7bpue15 SN 80001 - Repair Manual cl222-05

Service
Manual
7BPUE15
Serial Numbers
80,001 and up
TOYOTA
Service Manual
High Level Orderpicker
Model 7BPUE1 5
Serial No. 80,001 and up
00700-CL222-05,
15 March 2005
O 2005 by Toyota Industrial Equipment
All rights reserved. N o portion of this manual may be reproduced mechanically, electronically or by any
other means, including photocop y ing, electronic retrieval or transfer, or recording without the written
permission of the publisher.
Toyota Industrial Equipment believes the information in this manual is accurate and current as of the
publication date; such information is subject to change without notice. Toyota Industrial Equipment is not
responsible for any errors that may appear in the manual.
Toyota Orderpicker Model 7BPUE15 Service Manual Table of Contents
Table of Contents
How to Use This Manual ................................. 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 .
ManualDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 .
Page Revision Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 .
STARTPage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 .
Safety ............................................... 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 .
Generalsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 .
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 .
Staticsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 .
JackingSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 .
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 .
Towing a Disabled Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 .
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 .
Systems Overview ...................................... 3-1
Vehicle Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 .
General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 .
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 .
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 .
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 .
UL Label "EE" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12.
Planned Maintenance ................................... 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 .
Interval 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3.
Interval 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4.
Interval 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8.
Troubleshooting ....................................... 5-1
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 .
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-3 .
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 .
Troubleshooting Wiring Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 .
Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 .
Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 .
Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 .
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
.
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
.
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . 5-16 .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
.
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . 5-18 .
Programmable Maintenance Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 .
Drive Unit Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 .
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 .
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . 5-31 .
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . 5-33 .
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . 5-34 .
Codes and Tests ....................................... 6-1
Operator Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 .
Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 .
...
00700.CL222.05, 1 5 March 2005 III
Table of Contents Toyota Orderpicker Model 7BPUE15 Service Manual
Traction Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Operator Display Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Component Procedures .................................. 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Component Locator Photos .............................. 7-5
Covers and Finish .................................... 7-11
Tractor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 .
Operator Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 .
Mast Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13.
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
.
Steering and Controls .................................. 7-15
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 .
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 .
DriveandBrake ...................................... 7-23
Driveunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24.
Drivewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 .
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
.
Electrical Components ................................. 7-31
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 .
Motors (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 .
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39.
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
.
Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 .
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
.
Contactor Tip Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50
.
Circuit Cards (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 .
Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55 .
Hydraulic Components ................................. 7-57
Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 .
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 .
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60.
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Lift Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 .
Lift Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . .7-63
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64 .
Side Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 .
Center Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69.
Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Mast Section ........................................ 7-73
Three-Stage Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 .
InnerMast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-78 .
Outer Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-81 .
Two-Stage Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 .
Two-Stage Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Mast Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85 .
Mast Disassembly and Shimming . . . . . . . . . . . . . . . . . . . . . . . . . .7-87
Lift Chains. Three-Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91 .
Lift Chains. Two-Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93 .
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-94
.
00700.CL222.05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Table of Contents
Pallet Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95

Loadwheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96 .
SkidPads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-97 .
Wire Guidance ......................................... 8-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..2
Install K t Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. .3
Set-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..9
CodesandTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 .
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-35
.
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8..37
Troubleshooting in Flashware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8..38
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. .40
Theory of Operation .................................... 9-1
Battery Plugged In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9..4
Key Switch (Sl)On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . 10
Closing Deadman Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 .. 16
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
..
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9..28
Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34.
Primary Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. .50
PinoutMatrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-51 .
Firmware Configuration ................................. 10-1
Flashware Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 .
Appendix ............................................. A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 .
Torque Chart . Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 .
Torque Chart . Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 .
Torque Chart . Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5 .
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6 .
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8 .
Electrical Schematics ................................. A- 11
Hydraulic Schematic .................................. A- 18
00700.CL222.05, 1 5 March 2005

Table of Contents Toyota Orderpicker Model 7BPUE15 Service Manual
This page intentionally left blank
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 1 . How to Use This Manual
Section 1. How to Use This Manual
00700-CL222-05, 1 5 March 2005

Section 1 . How to Use This Manual Toyota Orderpicker Model 7BPUE15 Service Manual
M a p of the Manual
Map of the Manual
How To Use This

Manual
r Table of Contents
rn Safety Map of the Manual
I
Systems Manual Design
Overview Vehicle Specifications
Page Revision Record

Planned Special Tools
Maintenance
Troubleshooting
rn
Codes and Tests
9 Go to Chart
Figure 1 - 1
00700-CL222-05, 1 5 March 2005

