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7BPUE15
Toyota 7BPUE15 User Manual
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Toyota
Orderpicker
Model
7BPUE
15
Service
Manual
Section
3.
Systems
Overview
General
System
Data
General
System
Data
Chassis
Carriage
D
E
F
I
N
I
T
I
O
N
:
Part
of
the
truck
that
moves
by
hydraulic
force;
includes operator
platform.
Mast
ss
Operato~
Platform
Bumper
Baseleg
Figure
3
-
1.
Model
7BPUE
15,
Carriage
View
00700
-
CL222
-
05,
1
5
March
2005
D
E
F
I
N
I
T
I
O
N
:
Basic
frame
of
the
lift
truck;
includes baselegs,
bumper
and
mast.
41
43
Table of Contents
Default Chapter
10
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
Electrical Motors
91
Motor Overheating
91
Display Is Dark; Lift Truck Is Not Operational
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 Bearings and Shims
248
Staging of Mast Prior to Shimming Bearings
248
Upper Mast Bearing Replacement
249
Mast Bearing Stud Retaining Bolt Torque Values
249
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
Index
392
General Information
402
Switch Replacement for “Bolt-On” Type Deadman Pedal
407
Switch Replacement for “Welded” Type Deadman Pedal
408
5
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Toyota 7BPUE15 Specifications
General
Brand
Toyota
Model
7BPUE15
Category
Lifting Systems
Language
English
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