 volts No travel request Full speed request Replace TPA Troubleshoot approx. 4.25 volts...
  • Page 102 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests TPA Code 3,3 TPA Code 3 , 3 Corrective Actions and Checks S 1 and S2 wires S2 wire About 1 OHM Step 2 Troubleshoot disconnected wires to motor...
  • Page 103 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual TPA Code 4,1 Code 4 , l : After one minute of inactivity, the PC contactor O TE will drop out. This will activate a blinking 4 , l code.
  • Page 104 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests TPA Code 4,3 Corrective Actions and Checks TPA Code 4 , 3 Corrective Actions and Checks been parked in a freezer for an hours, take it amount of time...
  • Page 105 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual TPA Code 4,3 Park the truck Code clears Inspect the Replace the and allow it to mounting of cool down for a the TPA to the few hours truck frame.

  • Page 106: Operator Display Fault Codes

    Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Operator Display Fault Codes Operator Display Fault Codes 00700-CL222-05, 1 5 March 2005...
  • Page 107 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 1,3 Code 1,3 Corrective Actions and Checks : Use step 1 if the contactor tips do open O TE when the lift request is removed. Use steps 2 and 3 if the contact tips do not open when the request is removed.
  • Page 108 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 1,4 Code 1,4 Corrective Actions and Checks : Use steps 1 and 2 if the contactor tips O TE do close when a lift is requested. Use steps 3 and 4 it the contact tips do not close when a lift is requested.
  • Page 109 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 6. Codes and Tests Code 1,5 Code 1,s a problem with a switch 2. Sol'twwrc Alarm Sounds Operator Display P C Contactor Closed Speed Limit Limited Check all mast switches per Figure 5-2 on Corrective Actions and Checks page 5-10 and the steps in the chart below.
  • Page 110 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 1,6 Code 1,6 Corrective Actions and Checks JPC12-22 Replace CM Troubleshoot JPC12-11 Step 4 Replace CM Replace STM Replace over mast cable 00700-CL222-05, 1 5 March 2005...
  • Page 111 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 1,8 Click here for Sub Harness update Code 1,8 info Corrective Actions and Checks 00700-CL222-05, 1 5 March 2005...
  • Page 112 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 2,1 Code Corrective Actions and Checks J P C 13-7 Approx 5 volts Step 2 Replace CM Neutral 1.0 to 2.1 Replace CM Adjust or J P C 13- I...
  • Page 113 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 2,2 Code 2 , 2 Corrective Actions and Checks Check TPA for Code Mashing Troubleshoot Replace STM code displayed per the TPA code 00700-CL222-05, 1 5 March 2005...
  • Page 114 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 2,3 Click here for Code 2 , 3 updated harness info Corrective Actions and Checks 00700-CL222-05, 1 5 March 2005...
  • Page 115 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 2,4 Code 2 , 4 should close. Corrective Actions and Checks contactor for 00700-CL222-05, 1 5 March 2005...
  • Page 116 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 2,5 Code 2,5 1. If the code does not clear, follow the Corrective Actions and Checks Encoder a t rest 00700-CL222-05, 1 5 March 2005...
  • Page 117 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 2,6 Code 2,6 Corrective Actions and Checks Full lower less than 2.8 volts Full lift more than 00700-CL222-05, 1 5 March 2005...
  • Page 118 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 3,1 Code Corrective Actions and Checks disconnected 00700-CL222-05, 1 5 March 2005...
  • Page 119 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 6. Codes and Tests Code 3,2 3 , 2 Code Corrective Actions and Checks : If the drive unit will steer left and right, O TE start with step 1. If the drive unit will not turn in one or both directions, start with step 4.
  • Page 120 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 3,2 Turning tiller fast right 4.7 volts and Steer Power and Steer Power Motor Troubleshoot wires to motor 00700-CL222-05, 1 5 March 2005...
  • Page 121 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 3,3 Code 3 , 3 Operator Display Corrective Actions and Checks : Steering with the drive tire off the floor O TE will cause this code. Action/...
  • Page 122 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 3,3 and Steer Power and Steer Power At rest Fast t u r n about 1.5 volts. If truck and Steer Power h a s a fault and will...
  • Page 123 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 3,4 Code head senses current in the steer motor circuit. Corrective Actions and Checks between STM and Steer Power and Steer Power not steer test fails if jacked up/ DCV volts is not seen.
  • Page 124 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 3,5 Code P C Contactor Corrective Actions and Checks Action/ Lead Meter Setting Breakout Cable Approx. 4.85 volts Replace STM Remove connected Steering or not. If...
  • Page 125 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 3,6 Code 3 , 6 feedback encoder circuit. Corrective Actions and Checks 00700-CL222-05, 1 5 March 2005...
  • Page 126 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 3,7 Code Corrective Actions and Checks or 5 volts 00700-CL222-05, 1 5 March 2005...
  • Page 127 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 4,l Code 1 second or vice versa. Corrective Actions and Checks : Disconnect and step on the deadman O TE pedal. If the code still appears troubleshoot the circuit starting with step 1.
  • Page 128 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 00700-CL222-05, 1 5 March 2005...
  • Page 129 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 4,2 Code 4 , 2 Corrective Actions and Checks If contactor tips Check contactor for Step 2 Repair or are closed with burnt tips and replace the...
  • Page 130 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 4,3 Code after the PC contactor was commanded closed. Corrective Actions and Checks One side of Other Ohms Step 2 Replace fuse fuse side of fuse...
  • Page 131 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 4,6 Code 4 , 6 Corrective Actions and Checks 1. If a communication failure occurs, the continue to attempt communication. This communication will be evident by viewing the RECEIVE (IL3/IL10) and TRANSMIT and the steer/tractor manager.
  • Page 132 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 4,8 Code 4 , 8 Corrective Actions and Checks 00700-CL222-05, 1 5 March 2005...
  • Page 133 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 5,l Code Corrective Actions and Checks Meter Setting Cable 10.8 to 13 volts Replace CM Step 2 disconnected from PT7/DCV Remove wire 10.8 to 13 volts Step...
  • Page 134 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 5,2 Code 5,2 Corrective Actions and Checks Replace STM : If this code is intermittent check truck O TE for shorts to frame and verify static straps are clean and contacting the floor.
  • Page 135 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 5,3 Code Corrective Actions and Checks 12 volts on the STM one at a Troubleshoot 12 volts on the Troubleshoot...
  • Page 136 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 5,4 Code 5,4 Corrective Actions and Checks Load new Clear codes Replace STM software to the truck 00700-CL222-05, 1 5 March 2005...
  • Page 137 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 5,5 Code 5,s Operator Display 1113131313 1313131313 Corrective Actions and Checks Replace CM : If this code is intermittent check truck O TE for shorts to frame and verify static straps are clean and contacting the floor.
  • Page 138 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 6,1 Code 1. If the code does not clear, follow the Corrective Actions and Checks Check FU14 if 22 to 36 volts Step 2 Troubleshoot wiring to STM...
  • Page 139 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 6 , l disconnected that causes 12 00700-CL222-05, 1 5 March 2005...
  • Page 140 Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests Code 6,2 Code 6,2 1. If the code does not clear, follow the Corrective Actions and Checks the code shown on the Steer Controller card : Check adjustment of the line driver.
  • Page 141 Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual Code 6,3 Code 6 , 3 Corrective Actions and Checks Troubleshoot per the code shown on the Steer Controller card display : Check adjustment of the line driver. Check for mechanical binding in the Drive Unit and O TE steering gear box.
  • Page 142 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Section Component Procedures 00700-CL222-05, 1 5 March 2005...
  • Page 143 Service Manual Change History, Electrical Systems Description Page# Date 1 Added Drive Unit Overhaul Procedure 7-24 4/15/11 Page 1 of 1...
  • Page 145 Section 7 . Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual List of Component Procedures ....List of Component Covers. Tractor 7-11 Cylinders .
  • Page 146 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7 . Component Procedures of Component Procedures List ... Lift Pump Brush Spring Tension 7 . 6 2 7-37 ....
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  • Page 148 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Component Locator Photos Component Locator Photos Side Cylinder Chains Mast Guard Page 7-9 1 , page 7-93 7- 13 Page Side Center Cylinder Cylinders Page 7-69 7-65 Page Forks...
  • Page 149 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Component Locator Photos Hydraulic Reservoir Page 7-59 Lift Motor Page 7-41 Lift Pump Page 7-62 Solenoid Valves Page 7-61 Hydraulic Manifold Page 7-58 Power Cables Figure Inside Tractor 00700-CL222-05, 1 5 March 2005...
  • Page 150 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Component Locator Photos Electrical Panel Cover Removed Traction Power Amplifier 7-45 Page Figure Electrical Panel 1 5 0 Limit Switch (S29) 7-53 Page Figure Mast Switches 00700-CL222-05, 1 5 March 2005...
  • Page 151 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Component Locator Photos Carriage Manager lEDs Figure 00700-CL222-05, 1 5 March 2005...
  • Page 152 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Component Locator Photos IL6-1 Warning Light IL6-2 Not Used IL6-3 Hour Meter IL6-4 Brake IL6-5 Pump IL6-6 Horn IL6- 10 Figure 7 -7 : Figure 7 - 6 .
  • Page 153 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Component Locator Photos Figure Steer Power Head 00700-CL222-05, 1 5 March 2005...
  • Page 154 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Covers and Finish Tractor Covers Covers and Finish Tractor Covers 7- 10. Figure Top Cover Removal Removal Press in the two latch buttons then lift the top cover straight up and out. See Figure 7- 10.
  • Page 155 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Operator Console Cover Covers and Finish Operator ConsoleCover 1. Position cover over console components and secure to the platform with-the two captivating knobs. Make sure the operator platform is fully lowered before placing any part of your body between the masts.
  • Page 156 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Covers and Finish Mast Guard Guard Mast 7- 13. Figure M a s t G u a r d Removal 1. Lower platform fully to floor. Turn key switch OFF and disconnect battery.
  • Page 157 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Decals Covers and Finish Decals Location Refer to the Parts Manual Finish Instructions Replace any missing decals. Remove and Section to locate decals on the truck. replace any decals which are damaged.
  • Page 158 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Steering and Controls Steering and Controls 00700-CL222-05, 1 5 March 2005...
  • Page 159 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Operator Display Steering and Controls Operator Display 7- 15. Figure Replacing Operator Display Replace 1. Turn key switch OFF and disconnect battery. 2. Remove operator console cover. 3. Disconnect the JPC 1 from carriage manager.
  • Page 160 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Control Handle : Carefully slide the two spacer washers, Control Handle washer off of the lift pot shaft. See Figure 7- 16. For replacement parts, refer to the parts manual for the truck the handle is installed on.
  • Page 161 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Control Handle 7. Carefully unsolder the harness wires from should be located in the slot furthest the lift/lower pot. from the pin in the pot bracket. 4. Remove the lift/lower pot and bracket Assembly from the cover.
  • Page 162 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Control Handle spring with the tangs straddling the pot pull the travel pot/bracket assembly from bracket pin. See Figure 7- 16. the enclosure. See Figures 7-23 and 7-24. : Replace the spring if the tangs are not O TE parallel.
  • Page 163 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Control Handle 6. Carefully unsolder the harness wires. 2. Use a pin removal tool and pull pins 3 thru 6 from JC-9. These wires pass through the shaft to the lift/lower pot and horn switch.

