TOYOTA 6BPU15 ORDERPICKER Service Repair Manual SN:70001 to 79999

This is the Highly Detailed factory service repair manual for theTOYOTA 6BPU15 ORDERPICKER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA 6BPU15 ORDERPICKER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. 
Covers the following serials:
Toyota 6BPU15 Orderpicker – SN:70001 to 79999
Service Repair Factory Manual Covers:
How to use this manual
Safety
Systems Overview
Planned Maintenance
Troubleshooting
Electrical Codes and Tests
Component Procedures
Theory of Operation
Appendix
Index
Wiring
File Format: PDF 
Compatible: All Versions of Windows & Mac 
Language: English 
Requirements: Adobe PDF Reader

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8

1. ServiceManual
TOYOTAORDERPICKER
Model6BPU15
00700-CL221
Serial
No.70001-79999
Issued:9/10/98

2. ToyotaOrderpickerServiceManual Howto UseThisManual
HowtoUseThisManual
00700-CL221Issued: 9/10/98 1-1

3. Howto UseThisManual ToyotaOrderpickerServiceManual
Map
oftheManual
MapoftheManual
HowtoUseI
ThisManual
I
ITableofContents
Manu~ Design
StartPage
Component
LocationPhotos
~
I
ScheduledI
MaintenanceI
1-2 00700-CL221 Issued:9/10/98

4. ToyotaOrderpickerServiceManual
ManualDesign
TheToyotaOrderpickerServiceManualis
designedwiththefollowingobjectivesinmind:
•Providetechnicalcoveragefor expected
levelsofuserexpertise.
•Anticipateyourneedsandreduceyour
decisionsregardingmaintenance.
•Reducepageflippingthrougha"one-stop
shopping"approach.
Thetwo-linerunningpageheaderatthetopof
eachpagetellsyou:
•thenameofthemanual
(ToyotaOrderpickerServiceManual)
•thecurrentChapterTitle
(e.g.,
thispageHowtoUseThisManual)
•thecurrenttopic.
(e.g.,
thispageManualDesign)
Wesuggestyou·getinthehabitofturningtothe
STARTpagefirst
whenyouusethismanual.
00700-CL221Issued:9/1 0/98
HowtoUseThisManual
ManualDesign
1-3

5. Howto UseThisManual
ManualDesign
TheSTARTpageasksafewsimplequestionsto
gUideyoutotheproperchapter.
•HowtoUseThisManualexplainsthe
manualformatanddesignandcontainsthe
TableofContentsandSTARTpage.
•Safetyexplainswarningandcautionnotes,
generalsafetyrulesandsafetyrulesfor
batteries,static,jacking,andwelding.
•SystemsOverviewincludestruck
specificationsandfunctionaloverviewof
themajorsystems.
•PlannedMaintenanceoutlinesthe
recommendedscheduleofpreventive
servicestokeepyourtruckworkingmost
efficiently.
•Troubleshootingisasetof"decision-tree"
chartsdesignedtotakeyoufroma
symptomtoaspecificsequenceoftestsin
ordertoisolateafailingcomponent.
•TheGENERALTROUBLESHOOTING
chart(seeList
ofTroubleshooting
Chartsonpage5-25),willgUide youto
theindividualtroubleshootingsymptom
chartyouneed.
•Onceyou'refamiliarwiththesymptoms
listed,youmayinsteadsimplyfindthe
symptomchartfromtheListof
TroubleshootingChartsonpage5-27.
•Whenyoucompleteatroubleshooting
procedure,besuretofollowthestepsin
EndofTroubleshootingChartEND-I.
•ElectricalCodesandTestscontains
informationaboutelectricalfaultcodesand
diagnostictestsunderthecontrolofthe
systemfirmware.
•ComponentProceduresgivesstep-by-step
proceduresfortesting,removal,
installation,andadjustmentofindividual
truckcomponents.Componentsarelisted
inanorderwhichconsiders:
•Frequencyofattention
•Physicalattachment(e.g.,brakemust
beremovedbeforedrivemotor)
•
Functionalrelation(e.g.,carriageand
mastcomponentsaregroupedtogether)
1-4
ToyotaOrderpickerServiceManual
00700-CL221Issued: 9/10/98

6. HowtoUseThismanual
Tofmdacomponentprocedure,youmay
useoneofthreemethods:
•Lookupthecomponentnameinthe
AlphabeticalListofComponents.
•FindthecomponentintheComponent
Locators.
•Lookupthecomponentnameinthe
maintenancemanual
Index.
•TheoryofOperationgivesdetailed theory
ofoperationinformationforallmajor
systems.
•Appendix:containsreferenceinformation
suchastorquevaluesandlubricants.
•Indexlistssubjectsalphabetically.
1-5
ToyotaOrderpickerServiceManual
.00700-CL221Revised:2/15/00

7. ToyotaOrderpickerServiceManual
PageRevisionRecord
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forthismanual.
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12. ToyotaOrderpickerServiceManual
TableofContents
Ho\VtoUseThisManual.. . . . . . . .
HowToUseThisManual
Table
ofContents
1-1
MapoftheManual 1-2
ManualDesign.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
TableofContents.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
ListofFigures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
StartPage 1-19Safety'.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1
Definitions.. . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
GeneralSafe'ty 2-3
BatterySafe'ty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
StaticSafe'ty.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
JackingSafety 2-13
Tie-downforTransport 2-14
Towing 2-14
WeldingSafe'ty 2-15
SystelllsOvervie\V.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
SystemsOvenriew 3-2
1'ype 3-3
Power 3-3
Capaci'ty.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Mast 3-3
Controls.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Indicators.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3'-3
Electronics.. · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .~. . . . . . . . . .3-4
ElectricSteeringSystem.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Chassis· . . · · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Operator'sConsole.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
OperatorCompartmentOptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
SteeringandControls 3-13
00700-CL221Issued: 9/10/98 1-9

13. HowToUseThisManual
Table
ofContents
ToyotaOrderpickerServiceManual
SteerControllerGuidanceSystem.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
DriveandBrake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Drive
Unit 3-17
Brake 3-17
Mast 3-19
MastAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
HydraulicComponents 3-21Lift/wwerSystem 3-21
ElectricalComponentsandSystems 3-24
General 3-24
MiscellaneousCircuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Fuses 3-40
SidegateSwitches(S60,S61) 3-40
Tie-Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Cables.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Over-the-MastCables 3-41
PlannedMaintenance. . . . . . . . . .... . . . . . . . . . . . . . . . . ...4-1
PlannedMaintenance 4-2
GeneralMaintenanceInstructions 4-2
PlannedMaintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
MaintenanceManual.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
BatteryMaintenance 4-13
BatterySafety 4-13
BatteryInspectionandCare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
BatteryCleaningProcedure 0••••••••••••••••••••••••••••4-15
ChargingProcess.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1
HowtoUseThisChapter 5-2
ElectricalTroubleshootingGuidelines 5-2
ElectricalConnectorwcatorChart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
ShortstoFrameTest.· . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
ElectricMotorTests ' 5-12
1-10 Issued: 9/10/98

14. ToyotaOrderpickerServiceManual How ToUseThisManual
Table
ofContents
Motor
1)rpes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
OpenCircuitMotorTest.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
GroundedMotorTest 5-13
ShortCircuitedArmatureorFieldWinding.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
HydraulicTroubleshootingGuidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
HydraulicL,eakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
ListofTroubleshootingCharts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
ElectricalCodesandTests. . . . . . . . . . . . . . . . . . . . . . . . . ...6-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
ModesofOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..'. . . . . . . . . . . . . . . . . .6-3
Passwords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
DisabletheBrushWearWarning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
EnteringtheSecondaryPassword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
StarttheHourMeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
EnteringtheSecondaryPassword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Self-diagnosisMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Maneuveringwithin
Self-diagnosisMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Analyzer(AnL)Mode.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
EnteringtheSecondaryPassword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
EnteringAnalyzerMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
ManeuveringwithinAnalyzerMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Tuning(Tuning)Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
EnteringtheSecondaryPassword 6-13
ManeuveringwithinTuningMode.. . . . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
ExitingTuningMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Calibrate(Calibrte)Mode 6-16
EnteringtheSecondaryPassword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
EnteringCalibrateMode.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
ManeuveringwithinCalibrateMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Configure(Configur)Mode 6-20
EnteringtheSecondaryPassword 6-20
CodeSummaryTables. . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
00700-CL221Issued: 9/10/98 1-11

