Table Of Contents - Toyota 7BPUE15 Service Manual

Table of Contents

Table Of Contents10
How To Use This Manual14
Map Of The Manual15
Manual Design17
Page Revision Page18
Start Page20
Safety22
Definitions23
General Safety24
Battery Safety27
Static Safety30
Esd Plug On Operator Console30
Esd Plug On Tractor30
Jacking Safety32
Tractor32
Operator Platform32
Baseleg33
Tie-Down For Transport34
Vertical Transport34
Horizontal Transport34
Eye-Bolts Installed For Transport34
Towing A Disabled Unit35
Location For Release Bolts In Brake35
Brake Release Bolts35
Welding Safety36
Systems Overview38
Vehicle Specification39
Mast Specifications40
General System Data42
Carriage42
Chassis42
Installation Instructions44
Wire Guidance45
Cold Storage46
Heater Assemblies46
Cold Storage Schematic Legend46
Ul Label "Ee48
Special Tools49
Ram Service Tools49
Pin Extractor49
Lift/Lower Pendant49
Planned Maintenance50
Maintenance Guidelines51
Interval 152
Interval 253
Interval 357
Troubleshooting58
How To Use This Chapter59
Electrical Troubleshooting Guidelines60
Shorts To Frame Test61
To Test For Shorts To Frame61
Troubleshooting Wiring Problems65
Power Cables65
Wiring Harness65
Switches (General)67
Typical Hall Effect Switch67
Hall Effect Switch Schematic67
Key Switch67
Electric Motor Tests68
Open Circuit Motor Test68
Motor Types68
Motor Circuits68
Short-Circuited Armature Or Field Winding69
Grounded Motor Test69
Battery Discharge Indicator (Bdi)70
Setting Battery State-Of -Charge Cutout71
Contactors72
Testing Resistance72
Fuses72
Hydraulic Troubleshooting Guidelines73
Continuity74
Pulse Width Modulation74
Short Circuit Or "Short"74
Undertemperature74
Electrical Connector Locator Chart75
Programmable Maintenance Tool77
Diagnostic History77
Test Mode78
Clear78
Modes Of Operation79
Diagnostics And Special Diagnostics List79
Special Program Mode80
Programming81
Traction Power Amplifier Parameters81
Drive Unit Troubleshooting Guide82
Troubleshooting Flowcharts84
End Of Troubleshooting Procedure86
Symptom Tables: Hydraulic Functions88
Lift Function88
Motor Runs, No Codes88
Motor Does Not Run, No Codes88
Unable To Pick Up A Load; Lift Pump Runs; Travel Ok89
Lower Function89
No Lower, Lift And Travel Ok89
Load Drifting/Settling89
Symptom Tables: Travel Functions90
Slow Or Sluggish Acceleration90
Slow Travel; Lift/Lower90
Symptom Tables: Electrical Symptoms91
Electrical Motors91
Motor Overheating91
Display Is Dark; Lift Truck Is Not Operational91
Codes And Tests92
Steering Lndicator Messages93
Battery Indicator Messages93
Operator Display Messages93
Fault Code94
Info Display94
Maintenance Mode95
General Testing95
Horn Button Method95
Deadman Pedal Method95
Toyota Orderpicker Model 7Bpue15 Service Manual95
Throttle Potentiometer Test96
Learning Throttle96
Steer Encoder Test96
Traction Power Amplifier Fault Codes97
Tpa Code Led Off97
Corrective Actions And Checks97
T P A Code Led Solid On98
T P A Code Heartbeat98
Tpa Code 1,3100
Operator Display Fault Codes106
Code 6,2140
Component Procedures142
List Of Component Procedures145
Component Locator Photos148
Covers And Finish154
Tractor Covers154
Top Cover Removal154
Operator Console Cover155
Mast Guard156
Decals157
Steering And Controls158
Replacing Operator Display159
Control Handle160
Cover Retaining Screws - Bottom160
Cover Retaining Screw - Top160
Anti-Rotate Tab161
Horn Switch Removal161
Travel Pot162
Travel Pot Bracket Screws162
Travel Pot Cover Removal162
Travel Pot Enclosure (Cover Removed)162
Travel Spring And Pinion163
Plate Ground164
Control Handle Checks164
Hand Soldering Procedures165
Driveandbrake166
Drive Unit167
Drive Unit Drain Plug167
Drive Unit Mounting Bolts (Four Shown)167