  • Page 164: Component Procedures

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Control Handle 4. Check the potentiometer for proper 2. Route the lift/lower pot and horn wires operation and spring return to neutral. through the enclosure. Carefully slide the Correct any binding.
  • Page 165 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Control Handle Hand Soldering Procedures When hand soldering is performed on solid state potentiometers, the following is recommended: rosin base Solder Solder Iron 55 watt max. 0.118 in. (3mm) dia. x 1.182in.
  • Page 166 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Drive and Brake Drive and Brake 00700-CL222-05, 1 5 March 2005...

  • Page 167: Tractor Covers

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Drive Unit Drive and Brake Drive Unit Use extreme care whenever the truck jacked up. Never block the truck between the mast and the floor. Keep hands and feet clear from vehicle while jacking the truck.
  • Page 168 Toyota Orderpicker Model 7BPUE15 Service Manual Section 7. Component Procedures 00700-CL222-05, 15 March 2005 7-24a...
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  • Page 188 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Drive and Brake Drive Wheel Wheel Drive 2. Install drive wheel mounting bolts. Torque to 100 ft. lbs. (135.7 Nm). 3. Install bumper plate. 4. Remove block and lower tractor with jack.
  • Page 189 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Drive Wheel Drive and Brake longer than width of old tire to allow complete removal of old tire. The outside diameter of ram must be small enough to fit loosely in the insert of tire but must be large enough to rest squarely on flat surface on outer edge of hub.

  • Page 190: Brake

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Drive and Brake Brake Brake Installation 1. Install brake assembly on drive motor. 2. Align cable bracket on brake assembly and install bolts (3). 3. Connect PH5 and place cables in cable bracket.
  • Page 191 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Brake Drive and Brake Brake Friction Plate (Rotor) plate may drag. Replace the brake friction plate if the thickness is less than 0.236 inch (6 mm). See Figure 7-34.
  • Page 192 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Drive and Brake Brake Assembly 1. Position new friction plate in center of mounting plate. See Figure 7-36. 2. Install a 0.020 inch (0.508 mm) shim between a 0.709 inch (18 mm) spacer and mounting plate on each assembly screw.
  • Page 193 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Brake Drive and Brake This page intentionally left blank 00700-CL222-05, 1 5 March 2005...

  • Page 194: Electrical Components

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Electrical Components Electrical Components 00700-CL222-05, 1 5 March 2005...

  • Page 195: Battery Procedures

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Battery Procedures Electrical Components Battery Procedures When replacing battery cable ends, remove only one end at a time from the Before working on the battery, review connector, to avoid the cable ends Battery Safety, beginning on page 2-6.
  • Page 196 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Electrical Components Battery Procedures Inspect Battery Rollers 6. Remove battery with replacement device. Make sure the battery rollers turn freely. Clean off any electrolyte with a solution of 1 lb. (.45 kg) of baking soda added to 0.5 gal.
  • Page 197 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Battery Procedures Electrical Components Make sure the filler plugs are tight and the vent holes in the filler plugs are open. Maintenance For information on testing, charging, and maintaining your lift truck battery, consult the battery manufacturer's specifications and instruction manual.

  • Page 198: Motors (General)

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Motors (General) Electrical Components Motors (General) Never use a chemical solvent to clean a Motor Cleaning motor, as it can carry carbon dust to inaccessible areas and cause shorts within the motor.
  • Page 199 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Motors (General) Electrical Components Set up and rigidly adhere to a strict inspection 2. Check brush spring tension. See "Motor schedule to obtain the maximum efficiency Brush Spring Tension" on page 7-37.
  • Page 200 Toyota Orderpicker Model 7BPUE 1 5 Service Man ual Section 7. Component Procedures Electrical Components Motors (General) Motor Brush Spring Tension If the end of the brush is not already contoured to fit the commutator: Inspection 1. Turn the key switch OFF and disconnect the battery connector.
  • Page 201 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Electrical Components Motors (General) Commutator terminal securing nut to avoid twisting the stud. Motor Cable Securing Nut Fiber Securing Figure 7-50. View of Steer Motor Commutator Figure 7-5 1 . Motor Terminal...

