Toyota 7BPUE15 Manuals

Manuals and User Guides for Toyota 7BPUE15. We have 1 Toyota 7BPUE15 manual available for free PDF download: Service Manual

Toyota 7BPUE15 Service Manual

Toyota 7BPUE15 Service Manual (412 pages)

Serial No. 80,001 and up

Brand: Toyota | Category: Lifting Systems | Size: 9.95 MB

Table of Contents

Table of Contents
10
How to Use this Manual

14
- Map of the Manual
  15
- Manual Design
  17
- Page Revision Page
  18
- START Page
  20
Safety

22
- Definitions
  23
- General Safety
  24
- Battery Safety
  27
  - Static Safety
    30
  - ESD Plug on Operator Console
    30
  - ESD Plug on Tractor
    30
  - Jacking Safety
    32
  - Tractor
    32
  - Operator Platform
    32
  - Baseleg
    33
- Tie-Down for Transport
  34
  - Vertical Transport
    34
  - Horizontal Transport
    34
  - Eye-Bolts Installed for Transport
    34
- Towing a Disabled Unit
  35
  - Location for Release Bolts in Brake
    35
  - Brake Release Bolts
    35
- Welding Safety
  36
- Systems Overview
  38
- Vehicle Specification
  39
- Mast Specifications
  40
- General System Data
  42
  - Carriage
    42
  - Chassis
    42
- Installation Instructions
  44
- Wire Guidance
  45
- Cold Storage
  46
  - Heater Assemblies
    46
  - Cold Storage Schematic Legend
    46
- UL Label "EE
  48
- Special Tools
  49
  - Ram Service Tools
    49
  - Pin Extractor
    49
  - Lift/Lower Pendant
    49
Planned Maintenance

50
- Maintenance Guidelines
  51
- Interval 1
  52
- Interval 2
  53
- Interval 3
  57
- Troubleshooting
  58
Troubleshooting

59
- How to Use this Chapter
  59
- Electrical Troubleshooting Guidelines
  60
- Shorts to Frame Test
  61
- To Test for Shorts to Frame
  61
- Troubleshooting Wiring Problems
  65
  - Power Cables
    65
  - Wiring Harness
    65
- Switches (General)
  67
  - Typical Hall Effect Switch
    67
  - Hall Effect Switch Schematic
    67
  - Key Switch
    67
- Electric Motor Tests
  68
  - Open Circuit Motor Test
    68
  - Motor Types
    68
  - Motor Circuits
    68
  - Short-Circuited Armature or Field Winding
    69
  - Grounded Motor Test
    69
- Battery Discharge Indicator (BDI)
  70
- Setting Battery State-Of -Charge Cutout
  71
- Contactors
  72
  - Testing Resistance
    72
  - Fuses
    72
- Hydraulic Troubleshooting Guidelines
  73
  - Continuity
    74
  - Pulse Width Modulation
    74
  - Short Circuit or "Short"
    74
  - Undertemperature
    74
- Definitions
  74
- Electrical Connector Locator Chart
  75
- Programmable Maintenance Tool
  77
  - Diagnostic History
    77
  - Test Mode
    78
  - Clear
    78
  - Modes of Operation
    79
  - Diagnostics and Special Diagnostics List
    79
  - Special Program Mode
    80
  - Programming
    81
  - Traction Power Amplifier Parameters
    81
- Drive Unit Troubleshooting Guide
  82
- Troubleshooting Flowcharts
  84
- End of Troubleshooting Procedure
  86
- Symptom Tables: Hydraulic Functions
  88
  - Lift Function
    88
  - Motor Runs, no Codes
    88
  - Motor Does Not Run, no Codes
    88
  - Unable to Pick up a Load; Lift Pump Runs; Travel OK
    89
  - Lower Function
    89
  - No Lower, Lift and Travel OK
    89
  - Load Drifting/Settling
    89
- Symptom Tables: Travel Functions
  90
  - Slow or Sluggish Acceleration
    90
  - Slow Travel; Lift/Lower
    90
- Symptom Tables: Electrical Symptoms
  91
Codes and Tests