15. HowToUseThisManual
TableofContents
ToyotaOrderpickerServiceManual
AnalogInputs 6-25
Category1Class2: 6-25
Tests 6-29
SteerControllerGuidanceSystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-99
CodesandTests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-99
SteerControllerGuidanceSystem 6-149
AnalogInputTests:(Category1,Class2:12) 6-149
12-20:SteerControllerPowerSupplyVoltage 6-149
SteerControllerGuidanceSystem 6-173
DigitalInputTests '0••••••••••••••••••••••••6-173
ComponentProcedures.. . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-1
ComponentLocatorPhotos 7-2
GeneralMaintenanceInstructions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
MaintenancePractices.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
AdjustmentandRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
PowerSection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
TheoryofOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1
ElectricalFunctions ' 8-2
OperatingDescriptionOverview.. . . . . . . . . . . . . . . . . . . . . . . ...'. . . . . . . . . . . . .8-2
Lift/LowerSystem.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Overview.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
UniqueSystemFeatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Lift 8-4
Lower 8-4
BrakingSystem.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
ProportionalPlugging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-1
LubricationEquivalencyChart 9-2
TorqueChart-Standard(Ferrous) 9-4
TorqueChart-Standard(Brass) 9-5
TorqueChart-Metric. . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . .9-6
DecimalEqUivalentChart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
Standard/MetricConversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9
1-12 Issued:9/10/98

16. ToyotaOrderpickerServiceManual How ToUseThisManual
Table
ofContents
ElectricalSchematic.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . .9-11
HydraulicSchematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
Index.. . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . ...10-1
00700-CL221Issued:9/1 0/98 1-13

17. HowToUseThisManual
Table
ofContents
1-14
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ToyotaOrderpickerServiceManual
Issued:
9/10/98

18. ToyotaOrderpickerServiceManual Howto UseThisManual
ListofFigures
ListofFigures
Figure2-1:Anti-StaticKitwithWristStrapandMat 2-12
Figure2-2:CorrectJackingLocations 2-13
Figure3-1:ToyotaOrderpicker 3-2
Figure3-2:ComponentIdentification 3-8
Figure3-3:Operator'sConsole 3-12
Figure3-4:HydraulicCompartmentComponents(Sheet1of2) 3-26
Figure3-5:ElectricalCompartmentComponents 3-28
Figure3-6:PlatformComponents(ElectricSteering,CoverRemoved)3-29
Figure3-7:CarriageInterfaceCard 3-30
Figure3-8:TractorInterfaceCard. . . . . . . . . . . . . . . . .3-31
Figure3-9:SteerControllerCard 3-34
Figure3-10:DisplayControllerCard. . . . . . . . . . . . . . . . . . . . . . . .3-38
Figure3-11:FilterCard(withwireguidanceonly). . . . . . . . . . . . . .3-39
Figure4-1:Lubrication/InspectionPoints 4-12
Figure5-1:ShortstoFrameTest. . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Figure5-2:MotorCircuits 5-12
Figure5-3:GENl:GeneralTroubleshooting 5-26
Figure5-4:ENDl:EndofTroubleshootingProcedure 5-27
Figure5-5:W-l:TruckFunctionsPartially 5-28
Figure5-6:H-l:HydraulicLift/LowerProblem 5-29
Figure5-7:H-2:NoLift;Lift Motor/PumpWon'tTUITl 5-30
Figure5-8:H-3:NoLift;Lift Pump/MotorRotate 5-34
Figure5-9:H-4:LoadDriftsDownwhileForksareElevated 5-36
Figure5-10:H-5:CannotPickUpaLoad 5-38
Figure5-11:T-l:TravelProblem " 5-41
Figure5-12:T-2:NoTravelinEitherDirection 5-42
Figure5-13:T-3:TravelinOneDirectionOnly 5-43
Figure5-14:T-4:ProblemwithSlowTravel 5-44
Figure5-15:T-5:TruckDoesNotAccelerateProperly 5-45
Figure5-16:T-6:TruckDoesNotTravel 5-47
Figure5-17:T-7:No SlowtravelWhenMastElevatedAboveS11
MastSwitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-52
Figure5-18:T-8:SlowtravelSpeedOccursAlltheTime 5-54
Figure6-1:MenuStructurefortheDifferentModes 6-4
Figure6-2:SteerControllerCard-Code52 6-101
Figure6-3:SteerControllerCard-Code53 6-102
Figure6-4:LocationofWireGuidanceCoilsandRelatedTests 6-153
Figure6-5:LocationofWireGuidanceCoilsandRelatedTests 6-155
Figure6-6:LocationofWireGuidanceCoilsandRelatedTests 6-157
Figure6-7:LocationofWireGuidanceCoilsandRelatedTests 6-159
Figure6-8:LocationofWireGuidanceCoilsandRelatedTests'6-161
00700-CL221Issued: 9/10/98 1-15

19. Howto UseThisManual
ListofFigures
ToyotaOrderpickerServiceManual
Figure6-9:LocationofWireGuidanceCoilsandRelatedTests 6-163
Figure7-1:ComponentLocations(Sheet1of5) 7-2
Figure7-2:CorrectJackingLocations 7-9
Figure7-3:Proper/ImproperMethodofHoldingCircuitCard 7-12
Figure7-4:IntegratedCircuitTool 7-15
Figure7-5:PreparingIntegratedCircuitforInsertion 7-15
Figure7-6:InstallationofIntegratedCircuit 7-16
Figure7-7:RemovingDriveUnit 7-19
Figure7-8:DriveUnitServiceTools
~'7-20
Figure7-9:DriveUnitCrossSection 7-20
Figure7-10:DriveUnitComponents-LowerEnd 7-21
Figure7-11:RemovingAxleBearing 7-21
Figure7-12:PressingBearingConeontoAxle 7-22
Figure7-13:AssemblyofAxleintoHousing 7-23
Figure7-14:PreparingAxleSealforAssemblyintoHousing 7-23
Figure7-15:Install/TorqueClampNutonAxle 7-24
Figure7-16:SecuringClampNutbyTighteningRetainingScrew 7-25
Figure7-17:InstallingCover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
Figure7-18:Drive,UnitAssembly 7-28
Figure7-19:CheckingSkidpads : 7-29
Figure7-20:DeadmanPedal/MasterCylinder 7-32
Figure7-21:BrakeBleedingSet-Up 7-34
Figure7-22:ExplodedViewofBrakeAssembly 7-35
Figure7-23:DeadmanSwitch(S2)Adjustment(NottoScale) 7-36
Figure7-24:2StageLiftCylinder(TopEnd) 7-38
Figure7-25:2StageLiftCylinder(BottomEnd) 7-39
Figure7-26:CenterLiftCylinder,3Stage(TopEnd) 7-41
Figure7-27:CenterLiftCylinder,3Stage(BottomEnd) 7-42
Figure7-28:Lift/LowerManifolds 7-44
Figure7-29:ProperInstallationofProportionalValve 7-45
Figure7-30:AccessforLiftCylinderBleedScrews. . . . . . . . . . . . . .7-47
Figure7-31:Directional/SpeedControl-ExplodedView 7-48
Figure7-32:Lift/LowerReturnSpringReplacement 7-52
Figure7-33:Lift/LowerControlAssembly,PotentiometerWiring 7-53
Figure7-34:ElevatingSection 7-56
Figure7-35:ElevatingSection(cont.) 7-57
Figure7-36:ElevatingSection(cant.) 7-58
Figure7-37:ElevatingSection(cant.) 7-59
Figure7-38:ThreeStageElevatingSection 7-60
Figure7-39:EndCapPulleyAssembly(3Stagemastonly) 7-61
Figure7-40:StagingofMastPriortoShimmingBearings. . . . . . . . . 7-62
Figure7-41:EndCapAssembly,3StageMast. . . . . . . . . . . . .7-63
Figure7-42:SteeringControlAssembly. . . . . . . . . . . . . . . . . ..,7-66
Figure8-1:SteeringEncoderOutput-LeftTurn , 8-12
Figure8-2:SteeringEncoderOutput-RightTurn 8-13
1-16 Issued: 9/10/98

20. ToyotaOrderpickerService.Manual HowtoUseThisManual
ListofFigures
Figure8-3:WireGuidanceFunctionalBlockDiagram 8-18
Figure8-4:LocationofWireGuidanceCoilsandRelatedTests 8-19
Figure8-5:WireGuidanceLEDsontheOperator'sDisplay 8-21
Figure9-1:LubricationEquivalencyChart 9-2
Figure9-2:TorqueChart-Standard 9-4
Figure9-3:TorqueChart-StandardBrass 9-5
Figure9-4:TorqueChart-FerrousMetric 9-6
Figure9-5:TorqueChart-BrassMetric 9-6
Figure9-6:DecimalEquivalentChart..,. ' 9-7
Figure9-7:ElectricalSchematic 9-12
Figure9-8:ElectricalSchematic 9-14
Figure9-9:HydraulicSchematic 9-18
00700-CL221Issued: 9/10/98 1-17

21. Howto UseThisManual
ListofFigures
1-18
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ToyotaOrderpickerServiceManual
Issued:
9/10/98

22. ToyotaOrderpickerServiceManual
StartPage
START
HowToUseThisManual
Toreviewsafety
precautions?
No
I
Toexamine
specifications?
No
>----yes---+!
>----yes---+I
GotoChapter2
"Safety"
GotoChapter3
"SystemsOverview"
Todo
scheduled
maintenance?
No
GotoChapter4
>----yes---+I"PlannedMaintenance"
Totroubleshoot
aproblem?
No
>----yes---+I
GotoChapter5
'Troubleshooting"
I--------~. :TroubleshootingGuidelines
I
00700-CL221Issued: 9/10/98
_IListofTroubleshooting
'---------.1.
1
Charts
'---------------'
1-19