  • Page 202: Drive Motor

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Drive Motor Electrical Components 9. Break seal between drive motor flange and Drive Motor drive unit. Use 2 screws from steer motor mounting plate. See Figure 7-54. Figure 7-53.
  • Page 203 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Drive Motor Electrical Components 12. If pinion needs to be installed: a. Clean threads using thread primer (P/N 00590-04963-7 1). b. Install the key and gear. c. Apply adhesive (P/N 00590-04964-71)to the threads.

  • Page 204: Lift Motor

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Lift Motor Lift Motor Removal 1. Turn key switch OFF and disconnect battery. 2. Remove tractor covers. See "Tractor Covers" on page 7- 1 1. : In the next steps you will need a 5 gallon 19 liter) capacity container.

  • Page 205: Steer Motor

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Steer Motor 9. Install new steer motor assembly on pivot Steer Motor ring. Secure with four bolts and adhesive Inspection Check brushes. Once brushes are removed, check commutator. See Figure 7-60.
  • Page 206 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Steer Motor Figure 7-63. Steer Motor and Gear Box, Disassembled Remove mounting bolt from pinion gear. See Figure 7-64. Note the number of shims located above and below the gear.
  • Page 207 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Steer Motor Electrical Components removed in step 3, and secure with the mounting bolt. Apply adhesive (P/N 00590-04964-71) on steer motor shaft. See Figure 7-65. 5. Install steer motor assembly. See "Steer Motor"...

  • Page 208: Traction Power Amplifier

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Traction Power Am p lifier Electrical Components 6. Remove traction power amplifier. See Figure 7-67. Remove 1. Turn key switch OFF and disconnect battery. 2. Remove top and tractor covers.
  • Page 209 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Contactors Electrical Components Remove Assembly This lift truck has two contactors, the PC and pump (P) contactors. The following procedtzres When repairing contactors, use only apply to either one.
  • Page 210 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Contactors and label if necessary for proper reinstallation. See Figure 7-7 6. Remove bus bars between contactors. See Figure 7-70. 7. Remove contactor coil wires (X and Y) by pulling wire connector.

  • Page 211: Contactor Tip Replacement

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Contactor Tip Replacement Electrical Components Disassembly Contactor Tip Replacement 7-73. Figure Pump Contactor Components 7. Remove nylon nuts (2) securing upper retaining blocks (2). See Figure 7-73. 7-72. Figure Contactor Components 8.
  • Page 212 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Contactor Tip Replacement Electrical Components Install new contact spring over insulator bushing. Install new fiber washer over rod assembly shaft. 5. Secure movable tip assembly with nut on top of core and rod assembly shaft.

  • Page 213: Fuses

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Fuses Auxiliary Power Fuses Fuses Replacement When replacing fuses, make sure fuses are installed in the proper order. See Figure 7-76. 7-76. Figure Fuse Locations Refer also to "Fuses" on page 5- 15.
  • Page 214 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Fuses Electrical Components 9. Mount the fuse holder plate with two thread-forming screws to the inside of the platform upright. See Figure 7-79. 7-79. Figure Close-up of Auxiliar y Power Fuse Holders 10.

  • Page 215: Circuit Cards (General)

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Circuit Cards (General) Electrical Components 2. Remove appropriate cover(s). See "Tractor Covers" on page 7- 1 1. 3. If removing a circuit card from tractor, remove circuit card cover.
  • Page 216 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Electrical Components Switches (General) Switches (General) While holding the two return springs in place, lift pedal straight up. Click here for information on updates switches 6. Remove the two screws mounting the...
  • Page 217 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Switches (General) Electrical Components 4. Loosen two screws on backside of EPO 4. Reconnect battery connector and check switch. operation. 5. Turn key switch OFF and disconnect 5. Hold lower half of switch, push in and battery connector.

  • Page 218: Warning Light

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Warning Light Electrical Components Warning Light Figure 7-85. Warning light Replace 1. Turn key switch OFF and disconnect battery. 2. Unplug warning light harness. See Figure 7-85. Cut cable ties.
  • Page 219 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Warning Light Electrical Components This page intentionally left blank 00700-CL222-05, 1 5 March 2005...

  • Page 220: Hydraulic Components

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Hydraulic Components Hydraulic Components 00700-CL222-05, 1 5 March 2005...

  • Page 221: Hydraulic Manifold

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Manifold Hydraulic Components Hydraulic Manifold 7-86. Figure Hydraulic Manifold location Lower the operator platform before removing the hydraulic manifold. Remove 1. Turn key switch OFF and disconnect battery.

  • Page 222: Hydraulic Reservoir

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Hydraulic Reservoir Hydraulic Components 5. Install tube weldment. Hydraulic Reservoir 6. Install strainer and filler breather cap. See Figure 7-87. Remove : To help prevent the hoses from slipping...

  • Page 223: Hydraulic Fluid

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Hydraulic Fluid Hydraulic Components Hydraulic Fluid b. Drain hydraulic fluid. See Figure 7-89. Insert drain plug in drain hose and fill the hydraulic reservoir with new fluid. See Replace "Lubrication Specification Chart"...

  • Page 224: Solenoid Valves

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Solenoid Valves Solenoid Valves 7-9 1 . Figure Solenoid Valves on Manifold Emergency Lowering Knob This knob allows you to lower the carriage without using the lower switch.

  • Page 225: Lift Pump And Motor

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures H y draulic Components Lift Pump and Motor Pump 6. Remove and replace both hydraulic fittings Lift Motor on the lift pump. Figure 7-93. Pump and Motor Connection 7. Apply molybdenum anti-seize compound surfaces of the lift motor spline and pump.

  • Page 226: Lift Pressure Relief Valve Adjustment

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Lift Pressure Relief Valve Adjustment required to lift maximum rated load (value recorded earlier). Adjustment increase pressure, turn adjusting screw clockwise. To decrease pressure, turn adjusting screw counterclockwise.

  • Page 227: Bleeding The Hydraulic System

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures H y draulic Components Bleeding the Hydraulic System Bleeding the Hydraulic 4. Repeat cylinder. the steps for the other side Connect battery and turn key switch ON. 6. Lower operator platform all way down to floor.

  • Page 228: Side Cylinder

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Side Cylinder Side Cylinder Remove the bolt in the top of the lift cylinder that connects it to the bracket on mast. 5. Elevate the platform until it clears the ram...
  • Page 229 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Side Cylinder Hydraulic Components 4. Pull piston until piston stop pushes Installation cylinder. See Figure 7-99. 2. Install the bolt that attaches the cylinder 5. Pull piston out of housing. Place piston on housing to the main frame of the truck.
  • Page 230 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Side Cylinder 10. Remove seal from cushion. See 12. Install spring. Make sure it is fully seated Figure 7- 100. in cushion piston. 13. Install cushion piston.
  • Page 231 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Side Cylinder Hydraulic Components Service guide, P/N 00590-45416-7 1 Seal Repacking 1. Remove cylinder. See "Side Cylinder" on page 7-65. Figure 7- 105. Using C y linder Service Tools 5.

  • Page 232: Center Cylinder

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Center Cylinder Center Cylinder 4. Install carriage. See "Three-Stage Carriage" on page 7-74. 5. Install end cap on center cylinder. Removal 6. Connect power and test lift function before returning truck to service.
  • Page 233 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Center Cylinder Hydraulic Components See View See View View View 7- 107. Figure Center Lift Cylinder, Three-Stage with Cushions Seal Replacement Install the retaining ring Refer to See Figure 7-107 on page 7-70 for the Installation following steps.

  • Page 234: Flow Control Valve

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Hydraulic Components Flow Control Valve Flow Control Valve 7. Place the hydraulic fitting in the valve housing block with the O-ring end first and tighten. Install hydraulic tubing. Remove blocks and bleed the hydraulic system.
  • Page 235 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Flow Control Valve Hydraulic Components This page intentionally left blank 00700-CL222-05, 1 5 March 2005...

  • Page 236: Mast Section

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Mast Section Mast Section 00700-CL222-05, 1 5 March 2005...