M a p of the Manual
Component Alphabetical List of

Procedures Component
Procedures
Q
Component Location
!
Wire Guidance Photos
Appendix
I Lubrication
Specification Chart
Component
Procedures by Lift
Theory of Truck Systern
Operation
Torque Charts
Software
Configuration
Decimal Equivalent
Chart ~
Standard/Metric
Conversions
Electrical and
Hydraulic
Schematics
00700-CL222-05, 1 5 March 2005

Manual Design
Once you're familiar with the symptoms
Manual Design listed, you may instead simply find the
symptom chart from the
This Service Manual is designed with the Troubleshooting Flowcharts
following objectives in mind: (Page 5-27).
Provide technical coverage for expected When you complete a troubleshooting
levels of user expertise. procedure, be sure to follow the steps in
Anticipate your needs and reduce your End of Troubleshooting Chart END-1
decisions regarding maintenance. (Page 5-28).
Reduce page flipping through a "one-stop Codes and Tests lists the electrical fault
shopping" approach. codes and procedures for running
firmware electrical tests.
The two-line running page header a t the top of Component Procedures gives
each page tells you: step-by-step procedures for testing,
Name of the manual removal, installation, and adjustment of
(OrderpickerModel 7BPUE15Service individual truck components. Components
Manual) are grouped by truck system.
Current Chapter Title To find a component procedure, you may
(e.g., this page How to Use This Manual) use one of three methods:
Current topic Look u p the component name in the
(e.g., this page Manual Design) List of Component Procedures
(Page 7- 1).
We suggest turning to the START page first Find the component in the Component
when you use this manual. Locator Photos (Page 7-5).
Look u p the component name in the
The START page asks a few simple questions to
Service Manual Index (Page I- 1).
guide you to the proper chapter.
Theory of Operations explains signal flow
How to Use This Manual explains the
within hydraulic and electrical schematics
manual format and design and contains
for various conditions of truck operation.
the Table of Contents and START page.
Appendix contains reference information
Safety explains warning and caution
such a s torque values, lubrication
notes, general safety rules and safety rules
specifications, and system schematics.
for batteries, static, jacking, and welding.
Index lists subjects alphabetically.
Systems Overview includes truck
dimensions and specifications.
Planned Maintenance outlines the
recommended schedule of preventive
services to keep your truck working most
efficiently.
Troubleshooting is a set of "decision-tree"
charts designed to take you from a
symptom to a specific sequence of tests in
order to isolate a failing component.
The START TROUBLESHOOTING
chart (on Page 5-27) will guide you to
the individual troubleshooting
symptom chart you need.
00700-CL222-05, 1 5 March 2005

Page Revision Page
Page Revision Page

This section is a record of all revised pages in
this manual. Whenever a page is revised, this
section is updated and included in the revision
package. this lets you keep track of the latest
revised pages for this manual.
Original Issue - No Changes
00700-CL222-05, 1 5 March 2005

Page Revision Page
00700-CL222-05, 1 5 March 2005

START Page
START Page
( START
Go to Section 2
Y e s 4 "Safety
precautions?
To examine Go to Section 3
specifications? Yes "Systems Overview"
Go to Section 4
To do scheduled "Planned Maintenance"
Yes
maintenance?
Go to Section 5
Yes "Troubleshooting"
a problem?
1 Go to Chart 1
\ Troubleshooting Guidelines
Troubleshooting Charts
Figure 1-2.
00700-CL222-05, 1 5 March 2005

START Page
Go to Section 7
inspect, adjust,
remove/install a "Component Procedures"
1 Go to Section 9
Yes
7 ' m e o l y of Operation' I
Go to Section A
"Appendix
Yes
Yes
1 Return to 1
Figure 1-3.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 2. Safety
Section 2. Safety
00700-CL222-05, 1 5 March 2005

Section 2. Safety Toyota Orderpicker Model 7BPUE15 Service Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

situation exists which, if not avoided,
could result in death or serious injury.
ACAUTION
Caution means a potentially hazardous
situation exists which, if not avoided,
could result in minor or moderate injury
or in damage to the truck or nearby
objects.
00700-CL222-05, 1 5 March 2005

General Safety
General Safety
Operate this truck only from the operator's

position. When elevated, be sure to wear a
Do NOT operate or work on this truck unless safety belt attached to a secured tether.
you are trained, are qualified and authorized to
do so, and you have read the Owner/Operator
Manual.
Before working on this truck, always turn the

kev switch OFF and disconnect the truck's
d
battery connector (unless this manual tells you