23. HowToUseThisManual
StartPage
START-2
No
Totest.
inspect.adjust.
remove/installa
component':!
No
r---yes---+I
>----yes---+I
ToyotaOrderpickerServiceManual
GotoChapter6
"Electrical
Codesand
Tests"
GotoChapter7
"ComponentProcedures"
>----yes---+I
GotoChapter8
'TheoryofOperation"
No
Tofmd
generalreference
information?
No
Tolocate
anobjector
procedureby
name?
No
1-20
>----yes---+I
r----yes---+I
GotoChapter9
"Appendix"
GototheIndex
00700-CL221Issued:9/10/98

24. ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98
Safety
Safety
2-1

25. Safety
Definitions
Definitions
Throughoutthismanual,youwillseetwokinds
ofsafetyreminders:
~
Warningmeansapotentiallyhazardous
situationexistswhich,ifnotavoided,
couldresult indeath
orseriousiniury.
ACAUTION
Cautionmeansapotentiallyhazardous
situationexistswhich,ifnot~voided,
couldresultinminor ormoderateiniury
orindamagetothelifttruck ornearby
obiects.
2-2
ToyotaOrderpickerServiceManual
00700-CL221Issued: 9/10/98

26. ToyotaOrderpickerService Manual
GeneralSafety
Donotoperateorworkonthislifttruckunless
youaretrained,qualified,authorizedtodoso,
andhavereadtheoperator'smanual.
•
Safety
GeneralSafety
Knowthelifttruck'scontrolsandwhattheydo.
DoNOT
operatethislifttruckifitneedsrepair
orifitisinanywayunsafe.
Operatethislifttruckonlyfromtheoperator's
position.
00700-CL221Issued: 9/10/98 2-3

27. Safety
GeneralSafety
Beforeworkingonthislift
tIuck,alwaysturn
thekeyswitchtoOFFanddisconnectthelift
tIuck'sbatteryconnector(unlessthismanual
tellsyouotherwise). ..
ToyotaOrderpickerServiceManual
DoNOTwearwatches,rings,orjewelrywhen
workingonthislifttruck.
Followthescheduledlubrication,maintenance
andinspectionsteps.
FollowexactlythesafetyandrepairinstIuctions
inthismanual.Don'ttake"shortcuts".
2-4 00700-CL221Issued: 9/10/98

28. ToyotaOrderpickerServiceManual
DoNOT useanopenflamenearthelifttruck.
DoNOT usegasolineorotherflammableliquids
forcleaningparts.
Cleanupanyhydraulicfluid.oil orgreasethat
hasleakedorspilledonthefloor.
Always
parkthislifttruckindoors.
DoNOT washthislifttruckwithahose.
DoNOT addtoormodifythislifttruckuntilyou
contactyourlocalDealertoreceivewritten
manufacturerapproval.
DoNOT parkthislifttruckinacoldstorage
areaovernight.
00700-CL221Issued: 9/10/98
Safety
GeneralSafety
2-5

29. Safety
BatterySafety
BatterySafety
~
Asabatteryisbeingcharged, an
explosivegasmixtureformswithinand
aroundeachcell.
Iftheareaisnot
properlyventilated,thisexplosivegas
canremainin
oraroundthebatteryfor
severalhoursaftercharging.
Besure
there
arenoopenflames orsparksin
thecharging
area.Anopenflame or
sparkcanignitethisgas,resulting in
seriousdamageorinjury.
~
Batteryelectrolyte isasolutionofsulfuric
acid
andwater.Batteryacidcauses
burns.Should
anyelectrolytecomein
contactwithyourclothing
orskin,flush
the
areaimmediatelywithcoldwater.
Shouldthesolutiongetonyourface
or
inyoureyes,flushthe areawithcold
waterandgetmedicalhelpimmediately.
Wearpersonalprotectiveequipmenttoprotect
eyes.face andskinwhenchecking.handlingor
fillingbatteries.Thisequipmentincludes
gogglesorfaceshield.rubbergloves(with or
withoutarmshields)andarubberapron.
2-6
ToyotaOrderpickerServiceManual
00700-CL221Issued:9/10/98

30. ToyotaOrderpickerServiceManual
Makesureashowerandeyewashstationare
nearbyincasethereisanaccident.
Safety
BatterySafety
..~W ....'
"'Jr!~
Abatterygivesoffexplosive gases.NEVER
smoke.useanopenflame.oruseanythingthat
givesoff sparksnearabattery.
Keepthechargingareawell-ventilatedtoavoid
hydrogengasconcentration.
Turnthekeyswitchoffbeforedisconnectingthe
batteryfromthelifttruckatthebattery
connector.Donotbreaklivecircuitsatthe
batteryterminals.Asparkoftenoccursatthe
pointwherealivecircuitisbroken.
00700-CL221Issued: 9/10/98 2-7

31. Safety
BatterySafety
Donotlaytoolsormetalobjectsontopofthe
battery.Ashortcircuitorexplosioncould
result.
Keepbatteriesclean.Corrosioncausesshorts
totheframeandpossiblysparks.
Keepplugs,terminals,cablesandreceptaclesin
goodconditiontoavoidshortsandsparks.
2-8
ToyotaOrderpickerServiceManual
00700-CL221Issued: 9/10/98

32. ToyotaOrderpickerServiceManual
Keepfillerplugsfirmlyinplaceatalltimes
exceptwhentheelectrolytelevel ischecked.
whenwaterisaddedtothecellsorwhenthe
specificgravityischecked.
Makesuretheventholesinthefillerplugsare
opentoallowthegastoescapefromthecells.
Do
notallowcleaningsolution,dirtorany
foreignmattertoenterthecells.
Makesureyouinstallthecorrectsizebattery.A
smallerorlighterweightbatterycouldseriously
affectlift truckstability.Seethelifttruck's
specificationplateformoreinformation.
Neverplugabatterychargerintothelifttruck's
batteryconnector.Plugthebatterychargeronly
intothebatteryconnectorfromthebattery.
00700-CL221Issued: 9/10/98
Safety
BatterySafety
2-9

33. Safety
BatterySafety
FollowthechargingproceduresintheBattery
InstructionManualandintheBatteryCharger
InstructionManual.
2-10
ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98

34. ToyotaOrderpickerServiceManual
StaticSafety
Electroniccircuitboardsanddevicesusedon
theToyotalifttruckcanbedamagedbythe
dischargeofstaticelectricity,called
electrostaticdischarge.
Staticchargescanaccumulatefromnormal
operationofthelifttruckaswellasmovement
orcontactbetweennon-conductivematerials
(plasticbags,syntheticclothing,syntheticsoles
onshoes,styrofoamcoffeecups,etc.)
Accumulatedstaticcanbedischargedthrough
humanskintoacircuitboardorcomponentby
touchingtheparts.Staticdischargeisalso
possiblethroughtheairwhenachargedobject
isplacedclosetoanothersurfaceatadifferent
electricalpotential.Staticdischargecanoccur
withoutyourseeingorfeelingit.
Wheneverworkingonornearstatic-sensitive
electronics,alwaysusestaticdischarge
precautions.
1.Placeastaticdischargewriststraparound
YO.urwrist.Connectthegroundleadtothe
wriststrapconnector.
2.Connectthegroundclamptoanunpainted,
groundedsurfaceonthelifttruckframe.
3.Ifyouwillberemovingorinstallingstatic­
sensitivecomponents,placethemona
properlygroundedstaticmat.
4.Totransportstatic-sensitivecomponents,
includingfailedcomponentsbeing
returned,placethecomponentsinan
antistaticbagorbox(availablefromyour
dealer).
Thewriststrapandassociatedaccessories
shouldbetestedmonthlytoverifytheyare
workingproperly.Adefective staticdischarge
wristbandwillnotalertyouthatitisbad.
00700-CL221Issued: 9/10/98
Safety
StaticSafety
2-11

35. Safety
StaticSafety
ToyotaOrderpickerServiceManual
Figure2-1:Anti-Static KitwithWristStrapandMat
Figure2-1showsthecomponentsoftheToyota
antistaticfieldservicekit,partnumber00590­
04849-71.Thekitincludesawriststrap,
groundcordandstatic-dissipativeworksurface
(mat).Followtheinstructionspackagedwith
thiskit.
Wriststrapsareavailableinquantitiesof25,as
partnumber00590-04848-71.
Awriststraptesterisavailableaspartnumber
00590-04850-71.
ContactyourlocalDealerforfurther
information.
2-12 00700-CL221Issued: 9/10/98