  • Page 237: Three-Stage Carriage

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Three-Stage Carriage Mast Section Three-Stage Carriage Do not dace hands between the masts before blockin the carriage. 6. Feed cable through carriage to tractor. Use extreme care whenever the truck is jacked up.
  • Page 238 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Three-Stage Carriage 7- 1 12. Figure 7- 1 14. Figure Underside of Carriage 4. Position platform 3 ft. (1 m) from floor. 5. Install rocker assembly, its associated hardware and chain on center cylinder.

  • Page 239: Mast Guard

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Three-Stage Carriage : There are 6 in.(152 mm) from the top of 9. Tie electric cables to platform. See O TE the spring on the carriage to the center Figure 1 16.
  • Page 240 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Three-Stage Carriage 7- 1 19: Figure Before chain goes slack 7- 120: Figure After chain goes slack for wear and replace if necessary. See the emergency lower valve. Lift the Figure 7- 120.
  • Page 241 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Inner Mast Mast Section lnner Mast mast Use extreme care whenever the truck is jacked up. Never block the truck between the mast and the floor. Keep hands and feet clear from vehicle while jacking the truck.
  • Page 242 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Inner Mast 5. Apply adhesive (P/N 00590-04964-7 1) to bolts and install chain pulleys. See 1. Line up bottom roller bearings in the outer Figure 7- 125.
  • Page 243 Toyota Orderpicker Model 7BPUE 15 Service Section 7. Component Procedures Manual Section lnner Mast Mast 10. Install cables and hoses. Attach cable ties to bracket on inner mast cable bracket. See Figure 7- 127. 7- 127. Figure Tie Points for Cables a n d Hoses on lnner masf 11.

  • Page 244: Outer Mast

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Outer Mast Outer Mast 6. Remove top bearing on main frame. 7. With a suitable hoist, remove outer mast. See Figure 7- 128. Installation Use extreme care whenever the truck is 1.

  • Page 245: Two-Stage Carriage

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Two-Stage Carriage Mast Section -Stage Carriage 8. Remove finger guard. See Figure 7- 130. Use extreme care whenever the truck is jacked up. Never block the truck between the mast and the floor. Keep hands and feet clear from vehicle while jacking the truck.
  • Page 246 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Two-Stage Carriage 11. Remove both chain pulleys from top of 4. Install stop a t top of mast. See cylinder. See Figure 7- 132. Figure 7- 133.

  • Page 247: Two-Stage Mast

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Two-Stage Mast Two-Stage Mast 3. Install stops to outside, top of main frame. 4. Install pulleys. 5. Install inner mast. See "Inner Mast" on page 7-78. 6. Install operator platform. See "Two-Stage Use extreme care whenever the truck is Carriage"...

  • Page 248: Mast Bearings

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Mast Bearings Mast Bearings If any marks are found within the masts or main frame where the rollers have been running, they should be removed with a sanding disk with 80 grit paper.
  • Page 249 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Mast Bearings Mast Section The shims used under each roller bearing come : If the bearings are worn or damaged, in the following sizes: thin, medium, and thick. replace them.

  • Page 250: Mast Disassembly And Shimming

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Mast Disassembly and Shimming Mast Disassembly and 9. Remove the main carriage by sliding it out the top of the inner mast. Set it aside for Shimming later reassembly.
  • Page 251 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Mast Disassembly and Shimming Mast Section 4. Use spare shim(s) as a gauge to determine 16. With the outer mast fully nested, use a pry the amount required to move the roller bar to check for bearing tightness.
  • Page 252 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Mast Disassembly and Shimming 8. Reinstall the roller bearings. Torque the retaining bolt. (See Table 7-2 on bolts per Table 7-2. page 7-86.) 9. Use a suitable lifting device and reinstall 18.
  • Page 253 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Mast Disassembly and Shimming Mast Section sure the carriage can be moved in and out by hand. 12. When the correct fit is obtained, measure Make sure all mast stops are installed...

  • Page 254: Lift Chains. Three-Stage

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Chains, Three-Stage Lift Side Cylinder Chains Lift Chains, Three-Stage Replace 1. Lift carriage enough to block between carriage and inner mast. Use extreme care whenever the truck is 2.
  • Page 255 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Lift Chains, Three-Stage Mast Section 7- 140. Figure Inside Chain Anchor, View from Operator Platform Remove block and hoist. 7. Connect power and test lift function before returning the truck to service.

  • Page 256: Lift Chains. Two-Stage

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Lift Chains, Two-Stage Lift Chains, Two-Stage 8. Connect power and test lift function before returning truck to service. Use extreme care whenever the truck is jacked up. Never block the truck between the mast and the floor.

  • Page 257: Forks

    Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Forks Mast Section Forks Install 1. Hold new fork in place underneath operator platform. Remove 1. Raise operator platform high enough to reach bottom of forks. 2. Block operator platform with 4 4"...
  • Page 258 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 7. Component Procedures Mast Section Pallet Clamp Pallet Clamp between the pallet clamp and the left hand pallet support. Torque the remaining hex nut to 2 1 ft. lbs. (29 Nm). 7- 145.
  • Page 259 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Load Wheels Mast Section Load Wheels Use extreme care whenever the truck is jacked up. Keep hands and feet clear of from the vehicle while jacking the truck. After the truck is jacked, place solid DO NOT blocks beneath it to support it.
  • Page 260 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Skid Pads Mast Section Skid Pads Location There are two skid pads on each truck. Inspection 1. Check clearance between each skid pad and floor. 2. If clearance is more than 3/4 inch (19.1 mm) on either side, replace skid pad.
  • Page 261 Section 7. Component Procedures Toyota Orderpicker Model 7BPUE 15 Service Manual Skid Pads Mast Section This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 262 Toyota Orderpicker Model Service Manual Section Wire Guidance Section Wire Guidance 00700-CL222-05, 1 5 2005 March...

  • Page 263: System Overview

    Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual System Overview System Overview Wire guidance is a means to automatically steer the truck while traveling in a n aisle. I t offers precise steering a t full-speed travel in very narrow aisle (VNA) applications.
  • Page 264 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Install Kit Components Install Kit Components Before installing kit components, turn the key switch OFF, disconnect the battery and remove the appropriate covers. : Once you install all the components,...
  • Page 265 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Install Kit Components Load Sensor Assembly 6. Connect the JW1 cable to the filter card. 1. Lift the platform, and securely place a safety stand under the platform. Lower the platform on the safety stand.

  • Page 266: Decals

    Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE 15 Service Manual Install Kit Components bolts for the pre-drilled holes. Connect to the filter card. Tractor Sensor Assembly, lnstalled Figure 5. Install the bumper plate. 6. Apply the bumper decal to the bumper plate a s shown in Figure 8-8.
  • Page 267 Toyota Orderpicker Model 7BPUE15 Service Manual Section 8. Wire Guidance Install Kit Components Feed the harness through the notch in the a. 3 lockwashers (P/N 00590-0285 1-7 1) housing. See Figure 8- 1 1. b. 3 washers (P/N 00590-03092-7 1) 8.
  • Page 268 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE 15 Service Manual Install Kit Components Installation 1. Clean the encoder shaft. Apply retaining 1. Remove the operator console cover. compound (Loctite 609) to the encoder 2. Remove the bezel. shaft. 3. From the backside of the bezel, use a hot 2.
  • Page 269 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Install Kit Components 8- 16. Figure 00700-CL222-05, 1 5 March 2005...

  • Page 270: Set-Up Procedure

    4. In the box that appears on the left, type in the 4-digit authorization code you 5. Type x to save these parameters and exit obtained from the Toyota Parts this menu. Distribution Center. 5. Type y a t the Wire Guidance prompt, and follow the instructions a t the bottom of the screen.
  • Page 271 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Set-Up Procedure Learn Guide Wire Frequency Learn Wire Guidance Offsets : Make sure the line driver is set up and : Make sure the line driver is set u p and adjusted properly.
  • Page 272 Toyota Orderpicker Model 7BPUE Service Manual Section Wire Guidance Set-Up Procedure 9. Drive the truck away from the guide wire. 9. Verify the horn chirps approximately 10 The truck has now learned the offsets and chirps per second and the center steer stored them in memory.

