Interval 2 - Toyota 7BPUE15 Service Manual

4.
Section Planned Maintenance

Interval 2

2
Interval
Check the weight stamped on the battery in the truck
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.
Inspect the battery connector and all leads for damage and
cuts in protective coatings. Shorts to the truck frame will
cause electronic component failure or intermittent electrical
failures.
Check the brake for proper stopping distance. The truck
should stop within 8 to 10 feet if brake is applied while the
truck is loaded, traveling tractor-first a t full speed.
Visually inspect the friction plate (rotor disk) with the brake
released. Minimum thickness of the pad and steel backing
plate is in. (6 mm).
1 /4
Inspect the contactor tips for burnt or pitted surfaces.
Failure to replace the tips may cause surfaces to weld
together, causing unscheduled downtime.
Check the plunger for smooth operation with no binding. If
binding occurs, the truck may exhibit intermittent fault
codes.
Operate the lift/lower function. Verify the response is
smooth and both speeds work.
Operate the travel function. Verify the full range of
acceleration is smooth and responsive. Make sure the
plugging is functioning properly.
Look for any play in the center position of the lift or travel. If
there is free play, replace the return springs.
Check for proper fluid level in the drive unit. If the fluid level
is low, investigate for leaks and determine the cause.
Inspect all power cables for nicks or cuts. Give special
attention to those cables that are not stationary, for
example, cables to the drive motor. Inspect the
over-the-mast cable for chafing or wear. Replace any cable
that is damaged or shows signs of excessive heat. Failure to
do so will cause intermittent system shutdowns and/or
electronic failures.
Toyota Orderpicker Model 7BPUE15 Service Manual
00700-CL222-05, 1 5 March 2005
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