36. ToyotaOrderpickerServiceManual
JackingSafety
Sometimesyoumayneedtojackupthelift
truckoffthefloortoperformmaintenance
procedures.Whendoingso,observetheproper
safetyprecautions:
1.Lowertheforkscompletely.Removeany
load.
2.Placeallcontrolsinneutral.
3.Blockthewheelstopreventmovementof
thevehicle.
4.Disconnectbatteryconnector.
5.Placethejackunderthedesignatedjacking
points.SeeFigure2-2.
~
Useextremecarewheneverthelifttruck
isjackedup.Keephandsandfeetclear
fromvehiclewhilejackingthelifttruck.
Afterthelifttruck
isjacked,placesolid
blocksbeneathit
tosupportit. DONOT
relyonthejackalonetosupportthelift
truck.
Tractor
1.Placethejackinthedesignatedjacking
position.SeeFigure2-2.
2.Jacktherearofthelifttrucksothatthe
drivetireisoffthefloornomorethan2"(51
mm).
3.Blockthelifttruckinplace.
Mast
1.Placethejackinthedesignatedjacking
position.SeeFigure2-2.
2.Jackthesideofthetrucksothattheload
wheelisoffthefloornomorethan1/2"(13
mm).
3.Blockthelifttruckinplace.
NOTE:Mterworkingonavehicle,testall
controlsandfunctionstoassureproper
operation.
00700-CL221Issued: 9/10/98
Safety
JackingSafety
Onlyjackinthisarea,nomoretban
112"
(13mm)offthefloor.
Figure2-2:CorrectJackingLocations
2-13

37. Safety
Tie-down
forTransport
Tie-downforTransport
TotransportyourToyotalifttruckinanover­
the-roadvehicleorrailcar,followthesesteps:
1.Lowertheforksandlocatethelifttruckin
thecenterofthetransportvehicle.
2.
Usingsuitableliftingdevice, removethe
battery.See"BatterySafety"onpage2-6.
3.Positiontheadjustablechainoverand
throughthebatterycompartment.
4.Positionanadditionaladjustablechainover
andthroughthebatterycompartment.
5.Positionthechainendsofonechaintoward
thefrontofthevehiclebedandthechain
endsoftheotherchaintothebackofthe
vehiclebedanddrawtaut.
Thiswillsecure
thelifttrucktothevehiclebedandprevent
tip-overandforwardorbackward
movement.
6.Securethebatteryaccordingtothebattery
manufacturer'sinstructions.
Towing
TosafelytowaToyotalifttruck:
1.Lowerthecarriagearidremoveanyload
fromtheforks.
2.
Turnthekey
s~tchOFFanddisconnect
thebatteryconnector.
3.Usingasuitabletowingvehicle,lift the
tractorendofthelifttruckuntilthedrive
tireisnomorethan1"offthefloor.
4.
Towthelifttruckslowlyinthetractor-first
direction.
ACAUTION
Usecaretoavoid damagetothewire
guidancesensorlocatedbeneath the
truck.
2-14
ToyotaOrderpickerServiceManual
00700-CL221Issued: 9/10/98

38. ToyotaOrderpickerServiceManual
WeldingSafety
~
Flamecutting orweldingonpainted
surfaces
mayproduce potentially
harmfulfumes,smokeandvapors.Prior
toperformingflamecuttingorwelding
operations,it
isrecommendedthatthe
coatingberemovedinthevicinitywhere
theoperation(s)willbeperformed.
Coatingremoval
maybebymechanical
methods,chemicalmethodsora
combination
ofmethods.Flamecutting
and/orweldingoperationsshouldbe
carriedoutonlyinwellventilatedareas
usinglocalexhaust
ifnecessary.
Beforeworkingonthislifttruck,makesure
that:
•Fireprotectionequipmentisnearby.
•Youknowwherethenearesteyewash
stationis.
00700-CL221Issued: 9/10/98
Safety
WeldingSafety
2-15

39. Safety
WeldingSafety
ACAUTION
Disconnectthebatterybeforeyou
attempttoinspect,service
orrepairthe
lifttruck.
•Checkforshortstoframeasdescribedin
"ShortstoFrameTest"onpage5-6.
•Ifanyshortsaredetected,removethem
beforeyouproceedwiththewelding
operation.
•Cleantheareatobewelded.
•Protectalllifttruckcomponentsfromheat,
weldspatteranddebris.
•Attachthegroundcableasclosetotheweld
areaaspossible.
•Donotperformanyweldingoperations
neartheelectricalcomponents.
Disconnectthefollowingconnectors:
•HD1 onDisplayCard
•JPC1-onCarriageInterfaceCard
•JPR1,JPR3onTractorInterfaceCard
•JP4,JP5onSteerControllerCard
•JT1,JT2onTractionPowerAmplifier
•
JL1,JL2onLiftPowerAmplifier
ACAUTION
Ifweldingmustbe donenearthebattery
compartment,removethebatteryfrom
thelifttruck.
•Whenyouarefinishedwelding,performall
groundtestsandelectricalinspections
beforethevehicleisoperated.
2-16
ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98

40. ToyotaOrderpickerServiceManual
SystemsOverview
00700-CL221Issued: 9/10/98
SystemsOverview
3-1

41. SystemsOverview
SystemsOverview
SystemsOverview
Figure3-1providesanoverviewoftheToyota
Orderpicker.Detailed descriptionsofmajor
components,supportedbyphotographsand
drawings,arecontainedherein.
Figure3-1:ToyotaOrderpicker
ToyotaOrderpickerServiceManual
3-2 00700-CL221Issued:
9/10/98

42. ToyotaOrderpickerServiceManual
Use
TheOrderpickerisdesignedforindoor
warehouseuseonly.
Type
Stand-up,ridertype,designedfornarrowaisle
installationswheretheoperatormustorderpick
itemsfromstorageracks.Thelifttruckis
operatedwithelectricsteeringandmaybewire
orrailgUided.
Povver
24-voltindustrialbattery.
Capacity
Refertospecificationplate.
Mast
Two hreestage,hydraulicliftwithavarietyof
overallloweredheights(OALH)andelevated
heights(EH).
Controls
Lockablekeyswitch,emergencypoweroff
switch,emergencylowervalve,steeringwheel,
electricsteering,wire/railgUidance,traction/
lift/loweramplifiers,brake,andhornbutton.
Selectorswitchesareavailableforoptionssuch
asworkinglights,fan,orothercustomer
selectedoptions.
Indicators
Operator'sdisplay,wire/railgUidance
acquisitionlight,andanaudiblealarmwhich
soundstoalerttheoperatorofcertainsystem
conditionsandwhenacquiringthegUidewire/
rail.A strobelighthelpstoalertothersofthe
orderpicker'spresence.
00700-CL221Issued: 9/10/98
SystemsOverview
Use
3-3

43. SystemsOverview
Electronics
Electronics
Thetractionandliftcontrolsystemsuse
separatePulseWidthModulated(PWM),solid
state,programmablepoweramplifiersto
monitorandcontrolcurrentflowthroughthe
tractionandliftmotors.Theamplifiersare
locatedontherightsideofthepowersection.
Bothamplifiersfeaturefailsafeoperationand
thetractionpoweramplifierhasregenerative
brakingcapability.
ElectricSteeringSystem
Theelectricsteeringsystemcontrolsallthelift
trucksteeringandwire/railgUidance
functions.Thesystemhasstand-alone
programmingandtestcapabilities.It
communicateswiththeDisplayCardthrough
theCANbus.
3-4
ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98

44. ToyotaOrderpickerServiceManual
Specifications
SystemsOverview
Specifications
Category Description
MODEL ToyotaModelDesignation
SER.NO. Serialnumberassignedbythefactoryfor
thisparticularlifttruckdUring
manufacture.
VOLTS Nominalbatteryvoltage.
TRUCKWEIGHT Approximateweightofthelifttruckwithout
(Minimum) batteryinstalled,minusoperatorandload.
TRUCKWEIGHT Approximateweightofthelifttruckwith
(Maximum) maximumsizebatteryinstalled,minus
operatorandload.
BATTERYWEIGHT Maximumweightofbatterydesignedfor
(Maximum) thislifttruck.
BATTERYWEIGHT Minimumweightofbatteryrequiredfor
(Minimum) thislifttruck.
BATTERYMAX.RATED
(MaximumAmpereHour
Powerratingofthebattery.
Capacity)
CAPACITYCHART
Maximumloadcapacityofthelifttruck.
Exceedingniaximumloadweightmay
damagethelifttruckoraffectstability.
00700-CL221Issued:9/10/98 3-5

45. SystemsOverview
Description
Description
Chassis
TheChassisisconstructedofthefollowing
parts:
PowerSectionFrame
ThePowerSectionFrameisconstructedof
formedsheetandplatesteelweldedtogetherto
formastrongintegralunit.
ThePowerSectionisboltedtothebaselegsand
mast.
BatteryCompartment
TheBatteryCompartmentwillacceptabattery
withthefollowingdimensions(alldimensions
aremaximum):
ToyotaOrderpickerServiceManual
24VoltBattery
Width Width
14.50"(370 mm) 13.25"(335 mm)
Height Height
32.25"(820 mm) 32.25"(820 mm)
Length Length
36.75"(935 mm) 31.50"(800 mm)
Batterygateslocatedoneachsideofthelift
truckliftouttoallowthebatterytoberemoved
orinstalledfromeitherside.Steelrollers
supportthebatteryandalloweasyremovaland
installation.Thebatterygatescontain
adjustmentscrewstolimitbatterymovement.
Baselegs
TheBaselegframeisconstructedofsquare
structuraltubingandsteelplate.Eachbaseleg
hasoneortwoloadwheels,dependingonlift
truckconfiguration.
3-6 00700-CL221Issued: 9/10/98