Know the truck's controls and what they do. otherwise).
Do NOT operate this truck if it needs repair or if Do NOT wear watches, rings, or jewelry when
it is in any way unsafe. working on this truck.
00700-CL222-05, 1 5 March 2005

General Safety
Do NOT use gasoline or other flammable liquids
for cleaning parts.
Follow the scheduled lubrication, maintenance
:a;
and inspection steps.
Clean u p any hydraulic fluid, oil or grease that
has leaked or spilled on the floor.
Follow exactly the safety and repair instructions

in this manual. Don't take "shortcuts".
Always use and park this truck indoors.
Do NOT park a truck in a cold storage area

overnight unless the truck is conditioned for
cold storage.
Do NOT use a n open flame near the truck.
Do NOT wash this truck with a hose.
00700-CL222-05, 1 5 March 2005

General Safety
Do NOT add to or modify this truck until you

contact your authorized Toyota Dealer to
receive written manufacturer approval.
00700-CL222-05, 1 5 March 2005

Battery Safety
goggles or face shield, rubber gloves (with or
Battery Safety without arm shields) and a rubber apron.
As a battery is being charged, an

explosive gas mixture forms within and
around each cell. If the area is not
properly ventilated, this explosive gas
can remain in or around the battery , for
several hours after charging. Be sure
there are no open flames or sparks in
the charging area. An open flame or
Make sure a shower and eyewash station are
spark can ignite this gas, resulting in
nearby in case there is a n accident.
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get on
your face or in your eyes, flush the area
with cold water and get medical help A battery gives off explosive gases. NEVER
immediately. smoke, use a n open flame, or use anything that
gives off sparks near a battery.
Wear personal protective equipment to protect

eyes, face and skin when checking, handling or
filling batteries. This equipment includes
00700-CL222-05, 1 5 March 2005

Battery Safety
Keep the charging area well-ventilated to avoid Keep plugs, terminals, cables and receptacles in
hydrogen gas concentration. good condition to avoid shorts and sparks.
Turn the key switch OFF before disconnecting

the battery from the truck a t the battery
connector. Do not break live circuits a t the
battery terminals. A spark often occurs a t the Keep filler plugs firmly in place a t all times
point where a live circuit is broken. except when the electrolyte level is checked,
when water is added to the cells or when the
specific gravity is checked.
Make sure the vent holes in the filler plugs are

open to allow the gas to escape from the cells.
Do not allow cleaning solution, dirt or any

foreign matter to enter the cells.
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect truck stability. See the truck's
specification plate for more information.
00700-CL222-05, 1 5 March 2005

Battery Safety
Never plug a battery charger into the truck's
battery connector. Plug the battery charger only
into the battery connector from the battery.
Follow the charging procedures in the Battery

Instruction Manual and in the Battery Charger
Instruction Manual.
00700-CL222-05, 1 5 March 2005

Static Safety
Static Safety Whenever working on or near static-sensitive

electronics, always use static discharge
precautions.
1. Place a static discharge wrist strap around
your wrist. Connect the ground lead to the
wrist strap connector.
2. Plug the ground cord into the ESD plug on
the electrical assembly panel or the
console panel. See Figure 2- 1 and
Figure 2-2.
3. Before removing or installing
static-sensitive components, place them
on a properly grounded static mat.
See Figure 2-3.
4. To transport static-sensitive components,
including failed components being
Figure 2- 1 . ESD Plug On Tractor returned place the components in a n
anti-static bag or box (available from your
Electronic circuit boards and devices used on Toyota Dealer).
this truck can be damaged by the discharge of
static electricity, called electrostatic discharge. The wrist strap and associated accessories
should be tested monthly to verify they are
Static charges can accumulate from normal working properly. A bad static discharge wrist
operation of the truck a s well a s movement or band will not alert you that it is bad.
contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles Figure 2-3 shows the components of the Toyota
on shoes, styrofoam coffee cups, etc.). anti-static field service kit, part number
00590-04849-71. The kit includes a wrist strap,
Accumulated static can be discharged through ground cord and static-dissipative work surface
human skin to a circuit board or component by (mat). Follow the instructions packaged with
touching the parts. Static discharge is also this kit.
possible through the air when a charged object
is placed close to another surface a t a different
electrical potential. Static discharge can occur
without you seeing or feeling it.
Figure 2-2. ESD Plug on Operator Console
00700-CL222-05, 1 5 March 2005