92
- Battery Indicator Messages
  93
- Operator Display Messages
  93
  - Steering Lndicator Messages
    93
  - Fault Code
    94
  - Info Display
    94
- Maintenance Mode
  95
  - Deadman Pedal Method
    95
  - General Testing
    95
  - Horn Button Method
    95
  - Toyota Orderpicker Model 7BPUE15 Service Manual
    95
    
    Learning Throttle
    96
    
    Steer Encoder Test
    96
    
    Throttle Potentiometer Test
    96
  - Corrective Actions and Checks
    97
  - TPA Code LED off
    97
- Traction Power Amplifier Fault Codes
  97
  - T P a Code Heartbeat
    98
  - T P a Code LED Solid on
    98
  - TPA Code 1,3
    100
- Operator Display Fault Codes
  106
- Code 6,2
  140
Component Procedures

142
- List of Component Procedures
  145
Component Locator Photos

148
Covers and Finish

154
- Tractor Covers
  154
- Top Cover Removal
  154
- Operator Console Cover
  155
- Mast Guard
  156
- Decals
  157
Steering and Controls

158
- Replacing Operator Display
  159
- Control Handle
  160
  - Cover Retaining Screw - Top
    160
  - Cover Retaining Screws - Bottom
    160
  - Anti-Rotate Tab
    161
  - Horn Switch Removal
    161
  - Travel Pot
    162
  - Travel Pot Bracket Screws
    162
  - Travel Pot Cover Removal
    162
  - Travel Pot Enclosure (Cover Removed)
    162
  - Travel Spring and Pinion
    163
  - Control Handle Checks
    164
  - Plate Ground
    164
  - Hand Soldering Procedures
    165
Driveandbrake

166
- Drive Unit
  167
- Drive Unit Drain Plug
  167
- Drive Unit Mounting Bolts (Four Shown)
  167
- Drive Unit - Standard
  168
- Pivot Ring Inspection
  168
- Removing Drive Unit
  168
- Inspect Housing for Hub Wear
  169
- Pivot Ring Disassembly
  169
- Pivot Ring Removal
  169
- Remove Steel Ball Bearings
  169
- Drive Unit Housing Disassembly
  170
- Grease Fitting Removal
  170
- Radial and Thrust Ring Removal
  170
- Roll Pin Removal
  170
- Axle Shaft and Bevel Gear Removal
  171
- Radial Ring Removal
  171
- Remove Axle from Housing
  171
- Turn Clamp Nut off
  171
- Lift out Bevel Gear
  172
- Remove Clamp Nut
  172
- Remove Spiral Pinion
  172
- Spiral Gear and Helical Gear Removal
  172
- Bearing Cup and Shim Removal
  173
- Lift Helical Gear from Housing
  173
- Spiral Gear Bearing Cup Removal
  173
- Axle Shaft Disassembly
  174
- Bearing Removal
  174
- Housing Cleaning and Inspection
  174
- Spur Gear Removal
  174
- Bevel Gear Disassembly
  175
- Spiral Gear Disassembly
  175
- Assembly Procedures
  176
- Calculate Shim Formulas
  176
- Gear Set Assembly
  176
- Bevel Gear Shim Calculation
  177
- Check Zero Offset of Bevel Gear
  178
- Drive in Bearing Cup
  178
- Housing Bearing Cup and Shim Assembly
  178
- Helical Gear/Spiral Pinion Gear Assembly
  179
- Install Helical Gear
  179
- Applying Locking Compound to Set Screw
  180
- Axle Assembly
  180
- Install Clamp Nut
  180
- Removing End Play
  180
- Axle Bearing Cone Installation
  181
- Axle Seal Installation
  181
- Bevel Gear Installation
  181
- Gear Locking Tool
  182
- Dial Indicator Position
  183
- Install Spherical Bearing
  183
- Pivot Ring Assembly
  183
- Spherical Bearing Alignment
  183
- Brass Bushing Installation
  184
- Drive Unit Assembly
  184
- Roll Pin Installation
  184
- Ball Bearing Installation
  185
- Bearing Filler Plug Installation
  185
- Pivot Ring Installation
  185
- Filler Plug Bolt Installation
  186
- Housing Cover Installation
  186
- Tighten Cover Bolts
  186
- Drive Tire Replacement
  188
- Drive Wheel
  188
- Drive Wheel Mounting Bolts
  188
- Brake
  190
  - Brake Air Gap Adjustment
    190
  - Measuring Brake Air Gap
    190
  - Brake Friction Plate (Rotor)
    191
  - Disassembling the Brake
    191
  - Brake Assembly, Detail View
    192
Electrical Components