  • Page 273: Operator Display

    Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Codes and Tests Codes and Tests Operator Display Fault Codes The codes listed in this section that appear on the operator display pertain only to wire guidance. All other operator display codes are listed in the Codes and Tests section.
  • Page 274 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 0 , l GM operating correctly Code 0 , 2 correctly Code 0 , 3 Motor Current Code 0 , 4 pen circuit with switch in Auto 00700-CL222-05, 1 5...
  • Page 275 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 0,7 Code 0,7 Open circuit with switch in Auto Guidance Manager Fault Codes The fault codes on the following pages appear on the guidance manager display whenever a code 6,2 or 6,3 appear on the operator display.
  • Page 276 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Code 1 ,P Code 1 ,P Corrective Actions and Checks Run Learn Install a new Message goes away Guidance a n d truck tracks Steer Controller Card 00700-CL222-05, 1 5 March 2005...
  • Page 277 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,l Code Corrective Actions and Checks 10.5 to 13 volts Step 2 Replace STM Home prox over Troubleshoot Check metal per Code 3.6 adjustment of Home prox not over prox.
  • Page 278 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 9,2 Corrective Actions and Checks : Check the adjustment of the line driver. O TE Check for mechanical binding in the Drive Unit and Steering Gear Box. Run Learn for Guidance. Check settings for Heading Angle and Distance from wire in configure.
  • Page 279 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,2 Sensor removed Centered: 32 mV step 7 Replace mVAC (LR) Antenna Card 1.5 in Right; 76 mV Bumper removed Centered: 1.1V step 8 Replace Filter 1.5 in Left; 0.6V...
  • Page 280 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 9,3 Corrective Actions and Checks 00700-CL222-05, 1 5 2005 March...
  • Page 281 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,4 Code 9,4 Corrective Actions and Checks 00700-CL222-05, 1 5 March 2005...
  • Page 282 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 9,6 either the load or tractor sensors. Corrective Actions and Checks JPW2 and J P l T Step 2 Replace cable disconnected ohms JPW2 PW2- 1 5 PW2- 14 Step 3 Approx 1 1.5 volts...
  • Page 283 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,6 Controller card 00700-CL222-05, 1 5 March 2005...
  • Page 284 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 9,8 Corrective Actions and Checks No troubleshooting steps required. 00700-CL222-05, 1 5 2005 March...
  • Page 285 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,C Code 9,C Corrective Actions and Checks Step 2 Replace cable disconnected ohms JPW 1 PW2- 15 Step 3 Approx 1 1.5 volts Step 4 disconnected Filter card J P 1 -A13 Approx 1 1.5 volts...
  • Page 286 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Code 9,C Antenna Card 00700-CL222-05, 1 5 March 2005...
  • Page 287 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,E Code 9,E Corrective Actions and Checks Antenna Card 00700-CL222-05, 1 5 March 2005 8-26...
  • Page 288 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Code 9,E Sensor Centered: 70mV step 9 Replace mVAC 1.5 in Left; 1 OOmV Antenna Card 1.5 in Right; 1 OOmV Sensor removed Centered: 2.5V step 10 Replace filter 1.5 in Left;...
  • Page 289 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,F Code 9,F Corrective Actions and Checks 8- 17. Figure Steer Controller Card and Filter Card, Installed Filter card plugged Replace Steer If 5 volts is volts controller read all the...
  • Page 290 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Code 9,H Code 9,H Corrective Actions and Checks JPW2 and J P l T Step 2 Replace cable disconnected ohms JPW2 PW2- 1 5 PW2- 14 Step 3 Approx 1 1.5 volts...
  • Page 291 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,H Antenna Card...
  • Page 292 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 8. Wire Guidance Code 9,J Code 9,J Corrective Actions and Checks Step 2 Replace cable disconnected ohms JPW 1 Approx 1 1.5 volts Step 4 Step 3 disconnected Filter card Approx 1 1.5 volts...
  • Page 293 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,J Antenna Card...
  • Page 294 Toyota Orderpicker Model Service Manual Section Wire Guidance Code Code 9,K Corrective Actions and Checks JPW2 and J P l T Step 2 Replace cable disconnected ohms JPW2 Approx 1 1.5 volts Step 4 Step 3 disconnected Filter card Approx 1 1.5 volts...
  • Page 295 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Code 9,K Antenna Card...

  • Page 296: Tests

    Toyota Orderpicker Model Service Manual Section Wire Guidance Tests 9. If voltages are good in steps 7 and 8, replace the guidance manager. Speed Feedback Encoder Test Steer Feedback Encoder Test This test should be r u n when the guidance This test should be run when the guidance system is not functioning properly.
  • Page 297 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Tests 1. Park the truck directly over the guide wire. : The steer LEDs indicate which coil is being tested. See Figure 8- 18. To change 2. Turn the key switch OFF.
  • Page 298 Section Wire Guidance Toyota Orderpicker Model Service Manual General Troubleshooting General Troubleshooting To troubleshoot poor performance of wire guidance when no fault code is generated, follow these corrective actions and steps. : In the following step, consult the battery O TE manufacturer's recommendations for the specific gravity.
  • Page 300 Toyota Orderpicker Model Service Manual Section W i r e Guidance Troubleshooting in Flashware : Switching from manual to auto mode O TE clears the values for the parameters above. 00700-CL222-05, 1 5 2005 March...
  • Page 302 Toyota Orderpicker Model Service Manual Section Wire Guidance Theory of Operation The steer controller compares the strength of The HA and DFW settings may be changed in four guidance signals (TL,TR, LL, RR) and the Truck Configure Menu using Flashware determines the truck's distance from wire software.
  • Page 303 Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual Theory Operation The steer controller monitors the direction of travel (forward and reverse) by monitoring the travel speed encoder. This encoder is mounted on top of the drive motor and turns with the armature shaft.
  • Page 304 Toyota Orderpicker Model Service Manual Section Theory of Operation Section 9. Theory of Operation 00700-CL222-05, 1 5 2005 March...