Static Safety
Wrist Strap Static-Dissipative

\ Work Surface
Ground Cord
Figure 2-3. Anti-Static Kit W i t h Wrist Strap a n d M a /
Wrist straps are available in quantities of 25, as

part number 00590-04848-7 1.
A wrist strap tester is available as part number

00590-04850-71.
Contact your authorized Toyota Dealer for

information.
00700-CL222-05, 1 5 March 2005

Jacking Safety
Jacking Safety Tractor
Sometimes you may need to jack the truck up

from the floor to perform maintenance
ACAUTION
Use care when jacking the tractor on
procedures. When doing so, observe the proper
wire-guided trucks. Sensors are
safety precautions:
installed under the bumper. See
1. Lower the forks completely. Remove any Figure 2-4.
load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Disconnect the battery connector.
5. Place the jack under the designated
jacking points listed in the following
procedures.
Use extreme care whenever the truck is Only jack in these areas,
jacked up. Keep hands and feet clear no more than 1 /2 in.
from the vehicle while jacking the truck. ( 1 3mm) off the floor.
After the truck is jacked, place solid
blocks beneath it to support it. DO NOT Figure 2-4. Tractor Jacking Points
rely on the jack alone to support the
truck. 1. Place the jack a t the designated jacking
point. See Figure 2-4.
Operator Platform 2. Jack one side of the truck so that the drive
tire is off the floor approximately 1 inch
1. Using the lift button, raise the operator (25.4 mm).
platform until you have enough clearance
for your procedure. 3. Block that side of the truck in place.
2. Place a safety stand or block between the 4. Jack u p the other side of the truck level
carriage and a baseleg and carefully lower with the first side.
the operator platform onto the safety 5. Block that side of the truck in place.
stand.
NOTE: After working on a vehicle, test all
3. Turn the key switch OFF and disconnect controls and functions to assure proper
the battery. operation.
00700-CL222-05, 1 5 March 2005

Jacking Safety
Baseleg
Figure 2-5. Baseleg Jacking Points
1. Place the jack a t the designated jacking

point. See Figure 2-5.
2. Jack the baseleg until you have enough
clearance to replace the load wheel.
00700-CL222-05, 1 5 March 2005

Tie-Down for Transport
a. Install eye-bolts (3/4 in. [19 mm] thread
Tie-Down for Transport size) in holes in the bumper. See
Figure 2-6.
b. Secure chain ti-on1 ye-bolts to vehicle
bed. See Figure 2-7.
4. Strap truck ti-on1 Ijumpcr or guide roller to
tloor of transport vehicle. See Figure 2-7.
5. Chock tlrive wheel to prevenr rractor-firs1
movement. See Figlire 2-7.
6. Place block Ijctwccn ljasclcg and platbrm,
Figure 2-6. Eye-Bolts Installed for Transport 7.5 in. (190.5 cm) from front edge of
platform. See Figure 2-7.
Vertical Transport 7. Position additional adjustable chain or
strap perpendicular to forks over
To transport this lift truck in a n over-the-road operator's platform and attach it to vehicle
vehicle or rail car, follow these steps: bed. This will prevent tip-over during
1. Lower operator platform and locate truck transportation. See Figure 2-7.
in center of transport vehicle.
2. Turn key switch OFF and disconnect Horizontal Transport
battery. 1. Remove forks from carriage.
NOTE: If guide rollers are present, place straps 2. Replace cap and screen in hydraulic
through guide rollers and secure to reservoir with shipping cap and screws.
floor; proceed to step 4.
3. Band down carriage and battery rollers.
3. If guide rollers (used for rail guidance) are 4. Remove dipstick, and plug drive unit.
not present:
5. Remove the bottom two bumper plate bolts
(to be replaced during shipping).
6. Use two hoists in conjunction and lay
truck on cradle.
7. Install long bolts through the holes in the
bumper and secure to cradle.
8. Band truck to cradle.
9. Secure forks to cradle below mast.
\ \ \
Chock Vehicle Strap or
Block Bed Chains
Figure 2-7. Tie-Down for Vertical Transport
00700-CL222-05, 1 5 March 2005