46. ToyotaOrderpickerServiceManual
Forks
TheForksareconstructedof2-inch(50nun)by
4-inch(100mm)rectangularsteel(thelengthof
theforksisanoptionspecifiedbythe
customer).Theforksareattachedtothebottom
oftheoperator'scompartment.Theoverall
widthoftheforksisadjustablefrom24to28
inches(610to710mm).
Covers
TwoCovers constructedofformedplastic
enclosecomponentsonthepowersection.
Buttonassembliesallowbothcoverstobe
removedfromthelifttruck.
00700-CL221Issued: 9/10/98
SystemsOverview
Chassis
3-7

47. SystemsOverview
Chassis
ChainsandPulleys
ToyotaOrderpickerServiceManual
MostGuard
KeySwitch
Sidegat~
SteeringWheel
Figure3-2:ComponentIdentification
Pollet
Clomp
Control
Panel
3-8 00700-Cl221Issued:9/10/98

48. ToyotaOrderpickerServiceManual
Operator'sCompartment
TheOperator'sCompartmenthasbeen
designedforsafety,efficiency,andoperator
comfort.
CompartmentDimensions
Theoperator'scompartmentis28inches
(710mm)long,76inches(1930mrn)high,and
39inches(990mm)wide.Thecompartment
floorwidthisexpandableto55inches
(1400mm).
CompartmentFloor
Thecentersectionofthefloorisplatesteel.Itis
coveredbyarubbercushion.Theextensions
areconstructedofnon-slipsteel.
Overheadguard
TheOverheadGuardisconstructedofsteel
tubingandbarstock.Theoverheadguard
coversthefloorareatoprotecttheoperatorand
complieswithANSI/ASMEspecificationB56.1.
Abarattherearoftheguardprovidesan
attachmentpointforthetether.
BeltITether
TheBelt/Tetherisasafetydevicewhichisworn
aroundthewaistoftheoperatorwheneverthe
lifttruckisoperated.Thetetherpreventsthe
operatorfromfallingfromthecarriage.
Sidegates
Theoperator'scompartmenthasoneSidegate
oneachsideoftheoperator.Theretractable
sidegatesarespringloadedtokeepthemin
eithertheraisedorloweredposition.See
"SidegateSwitches(S60,S61)" onpage3-40.
Operator'sConsole
TheOperator'sConsoleprovidestheoperator
withcompletecontrolofthelifttruck.The
controlshavebeendesignedforoperatorsafety,
efficiency,andcomfort.
Thesteeringwheelandthekeyswitchare
locatedontheleftsideoftheoperator'sconsole.
00700-CL221Issued:9/1 0/98
SystemsOverview
Operator'sCompartment
3-9

49. SystemsOverview
Operator'sConsole
Thetraction/lift/lowercontrol,hornbutton,
wiregUidanceon/offswitch,andemergency
poweroffarelocatedontherightsideofthe
operator'sconsole. .
Thelowerportionoftheoperator'sconsolehas
anaccessorybinforstoringpencils,pens,
clipboards,picklist,etc.
Operator'sDisplay
TheOperator'sDisplayisusedtodisplay:
•TOYOTA (turnonandsystemmessages/
faultcodes)
•
Totalhoursthekeyhasbeenturnedon(Ks)
•Totalhoursondeadman(Bp).
•
Totalhoursdrive(Dm)
•
Totalhoursspentlifting(Lt)
•Clock/Calendar
•Statusmessages:.Informational:
PerformanceLimiting:andFaultCodes.
Theoperatordisplayshowsinformationonan
eightcharacter,alphanumericdigitaldisplay.
Informationwillbedisplayedineitherstaticor
scrollingformat.Scrollingmessagesmovefrom
righttoleft.
SteeringIndicatorandKeypad
AlllifttrucksareeqUippedwithelectric
steering:fivedrive
unitpositionlightsare
locatedabovethesteeringwheeltoindicatethe
approximatepositionofthedriveunit.
Additionally,all truckshaveGuidanceStatus
lightslocatednexttothewheelposition
indicator:thestatuslightsarenotfunctional
unlessthelifttruckhastherail/wiregUidance
optioninstalled.
Thekeypadisusedtoaccess,enter,andchange
parametersontheinformation/statusdisplay.
EmergencyPowerDisconnectButton
TheEmergencyPowerDisconnectButtonis
locatedontheoperator'scontrolconsole,tothe
leftofthedirectional/speedcontrol.Theswitch
hastwopositions,UPallowsthetrucktotravel,
andDOWNwhichpreventstraveland.lift/lower
3-10
ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98

50. ToyotaOrderpickerServiceManual
functionsfromoperating.Themanual
emergencylowerfunctionisnotaffected.
KeySwitch
Thelockablekeyswitchislocatednearthe
steeringwheel.Thekeyswitchhastwo(2)
positions:OFForON.
BatteryDischargeIndicator(BDI)
TheBatteryDischargeIndicator(BDI)shows
theenergywhichremainsinthebattery,based
onactualvoltagereadings.Thevaluedisplayed
isthepercentageofusableenergy.Voltage
fluctuationsoccurdUringoperation.Dependent
uponthesettinginTuningmode,liftwillbe
preventeduntilthebatteryisrechargedor
replaced.
BrushWear, Overtemperature,Service
Required,and
LiftLimit
Individualiconsilluminatetoinformthe
operatorofthespecificcondition.
OperatorCompartmentOptions
Thefollowingcomponentsareavailableper
customerrequest(partiallist):
-Fan
•DomeLight
•WorkLights
00700-CL221Issued: 9/10/98
SystemsOverview
OperatorCompartmentOptions
3-11

51. SystemsOverview
OperatorCompartmentOptions
SteeringIndicatorLights
(electricsteering)
LockedOn
WireLights
Steering
Wheel
Figure3-3:Operator'sConsole
Operator's
Display
ToyotaOrderpickerServiceManual
Emergency
PowerDisconnect
Button
Auto/Manual
On/OffSwitch
3-12 00700-CL221Issued: 9/10/98

52. ToyotaOrderpickerServiceManual
SteeringandControls
SteerControllerGuidanceSystem
Theelectricpowersteeringsystemisa
microprocessor-basedcontrolsystemusing
sophisticatedsoftwaretomanagethesteering
operationofthelifttruck.Itprovidesthe
electronicintelligencetogovernlifttrucksteer
functionsunderdirectoperatorcontrolor
automatedwire/railgUidancesystems.
SteerMotorandGearReducer
Apermanentmagnetsteermotorconnectedtoa
gearreducerprovidesthemechanicalforceto
steerthedriveunit.Thegearreducerhasa
drainplugforchangingtheoil,andafillerlevel
plugtodeterminethequantityoflubricantin
theunit.Theoutputshaftturnsagearthat
powersagearonthedriveunit.
Directional/SpeedControl Assembly
ThemaincomponentsoftheDirectional/Speed
Controllerarethe:
•ControlHandle
•Housing
•ThrottlePotentiometer(VRl)
•LiftPotentiometer(VR2)
•HornSwitch(S3)
•
Auto/ManualSwitch(S45)(mountedon
bezel)
ControlHandle
TheControlHandleisconstructedofformed
plastic.Ithasprovisionsforahornbutton(S3),
andlift/lowerpotentiometer(VR2).
Housing
TheHousingprovidessupportandprotection
forthethrottlepotentiometer(VRl).Thecontrol
handleisalsoattachedtothehousingbya
rotatingshaft.Thehousingisconstructedof
moldedblackpolycarbonateandismounted
00700-CL221 Issued:9/10/98
SystemsOverview
Steering
andControls
3-13