  • Page 305: Control Handle

    Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual NOTES R E F E R E N C E P O W E R DISTRIBUTION DIAGRAM D20008910 DENT SHEET ZONE DESCRIPTION ELECTRICALLY RELEASED BRAKE CONTROL FUSE FOR B+PC, I 5 AMPS...
  • Page 306 Toyota Orderpicker Model Service Manual Section Theory of Operation DENT SHEET ZONE DESCRIPTION LOAD ANTENNA CONNECTOR TO FI L TER CARD TRACTOR ANTENNA CONNECTOR TO FI L TER CARD TRAVEL SPEED ENCODER CONNECTION TO GUIDANCE MANAGER POWER TO GUIDANCE MANAGER...
  • Page 307 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Battery Plugged In Battery Plugged In Refer to the schematic in Figure 9-2 on page 9-6. When a properly charged battery is connected to the truck battery positive is present with reference to TP4 (B-) a t the following points: 1.
  • Page 308 Toyota Orderpicker Model 7BPUE Service Manual Section Theory of Operation Battery Plugged In This page intentionally left blank 00700-CL222-05, 1 5 2005 March...
  • Page 309 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Battery Plugged In MANAGER STEER OIRI STEER DlR2 BOOST HOUR METER ENABLE DGND POWER SUPPLY Tracing! Legend Electrical Circuit = B+ = B- Circuit Signal Figure Battery Plugged In (Sheet 1 of...
  • Page 310 Toyota Orderpicker Model 7BPUE Service Manual Section Theory of Operation Battery Plugged In STEER NPUT ENCODER CARRIAGE MANAGER STEER NPUT ENCODER 1 DGND N /C N /C DGND DGND CONTROL HANDLE DGND DGND DGND ENCODER DGND DGND DGND HEARTBEAT Figure...
  • Page 311 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Battery Plugged In COLD STORAGE CARRIAGE CONTROL HANDLE JPC2 12 AGRD COLD STORAGE TRACTOR AGRD OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN ( E E ONLY] (OPTION] Figure...
  • Page 312 Toyota Orderpicker Model 7BPUE Service Manual Section Theory of Operation Battery Plugged In ..... . . COLD STORAGE LIGHTS AND FAN [OPTION)
  • Page 313 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Key Switch (S 1 Key Switch 5. The steer/tractor manager receives battery When the key switch is first turned on, the voltage and produces the following microprocessor control system performs a voltages: self-diagnostics of certain inputs and outputs.
  • Page 314 Toyota Orderpicker Model Service Manual Section Theory of Operation Key Switch controller micro processor, internal If a problem is detected, the steer/tractor circuitry, and the filter card. The 12 volts manager prevents truck operation and tells the is also supplied to: CM to display a corresponding fault code on the operator display.
  • Page 315 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Key Switch (S 1 Tracing Legend Electrical = B- Circuit Signal Figure Key Switch (Sheet 00700-CL222-05, 1 5 March 2005...
  • Page 316 Toyota Orderpicker Model Service Manual Section Theory of Operation Key Switch Figure (Cont.]. Key Switch On (Sheet 00700-CL222-05, 1 5 2005 March...
  • Page 317 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Key Switch (S 1 COLD STORAGE CARRIAGE COLD STORAGE TRACTOR I " OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN Figure Key Switch O n (Sheet 00700-CL222-05, 1 5 March 2005...
  • Page 318 Toyota Orderpicker Model Service Manual Section Theory of Operation Key Switch COLD STORAGE LIGHTS AND FAN [OPTION] ....... .
  • Page 319 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Closing Deadman Switches Closing Deadman tips, P-1 Switches MHA- 1 on the steer power head Drive motor (MD) armature terminal A1 Stepping on the deadman pedal closes M- terminal of traction power amplifier Drive motor (MD) armature terminal A2 travel, lift/lower and/or steer.
  • Page 320 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Closing Deadman Switches turns the drive unit to the physical stop. Current limit is invoked and a n error code is displayed. 10. The STM places the truck in a speed limit condition waiting to see inputs from the steer tiller.
  • Page 321 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Closing Deadman Switches MANAGER HOUR METER ENABLE Electrical = B- Circuit Signal Figure Closing Deadman Switches (Sheet 00700-CL222-05, 1 5 March 2005...
  • Page 322 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Closing Deadman Switches W/G AUTO MANUAL Figure 00700-CL222-05, 1 5 March 2005...
  • Page 323 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Closing Deadman Switches COLD STORAGE CARRIAGE CONTROL HWDLE WIRE GUIDANCE MANAGER [OPTION] COLD STORAGE TRACTOR OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN Figure 9-4 (Cont.). Closing Deadman Switches (Sheet...
  • Page 324 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Closing Deadman Switches COLD STORAGE LIGHTS AND FAN (OPTION] - - - - - - SUPPRESSOR N E W O R K T O F U 9 2...
  • Page 325 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theory of Operation Travel Travel traction power amplifier which will determine the drive motor field polarity to enable travel in the forward direction. General 3. The traction power amplifier will then drive...
  • Page 326 Toyota Orderpicker Model Service Manual Section Theory of Operation Travel Field current* M- shorted to B-* Battery under/over voltage: Less than +16 volts cuts down the output from the TPA and limits travel speed. Greater than +45 volts places the controller in a...
  • Page 327 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Travel MANAGER AGND STEER DIRl STEER DlR2 STEER DlR1 STEER DlR2 BOOST + BOOST STEER CURRENT LIMIT HEARTBEAT DISABLE DRIVE TRAVEL RE0 TRAVEL R E F WARN PAGE 2...
  • Page 328 Toyota Orderpicker Model Service Manual Section Theory of Operation Travel RELAY Figure 00700-CL222-05, 1 5 2005 March...
  • Page 329 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Travel COLD STORAGE CARRIAGE WIRE GUIDANCE MANAGER ( O P T W CONSOLE COLD STORAGE TRACTOR OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN Figure 00700-CL222-05, 1 5 March 2005...
  • Page 330 Toyota Orderpicker Model Service Manual Section Theory of Operation Travel COLD STORAGE LIGHTS AND FAN (OPTION] S U P P R E S S O R NEWORK TOFU92 SWITCH S U P P R E S S O R NETWORK...
  • Page 331 Section Theory of Operation Toyota Orderpicker Model Service Manual Steering Steering individual square waves are produced (CHA and CHB). The relationship between these two square waves tells the CM which way the The Steering Encoder is located on the steering wheel is turning. The number of pulses operator's carriage, behind the steering wheel.
  • Page 332 Toyota Orderpicker Model Service Manual Section Theory of Operation Steering The position of the drive wheel is indicated by the five LEDs on the operator display. These are based on the input from the steer feedback encoder. See Table 9- 1 on page 9-29...
  • Page 333 Section Theory of Operation Toyota Orderpicker Model Service Manual Steering MANAGER DGND STEER DIR2 STEER DR2 PWM BOOST S T E E R LIMIT BOOST HEARTBEAT STEER CURRENT F B DISABLE DRIVE TRAVEL R E F WARN BRAKE CTRL HORN CTRL...
  • Page 334 Toyota Orderpicker Model Service Manual Section Theory of Operation Steering Figure 00700-CL222-05, 1 5 2005 March...
  • Page 335 Section Theory of Operation Toyota Orderpicker Model Service Manual Steering COLD STORAGE CARRIAGE ----- CONTROL WIRE GUIDANCE MANAGER (OPTION] COLD STORAGE TRACTOR OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN Figure 00700-C L 2 2 2-05, 1 5 2 005 March...
  • Page 336 Toyota Orderpicker Model Service Manual Section Theory of Operation Steering COLD STORAGE LIGHTS AND FAN (OPTION] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 337 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual proportional solenoid valve coil a t ramp closed (this valve is normally open). The lift button commands the carriage to lift. See Figure 9-8 on page 9-35. When the lift button is pressed, the lift/lower proportional solenoid valve (normally open) 6.
  • Page 338 Toyota Orderpicker Model Service Manual Section Theory of Operation Figure on Steer/Tractor Controller 00700-CL222-05, 1 5 2005 March...
  • Page 339 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual MANAGER S T E E R DlR1 HEARTBEAT WARN PAGE 2 OPTION ONLY) PAGE 2 [WIRE GUIDANCE OPTION ONLY1 HORN H O U R METER ENABLE Electrical = B+...
  • Page 340 Toyota Orderpicker Model Service Manual Section Theory of Operation Lift Figure (Sheet 00700-CL222-05, 1 5 2005 March...
  • Page 341 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual COLD STORAGE CARRIAGE CONTROL WIRE GUIDANCE MANAGER (OPTION] COLD STORAGE TRACTOR r - - - - - I r - - - - - I OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN...
  • Page 342 Toyota Orderpicker Model Service Manual Section Theory of Operation COLD STORAGE LIGHTS AND FAN (OPTION] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 343 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual LEGEND Pressure L i n e s Return L i n e s 1 1 G P M FLOW CTRL Figure 00700-CL222-05, 1 5 March 2005...
  • Page 344 Toyota Orderpicker Model Service Manual Section Theory of Operation Lower 3. The steer/tractor manager provides the negative potential for the lift/lower proportional valve coil a t JPT12-8, The lower button commands the carriage to indicated by the load holding solenoid LED lower.
  • Page 345 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual This page intentionally left blank 00700-CL222-05, 1 5 March 2005...
  • Page 347 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual MANAGER STEER DlR1 STEER DlR2 STEER DIRl PWM STEER DlR2 LIMIT STEER CURRENT LIMIT STEER CURRENT FB DISABLE PC DRIVE TRAVEL RE0 TRAVEL PUMP SPARE WARN CTRL BRKE...
  • Page 348 Toyota Orderpicker Model Service Manual Section Theory of Operation S T E E R ENCODER H E I G H T 120"illo''S'~' CARRIAGE MANAGER DGND L E D L E D 7 HEIGHT l8O"SW LED 9 DGND LOWER LIMIT DGND...
  • Page 349 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual COLD STORAGE CARRIAGE CONTROL HANDLE WIRE GUIDANCE MANAGER ( O P T W WIRES COLD STORAGE TRACTOR r - - - - - I r - - - - - I...
  • Page 350 Toyota Orderpicker Model Service Manual Section Theory of Operation COLD STORAGE LIGHTS AND FAN (OPTION] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 351 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual 24" Limit Switch (56) 180" Limit Switch (525) (Optional) The 24" limit switch is mounted to the carriage, and the switch rail is mounted on the truck The 180" limit switch is included with the High frame 24"...
  • Page 352 Toyota Orderpicker Model Service Manual Section Theory of Operation Pump Sense The pump sense line monitors the status of the pump contactor a t all times. If the pump contactor is closed when commanded open, a n error code displays and the PC contactor opens.
  • Page 353 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Primary Memory Primary Memory c. If the test fails, the STM is not communicating and should be replaced. The primary memory location of the truck's identification and options are stored in the...
  • Page 354 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix b. Identifies possible causes for lack of Pinout Matrix proper signal. Normal Level: the approximate voltage that The pinout matrix chart lists functions and should be seen on that wire for the state normal voltages of terminals and harness indicated.
  • Page 355 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix in the top side of the H bridge S R T PSI -2. STEER Input to the STM telling it the steer power Steer CURRENT head has detected the steering system in steering.
  • Page 356 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix TRAVEL Same as J1 on traction amp. MDA2 SENSE Not used for anything. Contactor DGND Same as PSI on the steer power head. 12VP Same as PSI on the steer power head.
  • Page 357 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix CURRENT LIMIT Same as PSI on the steer power head. Same as PSI on the steer power head. Same as PSI on the steer power head.
  • Page 359 Toyota Orderpicker Model 7BPUE 15 Service Manual Section Theory of Operation Pinout Matrix motor stops rotating. That information is JPT12-4 DGND Battery negative for the control circuitry Steer on the steer power head. It comes from Power (B-) the STM.
  • Page 360 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix usable measurements available. measurable Connection for computer interface no No useful usable measurements available. voltages are measurable Not connected to any circuitry on the STM. 12VP Supplies working voltage to the lift lower Lift Lower pendant.
  • Page 361 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix Supplies B+ Key to the circuitry on the Carriage STM via the over mast cable when the key switch closed. Manager switch is closed. O V with key switch open.
  • Page 362 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix J PT6- 1 This is a square wave generated Voltage should Steer whenever there is movement of the Steer vary between Feedback Feedback Encoder. Voltage varies Encoder between about 4Vdc and about OVdc as as encoder shaft the encoder shaft rotates.
  • Page 363 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix 12VP Supplies working voltage to the Steer Steer Position Prox when B+Key is present on with key switch Position the STM. not present, check voltage at...
  • Page 364 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix Takes LED 6 to B- when the C M wants it LED Off=13V Carriage Displa y turned on. LED On=16.5V Manager Card WRT B+ JPC 1-5 Takes LED to B- when the C M wants it...
  • Page 365 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix the steer wheel is spun by the operator. The C M uses the quadrature phase A & relationship between CH B to determine direction and speed of steering requested.
  • Page 366 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix Not Connected AUTO Input from the switch (optional wire Switch closed Carriage Switch MANUAL guidance auto manual switch). Manager Switch open 5Vdc DGND to the S61 switch (optional wire...
  • Page 367 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 9. Theor y of Operation Pinout Matrix input to the STM. The STM determines the request for lift or lower and speed based on the learn values stored in the STM. Second s p eed shift or lower is activated at about 50% of the stroke on the pot.
  • Page 368 Section Theory of Operation Toyota Orderpicker Model Service Manual Pinout Matrix Carriage 1.3 V P Positive supply from the STM power Manager with key switch closed Switch closed Carriage Input from the 6 0 inch switch, S7. HEIGHT 6 0 in.
  • Page 369 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix her side you should see around 1.5 in. to the right you should see around around 75mVAC. Communication lines used by the steer No useful Steer...
  • Page 370 Toyota Orderpicker Model Service Manual Section Theory of Operation Pinout Matrix 12 V Positive supply for the antenna card from Steer Antenna the wire guidance manager power supply. Controller Card closed Card SHIELD Shield that helps reduces noise Steer Antenna...
  • Page 371 Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual Pinout Matrix A & relationship between CH B to determine direction and speed. 12 V Positive supply for the steer motor encoder Steer Steer from the wire guidance manager power...