Towing a Disabled Unit
Towing a Disabled Unit release bolts provided. See Figure 2-8

and Figure 2-9.
To safely tow a Toyota Orderpicker: Steering is disabled while you are

towing, so you will need to manually
1. Lower the operator platform and remove turn the drive unit to steer.
any load.
2. Turn the key switch OFF and disconnect
the battery connector.
3 . Using a suitable towing vehicle, lift the
tractor end of the truck until the drive tire
is no more that 1 inch (25.4 mm) off the
floor.
4. Tow the truck slowly in the tractor-first
direction.
Figure 2-9. Brake Release Bolts
Figure 2-8. Location For Release Bolts In Brake
NOTE: If you must tow the truck flat on the

ground, you must install the brake
00700-CL222-05, 1 5 March 2005

Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service or repair the
lift truck. Discharge residual charge in
Flame cutting or welding on painted the traction power amplifier by pressing
surfaces may produce potentially in the PC and P contactors at the same
harmful fumes, smoke and vapors. Prior time.
to performing flame cutting or welding
operations, it is recommended that the Check for any shorts to the frame a s
coating be removed in the vicinity where described on page 5-4. If any shorts are
the operation(s) will be performed. detected, remove them before you proceed
with the welding operation.
Clean the area to be welded.
Protect all truck components from heat,
weld spatter and debris.
Coating removal may be by mechanical
Attach the ground cable a s close to the
methods, chemical methods or a
weld area a s possible.
combination of methods. Flame cutting
and/or welding operations should be Do not perform any welding operation
carried out only in well ventilated areas near the electrical components.
using local exhaust if necessary. If welding must be done near the battery
compartment, remove the battery.
When you are finished welding, perform all
ground tests and electrical inspections
before the vehicle is operated.
Before working on this truck, make sure that:

Fire protection equipment is nearby.
You know where the nearest eyewash
station is.
00700-CL222-05, 1 5 March 2005

Welding Safety
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 3. Systems Overview
Section 3. Systems Overview
00700-CL222-05, 15 March 2005

Section 3. Systems Overview Toyota Orderpicker Model 7BPUE15 Service Manual
Vehicle Specification
Table 3- 1 . General Information a n d Dimensions
Power unit 24 Volt
Truck length 108.3 in. 2750 mm
Truck overall width (OAW) 40 in. 1016 mm
Turning radius 68.75 in. 1746.25 mm
Maximum usable battery compartment 31 x 13 x 30.88 in. 787 x 330 x 784 mm

(L x W x H)
Maximum usable battery compartment 36.88 x 14 x 30.88 in. 924 x 356 x 784 mm
with optional larger battery
compartment (L x W x H)
Gradability See Footnotea
Battery weight for alternate load 920 lbs. 2000 lbs. 418 kg 908 kg
capacity
Battery weight 1600 lbs. 2000 lbs. 726 kg 908 kg
Battery ampere-hours 450 Minimum
I I 1085 Maximum
Maximum load capacity 3000 lbs. to 216" 1361 kg to 5486 mm
2500 lbs. to 240-241" 1 135 kg to 6096 mm-612 1 mm
Alternate load capacity 3000 lbs. to 240-241" 1350 kg to 6096 mm-6121 mm
a. The Model 7BPUE15 is designed for level floor operation only. It is capable of being driven
in a fully lowered, unloaded condition on a maximum 100 ft. long ramp with a maximum
incline of 6%.
00700-CL222-05, 1 5 March 2005

Table 3-2. Mast Specifications
7BPUE15 88.5 2248 123 3124 208 5283 4650 2109

(2-Stage) 95 2413 137 3480 222 5639 4680 2123
107 2718 161 4089 246 6248 4730 2146
127 3226 201 5105 286 7264 4814 2186
147 3734 241 6121 326 8280 4898 2224
7BPUE15 88.5 2248 183 4648 268 6807 3 76 5270 2390
(3-Stage) 95 2413 204 5182 289 7341 10 254 5300 2404
107 2718 240 6096 325 8255 22 559 5350 2427
a. Overall Collapsed Height (OACH).Tolerances = +.5 in. (+13mm)
b. Tolerances = +.5 in. ( + I 3mm)
c. Tolerances = +2.5/-.5 in. (+67/-13 mm)
00700-CL222-05, 1 5 March 2005

24"-28" (610-71 1mm)

Fork Adjustment
40" (1016mm) 39"

min. OAW (99 1mm)
Power Unit & Platform
Baselegs Width
\ 2" (51mm)
Opening
Safety Belt & 2" (5 1mm) OHG Thickness

Tether \ J
Extended 78.5" (1994mm)
Operator Compartment 85"
(2 159mm)
7" (178mm) Battery
Bumper to CL of
Drive Tire 72.5" (1 842mm)
Head Length
1 . Standard fork length = 42" (1067 mm)

Optional fork lengths = 30" (762 mm),
36" (914 mm) or 48" (1219 mm)
00700-CL222-05, 1 5 March 2005