194
- Battery Procedures
  195
  - Battery Connector/Cables
    195
  - Battery Removal
    195
  - Removing Battery Cable from Connector
    195
  - Battery Exterior Cleaning
    196
  - Battery Installation
    196
  - Inspect Battery Rollers
    196
  - Replace Battery Rollers
    196
  - Battery Filler Plugs and Vent Holes
    197
  - Battery Discharge Indicator
    197
- Motors (General)
  198
  - Motor Cleaning
    198
  - Motor Brushes
    198
  - Motor Brush Location
    198
  - Drive Motor Brushes, Location
    199
  - Steer Motor Brushes, Location
    199
  - Lift Motor Brushes, Location
    199
  - Motor Brush Spring Tension
    200
  - Motor Brush, Steer Motor
    200
  - Motor Brush Spring Tension Inspection
    200
  - Commutator
    201
  - View of Steer Motor Commutator
    201
  - Terminal Nuts
    201
- Drive Motor
  202
  - Removing Dipstick
    202
  - Bottom of Drive Motor
    202
  - Connecting Drive Motor to Truck Systems
    203
- Lift Motor
  204
  - Pump-To-Motor Connection
    204
  - Lift Motor Connections
    204
  - Bottom of Pump
    204
- Steer Motor
  205
  - Separating Steer Motor from Gear Box
    205
  - Steer Motor Mounting
    205
  - Steer Motor Commutator, Brushes Removed
    205
  - Pinion Gear
    206
  - Steer Motor Mounting Shaft
    206
  - Steer Motor Pinion Gear
    206
- Traction Power Amplifier
  208
- Contactors
  209
- Install Assembly
  210
- Contactor Tip Replacement
  211
  - Pump Contactor Components
    211
  - Contactor Components
    211
  - Contactor Assembly
    212
  - Auxiliary Power Fuses
    213
  - Fuse Locations
    213
  - Fuse Plate Mounting and Cable Routing
    213
  - Close-Up of Auxiliary Power Fuse Holders
    214
  - Steer Power Head Circuit Cart
    215
  - Carriage Manager in Operator Console
    215
- Circuit Cards (General)
  215
- Switches (General)
  216
- Warning Light
  218
Hydraulic Components

220
- Hydraulic Manifold
  221
- Hydraulic Manifold Location
  221
- Hydraulic Reservoir
  222
- Hydraulic Reservoir, Installed
  222
- Hydraulic Fluid
  223
  - Cold Storage Hydraulic Fluid
    223
  - Drain Plug, Hydraulic Reservoir
    223
  - Draining Hydraulic Fluid
    223
- Solenoid Valves
  224
  - Emergency Lowering Knob
    224
  - Solenoid Valves on Manifold
    224
- Lift Pump and Motor
  225
  - Pump and Motor Connection
    225
  - Pump Location
    225
- Lift Pressure Relief Valve Adjustment
  226
- Adjusting Lift Pressure
  226
- Bleeding the Hydraulic System
  227
  - Center Cylinder
    227
  - Side Cylinder
    227
  - Bottom View of Housing (Using Mirror)
    228
  - Hydraulic Connection, Side Cylinder, Bottom
    228
  - Cushion Service
    229
  - Cushion, Removed
    229
  - Piston Removal
    229
  - Cushion Assembly
    230
  - Twisting Fiber Rings
    230
  - Seal Repacking
    231
  - Packing Components on Side Cylinder
    231
  - Using Cylinder Service Tools
    231
  - Service of Cylinder with Cushions
    232
  - Cushion Replacement
    232
- Center Cylinder
  232
  - Seal Replacement
    233
  - Center Lift Cylinder, Three-Stage with Cushions
    233
- Flow Control Valve
  234
  - Flow Control Valve Location
    234
  - Replacing Flow Control Valve
    234
Mast Section