Drive Unit - Standard168
Pivot Ring Inspection168
Removing Drive Unit168
Pivot Ring Disassembly169
Inspect Housing For Hub Wear169
Remove Steel Ball Bearings169
Pivot Ring Removal169
Drive Unit Housing Disassembly170
Radial And Thrust Ring Removal170
Grease Fitting Removal170
Roll Pin Removal170
Radial Ring Removal171
Axle Shaft And Bevel Gear Removal171
Turn Clamp Nut Off171
Remove Axle From Housing171
Spiral Gear And Helical Gear Removal172
Remove Clamp Nut172
Lift Out Bevel Gear172
Remove Spiral Pinion172
Bearing Cup And Shim Removal173
Lift Helical Gear From Housing173
Spiral Gear Bearing Cup Removal173
Spur Gear Removal174
Bearing Removal174
Housing Cleaning And Inspection174
Axle Shaft Disassembly174
Bevel Gear Disassembly175
Spiral Gear Disassembly175
Assembly Procedures176
Gear Set Assembly176
Calculate Shim Formulas176
Bevel Gear Shim Calculation177
Housing Bearing Cup And Shim Assembly178
Check Zero Offset Of Bevel Gear178
Drive In Bearing Cup178
Helical Gear/Spiral Pinion Gear Assembly179
Install Helical Gear179
Axle Assembly180
Install Clamp Nut180
Applying Locking Compound To Set Screw180
Removing End Play180
Axle Seal Installation181
Bevel Gear Installation181
Axle Bearing Cone Installation181
Gear Locking Tool182
Pivot Ring Assembly183
Dial Indicator Position183
Spherical Bearing Alignment183
Install Spherical Bearing183
Drive Unit Assembly184
Roll Pin Installation184
Brass Bushing Installation184
Bearing Filler Plug Installation185
Ball Bearing Installation185
Pivot Ring Installation185
Housing Cover Installation186
Filler Plug Bolt Installation186
Tighten Cover Bolts186
Drive Wheel188
Drive Wheel Mounting Bolts188
Drive Tire Replacement188
Brake190
Brake Air Gap Adjustment190
Measuring Brake Air Gap190
Brake Friction Plate (Rotor)191
Disassembling The Brake191
Brake Assembly, Detail View192
Electrical Components194
Battery Procedures195
Battery Connector/Cables195
Battery Removal195
Removing Battery Cable From Connector195
Battery Exterior Cleaning196
Battery Installation196
Inspect Battery Rollers196
Replace Battery Rollers196
Battery Filler Plugs And Vent Holes197
Battery Discharge Indicator197
Motors (General)198
Motor Cleaning198
Motor Brushes198
Motor Brush Location198
Drive Motor Brushes, Location199
Steer Motor Brushes, Location199
Lift Motor Brushes, Location199
Motor Brush Spring Tension200
Motor Brush, Steer Motor200
Motor Brush Spring Tension Inspection200
Commutator201
View Of Steer Motor Commutator201
Terminal Nuts201
Drive Motor202
Removing Dipstick202
Bottom Of Drive Motor202
Connecting Drive Motor To Truck Systems203
Lift Motor204
Pump-To-Motor Connection204
Lift Motor Connections204
Bottom Of Pump204
Steer Motor205
Separating Steer Motor From Gear Box205
Steer Motor Mounting205
Steer Motor Commutator, Brushes Removed205
Pinion Gear206
Steer Motor Mounting Shaft206
Steer Motor Pinion Gear206
Traction Power Amplifier208
Install Assembly210
Contactor Tip Replacement211
Pump Contactor Components211
Contactor Components211
Contactor Assembly212
Auxiliary Power Fuses213
Fuse Locations213
Fuse Plate Mounting And Cable Routing213
Close-Up Of Auxiliary Power Fuse Holders214
Steer Power Head Circuit Cart215
Carriage Manager In Operator Console215
Circuit Cards (General)215
Warning Light218
Hydraulic Components220
Hydraulic Manifold221
Hydraulic Manifold Location221
Hydraulic Reservoir222
Hydraulic Reservoir, Installed222
Hydraulic Fluid223
Cold Storage Hydraulic Fluid223
Drain Plug, Hydraulic Reservoir223
Draining Hydraulic Fluid223
Solenoid Valves224
Emergency Lowering Knob224
Solenoid Valves On Manifold224
Lift Pump And Motor225
Pump And Motor Connection225