General System Data
General System Data Chassis

DEFINITION: Basic frame of the lift truck;
includes baselegs, bumper and
Carriage mast.
DEFINITION: Part of the truck that moves by
hydraulic force; includes operator
platform.
Mast
ss
Operato~
Platform
Bumper
Baseleg
Figure 3- 1. Model 7BPUE15, Carriage View
00700-CL222-05, 1 5 March 2005

General System Data
Tractor
DEFINITION: Holds the majority of electrical and
hydraulic components of the lift
truck, including the power section
and lift motor and pump. For the
location of specific components, See
"Component Locator Photos" on
page 7-5.
Figure 3-2. Model 7BPUE15, Tractor View, Cover Removed
00700-CL222-05, 1 5 March 2005

Installation lnstructions
Installation Instructions
NOTE: These instructions pertain to trucks that
are shipped horizontally on a cradle.
1. Remove long bolts from bumper plate (two
bottom bolts).
2. Remove banding, forks and truck from
cradle.
3. Use two hoists in conjunction to stand
truck upright.
4. Install 2 bumper plate bolts.
5. Install dipstick in drive unit.
6. Remove shipping cap and screws in
hydraulic reservoir and install cap and
screen.
7. Install forks. See "Forks" on page 7-94.
8. Install battery. See "Battery Procedures"
on page 7-32.
9. Connect battery, turn key switch ON and
test truck functions.
00700-CL222-05, 1 5 March 2005

Wire Guidance
Wire Guidance
Wire guidance is a means to automatically steer
the truck while traveling in a n aisle. I t offers
precise steering a t full-speed travel in very
narrow aisle (VNA)applications.
A wire guidance system consists of two

sub-systems.
Warehouse-installed equipment includes a
guide wire and line driver. The guide wire
is in the floor and emits a n alternating
current (AC) signal a t a specific frequency
and amplitude generated from the line
driver.
Truck-installed equipment includes:
- Two guidance sensors, tractor end and
load end
- Guidance manager, in tractor
- Filter card, on guidance manager
- Travel speed feedback encoder, on top of
the drive motor
- Steer feedback encoder, on top of the
steer motor
- Auto manual switch, on operator
console
- Associated cables and mounting
brackets
The truck must learn the amplitude and
frequency of the guidance signal to
properly track the guide wire.
NOTE: This manual will cover all
truck-installed equipment.
To operate wire guidance, see the Model

7BPUEl5 Operator Manual.
See "Wire Guidance" on page 8- 1.
00700-CL222-05, 1 5 March 2005

Cold Storage
Cold Storage
Cold storage is a factory-installed option that
enables truck operation in temperatures of
-20" F (-28.86" C) to 40" F (4" C).
On cold storage trucks, the electrical panel on

the tractor is completely enclosed to contain
heat. Components added to the truck for cold
storage are listed in the tables below and shown
00700-CL222-05, 1 5 March 2005

Cold Storage
COLD STORAGE CARRIAGE

CONTROL HANDLE
JPC2 12
FU13
JPHl41 $& $&JPHIA~
JPH13 1
WIRES
TP4
JPH122
COLD STORAGE TRACTOR
Figure 3-3. Cold Storage Electrical Schematic
00700-CL222-05, 1 5 March 2005

UL Label "EE"
UL Label "EE"
Underwriters Laboratories (UL) ratings indicate
that specific criteria have been met by the
manufacturer, and tested and documented by
UL. "EE" designated trucks are electrically
powered units that have, in addition to all of the
requirements for "E" and "ES" units, electric
components completely enclosed. In certain
applications, an "EE" truck may be used where
an "E" or "ES" truck may not be considered
suitable.
00700-CL222-05, 1 5 March 2005

Special Tools
Special Tools BDI (Battery Discharge Indicator) cutout

threshold
Options
Learn throttle
Diagnostics
For operating instructions, See "PC Loader

Program" on page 10-2.
Ram Service Tools

Use these tools when repacking the side
cylinders or center cylinder.
Tool Part Number
Figure 3-4. Programmable Maintenance Tool Side Cylinder Service Guide 00590-454 16-71
Side Cylinder Service Driver 00590-454 15-71
Pro rammable Maintenance
Too f Center Cylinder Service
Guide
00590-05258-7 1
The optional programmable maintenance tool Center Cylinder Service 00590-05257-7 1