53. SystemsOverview
SteerControllerGuidanceSystem
undertheright-handsideoftheoperator's
controlconsole.
ThroHlePotentiometer(VR1)
TheThrottlePotentiometerismountedwithin
thehousing.Thepotentiometeristurnedby
twonylongears;onegearismountedonthe
potentiometershaftandtheothergearisonthe
controlhandleshaft.Potentiometer
specificationsincludethefollowing:
•
MechanicalRotation-312
0
•Resistance-2,000ohms(2K)
Asthethrottlepotentiometerisrotatedbythe
operator,avoltageproportionaltotheposition
ofthecontrolissenttotheCarriageInterface
Card.VRIvoltageissensedbythecarriage
interfaceandpassedtotheDisplayCard,which
determinesthedirectionandmagnitudeofthe
speedrequest.
Lift/LowerPotentiometer (VR2).
Thelift/lowerpotentiometerisdirectly
connectedtothethumblever;potentiometer
specificationsincludethefollowing:
•
MechanicalRotation-312
0
•Resistance-2,000ohms(2K)
Asthelift/lowerpotentiometerisrotatedbythe
operator,avoltageproportionaltotheposition
ofthecontrolissenttotheCarriageInterface
Card.Whenthelift/lowercontrolismovedto
lift,voltagefromVR2 increases;whenmovedto
lower,thevoltagefromVR2decreases.VR2
voltageissensedbythecarriageinterfacecard
andpassedtotheDisplayCardwhich
determineswhethertoliftorlower.Thisis
accomplishedbycomparingtheactualvoltage
tothelearnedvoltagevalues.NeutralforVR2 is
learnedandstored.
Horn(Hl)
Duringtheselfdiagnosis(powerup)mode,the
horn(HI)canbesoundedwheneverthekey
switchisON.Thehornassemblyismountedon
thefrontlowersectionofthepowersection.
3-14
ToyotaOrderpickerServiceManual
00700-CL221Issued:9/10/98

54. ToyotaOrderpickerServiceManual
HornSwitch(S3)
TheHornSwitchislocatedonthefront-sideof
thedirectional/speedcontrolhandle..
Auto/ManualSwitch(S45)
Switchpositionselectssteeringmode,i.e.,
directoperatorcontrolorautosteer.Wire
gUidance
(andrailgUidance)allows thelift
trucktofollowa predeterminedpath
automatically,withoutsteeringassistanceof
theoperator.Theswitchislocatedonthe
operator'sconsole,beneaththecontrolhandle.
DriveUnitPositionEncoder(ENC2)
TheDriveUnitPositionEncoderislocatednear
thegearreducerassembly.Thisencoderis
turnedasthedriveunitissteered.Thesignal
fromtheencoderissenttothesteercontroller.
Thesteercontrollerusesthissignal,inaddition
tothesignalfromtheHomeSwitchProximity
Sensor,todeterminethepositionofthedrive
unit.
HomeSwitchProximitySensor (PROX)
TheHomeSwitchProximitySensorislocated
onthedriveunitnexttotheSteeringPosition
Encoder.Theswitchopensorclosesdepending
uponitsproximitytoametalsurface.The
open/closesignalissenttothesteer
controller.Whenthelifttruckisinitiallyturned
on,anddeadmandepressed,thesteer
controllerwillsteerthedriveunittowardsthe
straightaheadpositionuntilthehomeswitch
proximitysensorchangesstate.Theswitch
changesstatewhenametalsurfacepasses
beneathit(whenthedriveunitisatthe
straig:qt
aheadposition).
SteeringEncoder(ENC1)
TheSteeringEncoderislocatedonthe
operator'scarriage,behindthesteeringwheel.
Asthesteeringwheelisturned,theencoder
generatesaquadraturephasesignalandsends
ittothedisplaycard.Thedisplaycard
processesthesignaltodeterminethedirection
andamountofsteeringrequest.Theresulting
steeringrequestissentviathe~us+/Bus­
ControllerAreaNetwork(CAN)totheSteer
00700-CL221Issued:9/10/98
SystemsOverview
SteerController
GuidanceSystem
3-15

55. SystemsOverview
SteerControllerGuidance
System
ControllerCard.TheSteerControllerCardthen
powersthesteermotortosteerthedriveunit.
SpeedFeedbackProximity Sensors(SPlandSP2)
TheSpeedFeedbackProximitySensors
determinethespeedanddirectionofrotationof
thedrivemotor. Theyareusedinconjunction
withtheholesinthebrakedrumtoproducea
quadraturesignalthatissenttothesteer
controller.Thecharacteristicpulsesofthe
quadraturesignalareproducedasthe
proximitysensorsreadeitherthemetalorvoid
oftherotatingbrakedrum.
3-16
ToyotaOrderpickerServiceManual
00700-CL221Issued:9/1
0/98

56. ToyotaOrderpickerServiceManual
DriveandBrake
DriveUnit
TheDriveUnitisacompact,self-contained
assembly.Itconsistsofapivotbearing,gear
housing,gearreductionassembly,drivemotor,
brake,anddrivewheel.
PivotBearing
ThePivotBearingisthepartofthedriveunit
assemblythatprovidessupportforthedrive
motor,wheel,andgearhousing.
GearHousing
TheGearHousingisaprecisionmachined
castingintowhichthegearreductionsystemis
assembled.
Gear·ReductionAssembly
TheGearReductionAssemblyiscomprisedofa
motorpinion,drivegear,drive pinion,
compoundgear,andsplinedshaft.Thegears
arecontinuouslybathedingearoil.Thesplined
axleshaftturnsontwoballbearings.
DriveWheel
TheDriveWheelconsistsofapolyurethanetire
mountedonaninnerhub.Thedesignofthe
wheelpermitsreplacementofthetirematerial.
Brake
TheBrakeAssemblyismountedontopofthe
drivemotor. Thebrakeishydraulically-applied
andelectricallyreleasedundercontrolofthe
deadmanpedal.
DeadmanPedal
ADeadmanPedalislocatedonthe
compartmentfloor.Thedeadmanpedalis
springloadedtothepoweroff/brakeengaged
position.Thedeadmanpedaldisablesthetravel
andlift/lowercircuitsandappliesthebrake
wheneverthepedalisreleased.
00700-CL221Issued: 9/10/98
SystemsOverview
DriveandBrake
3-17

57. SystemsOverview
Brake
DeadmanSwitch(52)
SwitchS2islocatedonthebrakeassembly,
nearthedrivemotor, inthepowersection.
Whenthedeadmanpedalisup,switchS2is
activatedcausingthecircuittoopen,
preventingtravelandlift/lowerfunctions.
3-18
ToyotaOrderpickerServiceManual
00700-CL221Issued:
9/10/98

58. ToyotaOrderpickerServiceManual
Mast
MastAssembly
TheMastAssemblyisconstructedofthe
followingparts:
MastMainFrame
TheMastMainFramehasaladdertype
construction.Themastuprightsaremadeof
structuralI-sections.Theuprightsaretied
togetherusingstructuralsteelcrossties.The
mastuprightsareweldedtothebaselegframe,
formingastrongintegralunit.
TelescopicFrame(s)
TheTelescopicFrameisalsoofladdertype
construction.Itis'constructedofstructural1­
sectionsandcrossties.
MastBearings
TheMastBearingsarerollertypeconstruction
andlubricatedforlife.
24"MastSwitch (S11)
The24"switchisphysicallylocatedonthe
carriage,andismountedsothatitisactivated
wheneverthecarriageisbelow24",andnot
activatedwheneverthecarriageisabove24".
60"MastSwitch (S12)
The60"Switchismountedonthe'right-hand
sideofthemast,andismountedsothatitis
activatedwheneverthecarriageisbelow60",
andnotactivatedwheneverthecarriageis
above60".
120"MastSwitch(S10)(with enhanced
speedoption)
The120"Switchismountedontheright-hand
sideofthemastandislocatedabout3feet
high.Itismountedsothatitisactivated
wheneverthecarriageisbelow120",andnot
activatedwheneverthecarriageisabove120".
00700-CL221Issued:9/1 0/98
SystemsOverview
Mast
3-19

59. SystemsOverview
MastAssembly
150"MastSwitch(S26)(without
EnhancedSpeedoption)
The150"Switchismountedontheright-hand
sideofthemastandislocatedabout5feet
high.Itismountedsothatitisactivated
wheneverthecarriageisbelow150",andnot
activatedwheneverthecarriageisabove150".
180"MastSwitch (S100)(withEnhanced
Speedoption)
The180"Switchismountedontheright-hand
sideofthemastandislocatedabout15feet
high.Itismountedsothatitisactivated
wheneverthecarriageisbelow180",andnot
activatedwheneverthecarriageisabove180".
3-20
ToyotaOrderpickerServiceManual
00700-CL221Issued:9/10/98

60. ToyotaOrderpickerServiceManual
HydraulicComponents
Lift/LovverSystem
TheorderpickervariablespeedLift/Lower
Systemiscontrolledmanuallybytheoperator
usingathumbleverlocatedonthedirectional/
speedcontrollerintheoperator'scompartment.
Thelift/lowersystemconsistsof:
•Lift
Pump/MotorAssembly
•LiftCylinders
•LiftChains
•ReseIVoir
•
ReturnLineFilter
•FlowControls
•ReliefValves
•
HydraulicManifoldAssembly
LiftPump
Asplined,fixeddisplacementgearpumpis
usedonallmodels.
LiftCylinderAssembly
TheLiftCylinderiscomposedofthefollowing:
•
CylinderHousing
•Piston
•FlowControls
CylinderHousing
TheCylinderHousingisconstructedofwelded
steeltUbing.Thecylinderhousingisattachedto
themastmainframe.
Piston
ThePistonisencasedwithinthecylinder
housingandliftsthetelescopicsectionofthe
mastassembly.Thepistonisconstructedfrom
chromeplatedtUbing.
FlowControls
TheFlowControllimitstheratefluidleavesthe
cylinderintheeventofa
br<?kenhose.
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SystemsOverview
HydraulicComponents
3-21