Pump Location225
Lift Pressure Relief Valve Adjustment226
Adjusting Lift Pressure226
Bleeding The Hydraulic System227
Center Cylinder227
Side Cylinder227
Bottom View Of Housing (Using Mirror)228
Hydraulic Connection, Side Cylinder, Bottom228
Cushion Service229
Cushion, Removed229
Piston Removal229
Cushion Assembly230
Twisting Fiber Rings230
Seal Repacking231
Packing Components On Side Cylinder231
Using Cylinder Service Tools231
Service Of Cylinder With Cushions232
Cushion Replacement232
Seal Replacement233
Center Lift Cylinder, Three-Stage With Cushions233
Flow Control Valve234
Flow Control Valve Location234
Replacing Flow Control Valve234
Mast Section236
Three-Stage Carriage237
Electrical Over-The-Mast Cable237
Center Cylinder Ride Spring Chain Anchors239
Before Chain Goes Slack240
After Chain Goes Slack240
Lnner Mast241
Bottom Chain Anchor Block241
Lower Chain Anchor Block242
Outer Mast244
Mast Stop244
Two-Stage Carriage245
Finger Guard245
Two-Stage Mast247
Top Of Mast, Tractor Side247
Mast Bearings248
Mast Bearings And Shims248
Staging Of Mast Prior To Shimming Bearings248
Upper Mast Bearing Replacement249
Mast Bearing Stud Retaining Bolt Torque Values249
Mast Disassembly And Shimming250
Shimming Main Frame To Outer Mast250
Shimming Outer Mast To Inner Mast251
Shimming Inner Mast To Carriage252
Lift Chains, Three-Stage254
Center Cylinder Chain254
Side Cylinder Chains254
Lift Chains, Two-Stage256
Unbolting Forks256
Outside Chain Anchor, Side View256
Forks257
Installing Forks And Shims257
Snap Ring, Pivot Pi N And Mounting Block257
Pallet Clamp258
Pallet Clamp Assembly, Underside258
Load Wheels259
Skid Pads260
System Overview263
Guidance Manager264
Guidance Manager, Installed264
Steer Controller Card264
Install K T Components264
Load Sensor Assembly265
Tractor Sensor Assembly265
Bumper Plate, Location265
Tractor Sensor Assembly, Lnstalled266
Speed Encoder266
Bumper Decal, Location266
Steer Encoder267
Top Of Steer Motor267
Auto/Manual Switch268
Steer Encoder, Installed268
Auto/Manual Switch Cable268
Set-Up Procedure270
Guidance Parameter Setup270
Enable Wire Guidance In Flashware270
Learn Guide Wire Frequency271
Learn Wire Guidance Offsets271
Guidance Check272
Code 0,7275
Guidance Manager Fault Codes275
Code 9,2278
Code 9,3280
Code 9,4281
Code 9,6282
Code 9,8284
Code 9,C285
Code 9,E287
Code 9,F289
Code 9,H290
Code 9,J292
Code 9,K294
Speed Feedback Encoder Test296
Steer Feedback Encoder Test296
Wire Guidance Sensor Test296
General Troubleshooting298
Troubleshooting In Flashware299
Wire Guidance Diagnostics Screen299
Troubleshooting In Flashware 8 . 3300
Theory Of Operation301
Functional Overview301
System Description301
Distance From Wire Settings302
Battery Plugged In307
Key Switch On313
Closing Deadman Switches319
Travel325
Moving Directional/Speed Control325
Steering331
Steer Position Encoder Output331
Tracing Legend333
Lift/Lower337
Lower344
24" Limit Switch (56)351
Lift Limit Switch351
Lift Limit Bypass Switch351
Pump Contactor351
Pump Sense352
Flow Control Valves352
Oil Filter Check Valve352
Rel-1352
Primary Memory353
Pinout Matrix354
Firmware Configuration372
Flashware Program373
Requirements373
Install Flashware On Pc373
Starting Flashware373
Appendix374
Lubrication Specification Chart375
Torque Chart . Standard (Ferrous376
Torque Chart . Standard (Brass377
Torque Chart . Standard (Brass)377
Torque Chart . Metric378
Decimal Equivalent Chart379
Conversions381
Standard/Metric Conversions383
Electrical Schematics384
Hydraulic Schematic391
Index392
General Information402
Switch Replacement for "Bolt-On" Type Deadman Pedal407
Switch Replacement for "Welded" Type Deadman Pedal408