(PMT) (P/N 00590-49981-71) allows you to test, Driver
program (or configure) and diagnose the
traction power amplifier in this truck. Lift/Lower Pendant
The PMT is powered by the host amplifier The lift/lower pendant (P/N 00590-46325-71) is
through the four-pin connector a t the top a tool that allows you to use the hydraulic
corner of the traction power amplifier. See system independent of the lift and lower
Figure 3-4. switches. This pendant connects to the
steer/tractor manager a t JT1.
See "Programmable Maintenance Tool" on
page 5-20.
Pin Extractor
Use the pin extractor (P/N 00590-04672-71)
when removing wires from any connectors.
FlashWare
The FlashWare software allows you to update
truck software, configure options and
troubleshoot electrical components on this lift
truck. Selections include:
Flash memory program
Clear primary memory
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 4. Planned Maintenance
Section 4. Planned Maintenance
00700-CL222-05, 1 5 March 2005

Section 4. Planned Maintenance Toyota Orderpicker Model 7BPUE15 Service Manual
Maintenance Guidelines
Maintenance Guidelines Interval 1 Daily or Eight Hours
Interval 2 Moderate Usage: Every 6 Months or 500

A planned maintenance program is
Hours
recommended to enable: Severe Usage: Every 3 Months or 250
Maximum truck performance Hours
Maximum truck life Interval 3 Moderate and Severe Usage: Every Year
Reduction of costly down time or 1500 Hours
Avoidance of unnecessary repairs Table 4- 7 . Suggested Maintenance tntervais
Planned maintenance includes:

See Figure on page A-2 in the Appendix for
Lubrication
lubrication specifications. Refer to the
Cleaning manufacturer's supplements for components
Inspection not listed on the following pages.
Service
The planned maintenance guidelines fall into

two categories:
Moderate usage
Severe usage:
More than 1500 hours of operation per
Year
A duty cycle greater than 100 picks per
hour
Extreme environmental conditions,
such a s a bumpy or abrasive floor, or
consistent exposure to air saturated
with dirt or metallic particles
Cold storage environments
UL Label "EE"
Perform all of the scheduled checks and

maintenance a t the suggested intervals. (See
Table 4- 1 on page 4-2.)
The time intervals given in this guide are based

on deadman hours under normal operating
conditions. When operating under abnormal or
severe conditions, perform these services more
often a s required to keep the unit in good
operating condition.
00700-CL222-05, 1 5 March 2005

Interval 1
Interval 1
Battery I Check cleanliness and exterior condition.

Check the charge.
Check the connector. Make sure all powered functions are shut
down when disconnected.
1 Gates must be properly installed and securely locked in place. I Page 7-33 1
Check the "free play" of the battery. Make sure it h a s no more Page 7-33
than 1/2" (13 mm) of movement.
General Operation Check that the horn operates when you press the horn button.
(Battery must be connected.)
1 Check the speed and directional controls.

1 Check the steering operation.
1 Check the lifting and lowering functions.
1 Check the operation of the emergency power off switch.
Note any unusual noise during operation, and report it to the
supervisor or maintenance personnel.
Brake Verify the drive motor does not run while the brake is applied.
Check that the control handle returns to the neutral position
when released.
Hydraulic System I Check for oil leaks.
Wheels Check the condition of the drive wheel and load wheels. Remove
any steel chips and foreign material to prevent damage to the
wheels.
Check for gouging and chunking of the surface. If damaged,
report to your supervisor and maintenance personnel.
Deadman Pedal The deadman pedal must operate smoothly with no binding. Page 7-27
Disables travel, lift/lower functions, and stops the truck when the
pedal is released.
Safety Belt and Inspect. Replace any components that show damage or excessive
Tether wear.
Fire Extinguisher Check charge. Replace if charge is low.
00700-CL222-05, 1 5 March 2005

Interval 2
Interval 2
Moderate Usage: E v e r y 6 M o n t h s o r 500 Hours;

S e v e r e Usage: E v e r y 3 M o n t h s o r 250 H o u r s
What to d o Refer to
Check the weight stamped on the battery in the truck Page 3-2
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 Page 7-28
released. Minimum thickness of the pad and steel backing
plate is 1 /4 in. (6 mm).
Inspect the contactor tips for burnt or pitted surfaces. Page 7-48
Failure to replace the tips may cause surfaces to weld
together, causing unscheduled downtime.
Check the plunger for smooth operation with no binding. If Page 7-46
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

Page 7-24
Page 5-8
I
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.
00700-CL222-05, 1 5 March 2005

Interval 2
Moderate Usage: Every 6 Months or 500 Hours;