61. SystemsOverview
Lift/LowerSystem
LiftChain
TheheavydutyLiftChainisconstructedof3/4
inchpitch,4x4lacedleafchain.Theliftchains
complywithANSI/ASME829.8requirements.
Reservoir
TheweldedsteelReservoirhasacapacityof
approximately5.5gallons(20.8L).The
reservoirislocatedabovethebatteryinthe
powersectionandisventedtotheatmosphere
throughthefillercap.
ReturnLineFilter
TheReturnLineFilterconsistsofa10micron
filterelementandbypassvalvesetat15psi
(103.4kPa)crackingpressure.Theunithasa
replaceablespin-ontypecanister.
Lift/LowerHydraulicManifoldAssembly
TheLift/LowerHydraulicManifoldAssembly
controlshydraulicflowrateanddirectioninthe
lift/lowersystem.Themanifoldassemblyis
controlledelectricallybythelifttruckTractor
InterfaceCard.Theassemblyislocatedinthe
lower,forward,left-handsideofthepower
section.
TheLift/LowerHydraulicManifoldAssembly
consistsof:
•
ManifoldHousing
•CheckValves
•
HighPressureReliefValve
•
FixedLowPressureReliefValve
•
ManualEmergencyLoweringValve
•
ProportionalLowerSolenoid(SOLI)
•
LoadHoldingSolenoid(SOL2)
•
PressureTestPorts
•PressureTransducer(optionalweight
measurement)
ManifoldHousing
TheManifoldHousingismachinedfrom
aluminumandcontainsthe
compon~nts
identifiedinFigure3-4onpage3-26.
3-22
ToyotaOrderpickerServiceManual
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62. ToyotaOrderpickerService Manual
LiftPumpCheckValve(5 PSI)(34kPa)
TheLiftPumpCheckValvepreventshydraulic
oilfromflowingbackthroughtheliftpump.
HighPressureReliefValve
TheHighPressureReliefValve issettoprevent
liftinga loadwhichexceedsthemaximumload
capacityofthelifttruck.
OutputCheckValve(100 PSI)(689kPa)
TheOutputCheckValveprovidesforsmooth
stoppingdUringlift.Itisalsousedasthefixed
lowpressurereliefvalve.
ManualEmergencyLoweringValve
AManualEmergencyLoweringValveprovides
groundlevelcontrolallowingtheoperator's
compartmenttobeloweredintheeventthe
operatorisunabletobringthecarriagedown.
Thisisaknurledknoblocatedonthelift/lower
hydraulicmanifoldassembly.
00700-CL221Issued:9/1 0/98
SystemsOverview
Lift/Lower
System
3-23

63. SystemsOverview
ElectricalComponents
andSystems
ElectricalComponents andSystems
General
Thissectionisanoverview;for actual
operation,seeTheoryofOperationorthe
OperatingInstructionsinthismanual.
The24-voltelectricalsystemsdescription
includes:
•Traction/LiftSystemComponents
•Traction/LiftPowerAmplifiers
•
ElectricSteering
•MiscellaneousCircuits
Traction/LiftPowerAmplifiers
TheTractionandLiftPowerAmplifiers(Figure
3-5onpage3-28)
monito~andcontrolcurrent
flowthroughthetractionandliftmotors,
respectively,Thetractionamplifierisseparately
excitedandcontrolstractionmotorspeedand
.torque.Theliftmotoramplifiercontrolsthe
series-woundliftmotor.Theamplifiersare
locatedontherightsideofthepowersection.
Theamplifiersfeature:
•Smooth,step-lessoperation
•Currentlimiting
•Under/overvoltageandthermalprotection
•Faultprotection
•Plugbraking(tractiononly)
Theamplifiersarelow-maintenancesealed
units,withnouser-serviceableparts.
BatteryConnector
TheBatteryConnectorislocatedontheleftside
ofthetruckandismountedonthepower
sectionframe.
Solenoid1 (SOL1)(VariableLower)
SOLIisthevariablelowersolenoid.Solenoid1
proportionallycontrolshydraulicflowfromthe
liftcylinders.
3-24
ToyotaOrderpickerServiceManual
00700-CL221 Issued:9/10/98

64. ToyotaOrderpickerServiceManual
Solenoid2(SOL2)
SOL2istheloadholdingsolenoid.Itprevents
hydraulicfluidfromleavingtheliftcylinder
whenthecarriageiselevatedandthelift/lower
controlisinneutral.
Solenoid12(SOL12)
SOL12isthebrakedumpsolenoid.When
activated,itreleasesthebrake;when
deactivated,thesolenoidallowshydraulic
pressuretoapplythebrake.
PowerDisconnectContactor(MM)
ThePowerDisconnectContactorisasingleunit
withonecontactactuate'dbyasinglecoil.
NOTE:Contactorsusedaremagnetictype,
designedformaximum
interchangeabilityofparts.Contactor
tipsaresilveralloyandarereplaceable.
DriveMotor
TheDriveMotorisas'hunt-wounddirect
currentmotorandusessealedbearingsforlong
servicelife.Thedrivemotortransmitspowerto
thereductionunitbyapiniongearonthe
motorarmatureshaft.Abrakedrummountson
theotherendofthearmatureshaft.
DriveMotorTemperatureSensor(DT)
Athermisterprovidesatractionmotor
temperatureinputtothetractorinterfacecard.
LiftMotor
Powertodrivetheliftpumpisaserieswound,
fancooled,intermittentdutymotor.
00700-CL221Issued:9/1 0/98
SystemsOverview
General
3-25

65. SystemsOverview
General
Reservoir ESDJack
ToyotaOrderpickerServiceManual
ReturnLineFilter
LiftPump
Motor(DMP)
LiftPump
Steer
Motor
(DMS)
DriveMotor
(DMD)
Figure3-4:HydraulicCompartmentComponents(Sheet 1of2)
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66. ToyotaOrderpickerServiceManual
LiftPump
Emergency
--­
Lower
Valve
ProportionalValve
SOL1
SystemsOverview
General
PressureTest
Connection
Figure3-4:HydraulicComportmentComponents (Sheet2of2)
00700-CL221Issued: 9/10/98
PressureTransducer
(optional)
3-27

67. SystemsOverview
General
LiftMotor _
Steer
Motor
DriveMotor
_~==
Figure3-5:ElectricalCompartmentComponents
ToyotaOrderpickerServiceManual
,F3
F'usesF4-F8
TractionAmplifier
Horn
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68. ToyotaOrderpickerServiceManual
SteeringWheel
KeySwitch Operator'sDisplay
De,adnnanPedal
SystemsOverview
General
Travel,Lift!
Lower
Control
Auto/Manual
On/Off
Switch
Carriage
Interface
Card
Brake
Dump
Solenoid
(SOL12)
PalletClamp
Release
Figure3-6:PlatformComponents(ElectricSteering,CoverRemoved)
00700-CL221Issued: 9/10/98 3-29

69. SystemsOverview
General
CarriageITractorInterfaceCards
Virtuallyalllifttruckinputsandoutputspass
throughandaremonitoredbytheCarriageand
TractorInterfaceCards.TheDisplayCardand
SteerControlleralsohaveI/Ofunctions.The
tractorinterfacecardcontrolsthetractionand
lift/lowersystemsand"talks"totheDisplay
cardovertheCANbus.Thecarriageinterface
cardacceptsinputsfromthecontrolhandle,
andtransfersdatatotheDisplayCard.The
CarriageCardinterfaceswiththeDisplayCard;
ofthetwo,onlytheDisplayCardhas
intelligence.
CarriageInterfaceCard
TheCarriageInterfaceCard(Figure3-7) isan
Input/Output(I/O)cardthatreadsandpasses
thereadingstotheDisplayCard.Readings
involveinput/outputfromswitches,thecontrol
handle,andthebrakedumpsolenoid,
including:
•ControlHandleSwitchesandControls
•EPOSwitch
•24"LimitSwitch
•60"LimitSwitch
•KeySwitch
•Auto/ManualSwitch(optional)
•Left
SidegateSwitch(optional)
•
RightSidegateSwitch(optional)
•
ControlHandle
ODD
PC7 PC8
PC9
PeS PC4 PC3
DD0
Figure3-7:CarriageInterfaceCard
ToyotaOrderpickerServiceManual
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70. ToyotaOrderpickerServiceManual
TractorInterfaceCard
TheTractorInterfaceCard(Figure3-8) isan
Input/Output(I/O)cardthatreceivesinput/
outputfromswitches.sensors.andsolenoids.It
iscontrolledbytheDisplayCard.
SwitchInputs:
•LiftBrushWearSwitch
•TractionBrushWearSwitch
•BrakeSwitch
•150"/180"Switch
•120"Switch
•LiftInhibitSwitch(optional)
SensorInputs:
•LiftSense
•MMContactorSense
Outputsare:
•
ProportionalSolenoid
•LoadHoldingSolenoid
•MMContactor
•Hom
SystemsOverview
General
PR2 PR1
[:]1 IDOD0D
PR11 PR10 PR9 PR8PR7PR6 PRS
Figure3-8:TractorInterfaceCard
RegulatedPowerSupply
ARegulatedPowerSupplyislocatedonthe
SteerControllerCard.Thepowersupply
deliversclean.stabilizedpowerthroughoutthe
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71. SystemsOverview
General
network.Voltagesgeneratedbythepower
supplyare:
• +
12volts(forallcards)
•+5voltsusedbytheSteerControllerCard
NOTE:Thispowersupplyshouldnotbeusedto
operateadd-onaccessories.
3-32
ToyotaOrderpickerServiceManual
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72. ToyotaOrderpickerServiceManual
SteerControllerGuidanceSystem
Theelectricsteeringcontrolsysteminterfaces
withtheTractorInterfaceCardandtheDisplay
Card,anddeterminesthetrucksteerdirection.
Thesteeringsystemiscomprisedofthe
followingcomponents:
•SteerController
•SteerMotor(DMS)
•
DisplayCard(seeNote)
•
FilterCard(optionalwiregUidance)
•
SteeringEncoder
•HomeSwitchProximitySensor
•Antennas(LoadandTractor-wire
gUidance)
•
Cables
NOTE:TheDisplayCardisintegratedwithall
systems.
SteerController
TheSteerControllerCard(Figure3-9onpage
3-34)containsstatusLED'sandamaintenance
display.Thissectiondescribeshowthedisplay
worksandwhattheLED'smean.
Theindividualitemsdiscussedarethe:
•HeartbeatLED
•
CANLED
•+12VoltLED
•+5VoltLED
•
SevenSegmentDisplay
00700-CL221Issued:9/1 0/98
SystemsOverview
SteerControllerGuidance
System
3-33