  • Page 372: Firmware Configuration

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section 10. Firmware Configuration Section Firmware Configuration 00700-CL222-05, 1 5 March 2005...
  • Page 373 Toyota Orderpicker Model 7BPUE 15 Service Manual Section 10. Firmware Configuration FlashWare Program FlashWare Program We recommend using a surge protector Overview P C from possible electrostatic discharge The FlashWare program allows you to update or voltage surge. software, configure options and troubleshoot...
  • Page 374 Toyota Orderpicker Model Service Manual Section Appendix Section A. Appendix 00700-CL222-05, 1 5 2005 March...

  • Page 375: Appendix Lubrication Specification Chart

    Section Appendix Toyota Orderpicker Model 15 Service Manual Lubrication Specification Chart Lubrication Specification Chart Drive Unit Gear Case Synthetic 75W-90 Gear oil 00590-04835-7 1 (below 30" F/- Gear Oil API Service CE,CD,CC,SG,SF (1 qt./0.9 liter) 00590-04837-7 1 (above 30" F/- 1 (5 gal./ 18.9 liters)
  • Page 376 Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix Torque Chart Standard (Ferrous) Torque Chart Standard (Ferrous) 1 1/2-6 1940 1460 3160 2360 1 1/2-12 2200 1640 3560 2660 A- 1 . Figure Torque Chart - Standard Figure A- 1 (Conk).* NOTE: Use " o i l e d values for bolts with thread locking compound...

  • Page 377: Torque Chart . Standard (Brass)

    Section Appendix Toyota Orderpicker Model Service Manual Torque Chart Standard (Brass) Torque Chart Standard (Brass) A-2. Figure Torque Chart - Standard Brass Figure NOTE: Use "oiled" values for bolts with thread locking compound 2 005 00700-C L2 2 2-05, March...

  • Page 378: Torque Chart . Metric

    Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix Torque Chart Metric Torque Chart Metric A-3. Torque Chart - Ferrous Metric Figure Figure A-4. Figure Torque Chart - Brass Metric Figure A-4 (Conk).* NOTE: Use " oiled values for bolts with thread locking compound...

  • Page 379: Decimal Equivalent Chart

    Section Appendix Toyota Orderpicker Model Service Manual Decimal Equivalent Chart Decimal Equivalent Chart MM Equivalent Places A-5. Figure Decimal Equivalent Chart 00700-C L 2 2 2-05, 1 5 2 005 March...
  • Page 380 Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix Decimal Equivalent Chart A-5. Figure Decimal Equivalent Chart 00700-CL222-05, 1 5 March 2005...
  • Page 381 Section Appendix Toyota Orderpicker Model Service Manual Conversions To Convert.. Multiply.. Inches to Millimeters Inches x 25.4 Millimeters to Inches Millimeters x 0.039 Inches to Centimeters Inches x 2.54 Centimeters to Inches Centimeters x 0.394 Feet x 0.305 Feet to Meters Meters to Feet Meters x 3.281...
  • Page 382 Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix To Convert Multiply.. Kilograms to ounces Kilograms x 35.27 Pounds to Kilograms Pounds x 0.454 Kilograms x 2.2 Kilograms to pounds Pounds per Square Inch (PSI) to Kilopascals (kPa) Pounds per Square Inch x 6.894 Kilopascals to Pounds per Square Inch Kilopascals x 0.145...
  • Page 383 Section Appendix Toyota Orderpicker Model Service Manual This page intentionally left blank 2 005 00700-C L2 2 2-05, March...