236
- Three-Stage Carriage
  237
  - Electrical Over-The-Mast Cable
    237
  - Center Cylinder Ride Spring Chain Anchors
    239
  - Before Chain Goes Slack
    240
  - After Chain Goes Slack
    240
  - Lnner Mast
    241
  - Bottom Chain Anchor Block
    241
  - Lower Chain Anchor Block
    242
- Outer Mast
  244
- Mast Stop
  244
- Two-Stage Carriage
  245
- Finger Guard
  245
- Two-Stage Mast
  247
- Top of Mast, Tractor Side
  247
- Mast Bearings
  248
- Mast Disassembly and Shimming
  250
  - Shimming Main Frame to Outer Mast
    250
  - Shimming Outer Mast to Inner Mast
    251
  - Shimming Inner Mast to Carriage
    252
  - Lift Chains, Three-Stage
    254
  - Center Cylinder Chain
    254
  - Side Cylinder Chains
    254
  - Lift Chains, Two-Stage
    256
  - Unbolting Forks
    256
  - Outside Chain Anchor, Side View
    256
- Forks
  257
  - Installing Forks and Shims
    257
  - Snap Ring, Pivot Pi N and Mounting Block
    257
  - Pallet Clamp
    258
    
    Pallet Clamp Assembly, Underside
    258
    
    Load Wheels
    259
    
    Skid Pads
    260
Wire Guidance

262
- System Overview
  263
  - Guidance Manager
    264
  - Guidance Manager, Installed
    264
  - Steer Controller Card
    264
- Install K T Components
  264
  - Load Sensor Assembly
    265
  - Tractor Sensor Assembly
    265
  - Bumper Plate, Location
    265
  - Tractor Sensor Assembly, Lnstalled
    266
  - Speed Encoder
    266
  - Bumper Decal, Location
    266
  - Steer Encoder
    267
  - Top of Steer Motor
    267
  - Auto/Manual Switch
    268
  - Steer Encoder, Installed
    268
  - Auto/Manual Switch Cable
    268
- Set-Up Procedure
  270
  - Guidance Parameter Setup
    270
  - Enable Wire Guidance in Flashware
    270
  - Learn Guide Wire Frequency
    271
  - Learn Wire Guidance Offsets
    271
  - Guidance Check
    272
  - Code 0,7
    275
  - Guidance Manager Fault Codes
    275
  - Code 9,2
    278
  - Code 9,3
    280
  - Code 9,4
    281
  - Code 9,6
    282
  - Code 9,8
    284
  - Code 9,C
    285
  - Code 9,E
    287
  - Code 9,F
    289
  - Code 9,H
    290
  - Code 9,J
    292
  - Code 9,K
    294
  - Speed Feedback Encoder Test
    296
  - Steer Feedback Encoder Test
    296
  - Wire Guidance Sensor Test
    296
- General Troubleshooting
  298
  - Troubleshooting in Flashware
    299
  - Wire Guidance Diagnostics Screen
    299
- Troubleshooting in Flashware 8 . 3
  300
  - Theory of Operation
    301
  - Functional Overview
    301
  - System Description
    301
  - Distance from Wire Settings
    302
- Theory of Operation
  304
- Battery Plugged in
  307
- Key Switch on
  313
- Closing Deadman Switches
  319
- Travel
  325
- Moving Directional/Speed Control
  325
- Steering
  331
  - Steer Position Encoder Output
    331
  - Tracing Legend
    333
- Lift/Lower
  337
  - Lower
    344
  - 24" Limit Switch (56)
    351
  - Lift Limit Switch
    351
  - Lift Limit Bypass Switch
    351
  - Pump Contactor
    351
  - Pump Sense
    352
  - Flow Control Valves
    352
  - Oil Filter Check Valve
    352
  - Rel-1
    352
- Primary Memory
  353
- Pinout Matrix
  354
Firmware Configuration

372
- Flashware Program
  373
  - Requirements
    373
  - Install Flashware on PC
    373
  - Starting Flashware
    373
Appendix

374
- Lubrication Specification Chart
  375
- Torque Chart . Standard (Ferrous
  376
- Torque Chart . Standard (Brass
  377
- Torque Chart . Standard (Brass)
  377
- Torque Chart . Metric
  378
- Decimal Equivalent Chart
  379
- Conversions
  381
- Standard/Metric Conversions
  383
- Electrical Schematics
  
  384
- Hydraulic Schematic
  
  391

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