73. SystemsOverview
SteerControllerGuidanceSystem
ToyotaOrderpickerServiceManual
+5VoltLED~ +12VoltLED
HeartbeatLED--...~_______
CANLED ~I::¥--rA!lili!lii!l:i!'~
A
'I JSl
!LJ~
j iI
Seven Ie ~-i
Segment iE1f1 -
Display I§EJPl
;~
Ip
i§i
Itffi
it$
!~
.~JP2
!lE
!LLW
FirmwareSocket
Fjgure3-9: SteerControllerCard
i§JP3
j;::q::q;ESE":
I,
!'++'+'JP4
'i:±:t:tt::
i~JP5
!t:!:I:t1:j
,
JS2(reij
HeartbeatLED
TheHeartbeatLEDwillturnOn/Offatarateof
approximately60timesperminute.
AslongastheheartbeatLEDisblinking.the
processoronthecardisworking.
CAN
CANstandsforControllerAreaNetwork.ACAN
isacommunicationprotocoldevelopedfor
"noisy"environments.ACANusestwodigital
signallinesreferredtoasBus+andBus-.
3-34 00700-CL221Issued: 9/10/98

74. ToyotaOrderpickerService Manual
CANLED
TheCANLEDindicatesthestatusof
communicationsontheCANBusbetweenthe
SteerControllerCardandtheDisplayCard.
•WhentheCANLEDisOff,communications
acrosstheCANBusarebeingprocessed
withouterror.
•WhentheCANLEDisOn,anerrorin
communicationsacrosstheCANBushas
beendetected.
+12VoltLED
The+12VoltLED islitaslongas+12voltsis
beinggeneratedbythepowersupplyonthe
SteerControllerCard.TheLEDonlyindicates
that+12voltsisbeinggenerated,notthatthe
voltageiswithinspecification.
+5VoltLED
The+5VoltLED islitaslongas+5voltsis
beinggeneratedbythepowersupplyonthe
SteerControllerCard.TheLEDonlyindicates
that+5voltsisbeinggenerated,notthatthe
voltageiswithinspecifications.
SevenSegmentDisplay
TheSevenSegmentDisplayisusedto
communicatethestatusofthesteercontroller
gUidancesystemtothetechnician.Whenthe
systemisoperatingnormallyatidle,each
segmentofthesevensegmentdisplaywilllight
oneatatime.Thisprocesswillrepeat
continuouslyuntilthesteering/guidance
systemisactivated.
Sincethisisasinglesegmentdisplay,a code
havingtwodigitsmustbedisplayedonedigitat
atime.Also, thedisplayisnotabletoshowall
characters.Anexampleofhowsomeofthe.
codesaredisplayedfollows:
00700-CL221Issued: 9/10/98
SystemsOverview
SteerControllerGuidance
System
3-35

75. SystemsOverview
SteerControllerGuidanceSystem
f I
[3]--[2]Code9KIsdIsplayed.
III1--1iICode53IsdIsplayed
fClEllLJ--~ CodeF2IsdIsplayed.
ToyotaOrderpickerServiceManual
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76. ToyotaOrderpickerServiceManual
DisplayControllerCard
TheDisplayControllerCardislocatedonthe
operator'sconsole.Thedisplaycontrollerserves
asacommunicationdeviceandasafeed
throughforsignalsfromthesteeringencoderto
theSteerControllerCard.Itdisplays,intext,
variousmessagesaboutallthetrucksystems.
ItalsohasakeypadandadditionalLED'sto
interfacewiththeoperatorandtechnician.
Figure3-10onpage3-38identifiesthevarious
partsofthedisplaycard.Individualitems
include:
•ILl
•LEDDisplay
ILl
ILlistheredLEDlocatedontheupperleft
cornerofthecardassembly.ILlwillblinkata
rateofapproximately60timesperminuteand
willstarttoblinkwhen:
•Successfulcommunicationswiththesteer
controllerisestablished.
Alpha-numericDisplay
TheAlpha-numericDisplayistheportionofthe
cardassemblythattheoperator/technician
sees.Thisdisplayshowsoperationandfault
messages.
00700-CL221Issued: 9/10/98
SystemsOverview
Display
ControllerCard
3-37

77. SystemsOverview
DisplayController
Card
ToyotaOrderpickerServiceManual
HDI
~
Firmware
Socket•
:~ :,
l;\:: ~HD5
HD2(baL;---/~/
HD3
JSI(backside)
Figure3-10:DisplayControllerCard
FilterCard
TheFilterCard(Figure3-11onpage3-39)is
usedonlywhenwiregUidanceisinstalled.The
filtercardmountsontopoftheSteerController
Card.Individualitemsonthefiltercard
include:
•JSl
•JWl
•JW2
•ILl(+12volts)
•IL2(+5volts)
JSl
Thisconnectorislocatedontheundersideof
thefiltercard.Thisconnectormateswiththe
SteerControllerCard.
JW1/JW2
TheJWlconnectorconnectsthetractor-end
sensorstothefiltercard.TheJW2connector
connectstheload-endantennatothefilter
card.
3-38
~\
HD4
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78. ToyotaOrderpickerServiceManual SystemsOverview
DisplayController
Card
ILl(+12volts)
The+12VoltLED islitaslongas+12voltsare
beinggeneratedbythepowersupplyonthe
SteerControllerCard.TheLEDonly indicates
that+12voltsarebeinggenerated.notthatthe
voltageiswithinspecification.
+5VoltLED
The+5VoltLED islitaslongas+5voltsare
beinggeneratedbythepowersupplyonthe
SteerControllerCard.TheLEDonly indicates
that+5voltsarebeinggenerated.notthatthe
voltageiswithinspecification.
IL2(+5volts)
~
I
• ILl(+12volts)
-
~------r-
.~
II
I
JS1(farside)
JW2IIIIII~l
/
i
Figure3-11:FilterCard(withwireguidanceonly)
00700-CL221Issued: 9/10/98 3-39

79. SystemsOverview
MiscellaneousCircuits
MiscellaneousCircuits
Fuses
FusesontheOrderpickerincludethefollowing:
ToyotaOrderpickerServiceManual
FuseNumber Rating Used For.
FI 70amps PowerFuseforSteerController
F2 350amps PowerFuseforTractionController
F3 450amps PowerFuseforLiftController
F4
15amps PowerFuseforTractorIIF,B+F
F5
15amps PowerFuseforTractorIIF,B+PC
F6
15amps GroundFuseforTractor I1F,B-F,
DGND
F7 6amps PowerFuseforTractor
IIF,ExtB+
F8 6amps GroundFuseforTractor
IfF,ExtB-
F9 1.5amps StrobeFuse
Sidegate
S\¥itches(560,S61)
TheSidegateSwitchespreventalltraveland
lift/lowerfunctionswhenthesidegatesarein
theverticalposition.Thesidegateswitches
supplyaninputsignaltotheCarriageInterface
Cardwhichmonitorstheirstatus.
Tie-Points
Four(4)Tie-Points(TP)arelocatedonthelift
truck:TPI(Fl-B+);TP2(F2-TractionMotor);
TP3(F3-LiftMotor) andTP4(B-).
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