  • Page 384: Electrical Schematics

    Section Appendix Toyota Orderpicker Model 7BPUE Service Manual Electrical Schematics Electrical Schematics 00700-CL222-05, 1 5 2005 March...
  • Page 385 MANAGER DGND A G N D STEER DIRI STEER DIR2 STEER DIRl P W M STEER DR2 P W M BOOST BOOST STEER CURRENT LIMIT HEARTBEAT STEERCURRENT FB DISABLE TRAVEL REQ TRAVEL REF WARN 1169 PC CTRL SPARE CTRL HORN HORN C P l PSENSE PCSENSE...
  • Page 386 Figure Elec. Schematic, Sheet Part 00700-CL222-05, 1 5 2005 March...
  • Page 387 COLD STORAGE CARRIAGE CONTROL HANDLE NEAR WIRE L E F T WIRES AGRD COLD STORAGE TRACTOR r - - - - - i AGRD PC-I OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN A-7. Figure Elec. Schematic, Sheet Part 00700-CL222-05, 1 5 2005 March...
  • Page 388 COLD STORAGE LIGHTS AND FAN (OPTION) ....... . SUPPRESSOR NETWORK T O F U 9 2 SUPPRESSOR NETWORK...
  • Page 390 IDENT. S H E E T ZONE DESCRIPTION JPI L LOAD ANTENNA CONNECTOR T O FILTER CARD JPIT T R A C T O R ANTENNA CONNECTOR T O F I L T E R CARD T R A V E L S P E E D ENCODER CONNECTION TO GUIDANCE MANAGER P O W E R T O GUIDANCE MANAGER GUIDANCE MANAGER CONNECTION T O CAN J P T 4...

  • Page 391: Hydraulic Schematic

    Hydraulic Schematic A-9. Figure Hydraulic Schematic 00700-CL222-05, 1 5 2005 March...
  • Page 392 Toyota Orderpicker Model Service Manual Index Index Chains 2-Stage 7-93 Center Cylinder. 3-Stage 7-91 Air Gap Adjustment. Brake 7-27 Side Cylinders. 3-Stage 7-91 Anti-Static Kit 2 . 9 . 2- 1 0 Circuit Cards 7 . 5 2 Armature 5- 1 2...
  • Page 393 Toyota Orderpicker Model 7BPUE 15 Service Manual Index ..........
  • Page 394 Toyota Orderpicker Model Service Manual Index Code 1. 6 . 9 Code 1. 6 . 9 Code 2 . 6 6 . 1 0 Fault Codes Code 3 . 3 Guidance Manager Code 4. 1 6 . 1 2 Code 1. P...
  • Page 395 Toyota Orderpicker Model 7BPUE 15 Service Manual Index ..Load Holding Solenoid. Theory 9-48 Hydraulic System ... . . Load Sensor Assembly Troubleshooting ..
  • Page 396 Toyota Orderpicker Model Service Manual Index Motors 7-35 to 7-44 Power Amplifier 5-17 Brush Spring Tension 7-37 Diagnostic History 5.20 Brushes 7-35 to 7-37 Fault Codes ....
  • Page 397 Index Toyota Orderpicker Model 7BPUE 15 Service Manual Software Tests Configuration 6.45 Electric Motor 5-11 Solenoid Valves 7.6 1 Motor Special Tools Grounded 5-12 Specifications Open Circuit 5-11 Speed Feedback Encoder Power Amplifier 5-21 Test 8-35 Speed Feedback Encoder 8-35 Stacked Fault Codes Steer Encoder.
  • Page 398 Toyota Orderpicker Model Service Manual Index Transport Wire Guidance Horizontal 2-13 Enable. Flashware Vertical 2-13 Guidance Parameter Setup Travel Functions Install Kit 8.3 to 8-8 Troubleshooting 5-33 Set-Up Procedure 8.9 to 8-11 Travel Pot (VR1) Wiring Harness 5.8 to 5-9...
  • Page 399 Index Toyota Orderpicker Model Service Manual This page intentionally left blank 00700-CL222-05, 1 5 2005 March...
  • Page 401 Printed in the...
  • Page 402 7BPUE15 GENERAL INFORMATION: A new Control Handle Interface Harness part number 00590-56284-71 is available. The new harness is more flexible. Trucks with serial numbers 7BPUE15-84640 and higher have the new harness installed during production. REPAIR INFORMATION: This harness can be installed on trucks with older serial numbers.
  • Page 403 Subject: Switch Replacement Page 1 of 3 MODEL APPLICATION: 6BPU15 and 7BPUE15 GENERAL INFORMATION: Switch part number 00590-02995-71 (used in multiple applications) is no longer available. If the switch is installed in a housing as shown in Figure 1, order Kit part number 00590-56871-71 which includes a replacement switch and the parts required for a field retrofit.
  • Page 404 Subject: Switch Replacement Page 2 of 3 Installation Instructions 1. Remove the connector from the switch assembly. 2. Remove and discard the old switch/housing assembly. See Figure 1. 3. Install new switch assembly (item 1). See Figure 2. Figure 2 4.
  • Page 405 Subject: Switch Replacement Page 3 of 3 d. Heat the shrink tubing until it is tight over the connection. See Figure 6. Figure 6 5. Connect the harness to the new switch. See Figure 7. Figure 7 6. Make sure the harness is secure and does not interfere with any moving parts. 7.
  • Page 406 Chassis Electrical CE17-005 August 31, 2017 Deadman Pedal Switch Replacement SERVICE INFORMATION BULLETIN 7BPUE15 Subject: Deadman Pedal Switch Replacement Page 1 of 4 MODEL APPLICATION: 7BPUE15 GENERAL INFORMATION: Deadman switch part number 00590-02995-71 is no longer available. Replace it with switch kit part number 00590-56969-71.
  • Page 407 Subject: Deadman Pedal Switch Replacement Page 2 of 4 INSTALLATION PROCEDURE A Switch Replacement for “Bolt-on” Type Deadman Pedal 1. Raise the carriage of the truck to a height the deadman pedal can easily be accessed. 2. Turn the key switch OFF and disconnect the battery connector. 3.
  • Page 408 Subject: Deadman Pedal Switch Replacement Page 3 of 4 INSTALLATION PROCEDURE B Switch Replacement for “Welded” Type Deadman Pedal 1. Raise the carriage of the truck to a height where the deadman pedal can easily be accessed. 2. Turn the key switch OFF and disconnect the battery connector. 3.
  • Page 409 Subject: Deadman Pedal Switch Replacement Page 4 of 4 9. The Normally Closed (NC) terminal of the new switch is not used. Cover it with shrink tubing (item 4) or install a Faston terminal (item 2) to insulate it as shown below. 10.
  • Page 410 CE18-005 April 30, 2018 7BPUE15 Mast Cables SERVICE INFORMATION BULLETIN 7BPUE15 Subject: 7BPUE15 Mast Cables Page 1 of 2 MODEL APPLICATION: 7BPUE15 GENERAL INFORMATION: The 12 conductor “Over the Mast Cable” is no longer available. The replacement is two 8 conductor cables available in a kit listed below.
  • Page 411 Subject: 7BPUE15 Mast Cables Page 2 of 2 INSTALLATION: 1. Mount the new pulley (Item 3) next to the original pulley. 2. Run one cable over the new pulley and the other cable over the original pulley. 3. Make sure that the cables run parallel to each other and do not cross.

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