Severe Usage: Every 3 Months or 250 Hours
Component What to do Refer to
Hardware Check the tightness of all wire and cable connections. This
can be done by trying to move the connection with your
hand.
Check for loose hardware for major truck components (steer
motor, brake assembly, drive motor and drive unit, hydraulic
assembly to tractor frame, electronic assemblies and
hardware.)
Forks Inspect the forks for unauthorized modifications, bends, Page 7-94
cracks or wear.
ACAUTION
If any of the imperfections above are found,
replace the fork immediately.
Hydraulic Hoses Inspect the hydraulic hose and tubing for leaks, nicks, cuts,
chafing and bulges. Replace defective hoses a s soon a s
possible.
Inspect all fittings for leaks. Repair any leaks immediately. I
Hydraulic Reservoir Check for proper fluid level and the proper fluid for the Page 7-60
working environment.
Lift Chains Check for proper adjustment of the chains. Inspect chain Page 7-76,
anchors and pivot rocker. Page 7-91 or
Page 7-93
Inspect the chains for excessive stretch or wear. There is a Page 7-76,
tool available to determine when lift chains must be Page 7-91 or
replaced. Page 7-93
Lights Check operation.
Lubrication Apply grease to both fittings on the drive unit.
Apply grease to load wheels.

Wipe off old grease on the mast uprights and apply new
grease. This will prevent damage from contamination in the
grease.
Coat any chains with a film of spray lubricant to keep chains
from rusting and wearing prematurely.
Mast Visually inspect the mast rails for abnormal wear. Page 7-73
Inspect the inside of the main frame for wear.
00700-CL222-05, 1 5 March 2005

Interval 2
do not reflect a normal wear pattern,
the chance of intermittent error codes caused by shorts

between maintenance intervals. It will also extend the life of
cables and harnesses.
00700-CL222-05, 1 5 March 2005

Interval 2
Figure 4- 1 . Bottom of Battery Compartment
00700-CL222-05, 1 5 March 2005

Interval 3
Interval 3
1 Hardware I Tighten or replace any loose, broken or missing hardware. I I

Drive Unit Change the fluid in the drive unit. Page A-2
Hydraulic System Replace the hydraulic fluid and filter. Page 7-60
Page A-2
00700-CL222-05, 1 5 March 2005

Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE15 Service Manual
How to Use This Chapter
How to Use This Chapter

This chapter contains a set of general
troubleshooting guidelines, a troubleshooting
task flow, and a set of troubleshooting tables for
symptoms not accompanied by a fault code.
Use the START TROUBLESHOOTING Chart

TS-1 on page 5-27 to guide you to the
individual symptom chart you need.
Use the Symptom Tables to identify possible

causes of problems that are not accompanied
by a fault code on the Operator Display.
As you work with a troubleshooting symptom

chart, you may be instructed to test various
electrical connector pins. Use the Electrical
Connector Locator Chart on Page 5-18.
Every time you complete a troubleshooting

procedure, be sure to follow the steps in End of
Troubleshooting Chart END1 on Page 5-28.
Another troubleshooting resource is the

Pinout Matrix on Page 9-51 in the Theory of
Operation chapter. The pinout matrix chart lists
functions and normal voltages of terminals and
harness connector pins.
If the troubleshooting symptom charts do not

isolate the problem, or if the symptoms are not
consistent or repeatable, go to the General
Troubleshooting Chart GENl on Page 5-28.
This chart will help you approach the problem
in a systematic and logical manner.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 5. Troubleshooting
Electrical Troubleshooting Guidelines
Electrical
Troubleshooting
Guidelines
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. See
"Battery Exterior Cleaning" on page 7-33.
Check the electrolyte level and state of charge.
Jack and block the lift truck whenever a

troubleshooting procedure requires
turning key switch S1 ON. This prevents
accidents caused by unexpected lift
truck travel. Opening the Emergency
Lowering Valve will prevent unexpected
lihing.
ACAUTION
Unless otherwise directed, disconnect
the b a ~ e r connector
y when you check
electrical circuits or components with an
ohmmeter. Electrical current can damage
the ohmmeter. Discharge residual
charge in the motor controller by
pressing PC and PCP contactors closed
simultaneously.
Save time and trouble by looking for

simple causes first.
For information on electrical connector
location and function, see "Electrical
Connector Locator Chart" on page 5-18.
00700-CL222-05, 1 5 March 2005

Section 5. Troubleshooting Toyota Orderpicker Model 7BPUE 15 Service Manual
Shorts to Frame Test

Then test for shorts between electrical
Shorts to Frame Test components and the truck frame.
"Shorts to frame" is a n industry term for To test for shorts to frame:

unintentional current leakage paths between 1. Turn the key switch OFF and disconnect
normally isolated electrical circuits and their the battery connector.
metal enclosures.
2. To test the battery for shorts to case,
Shorts to frame may be metallic connections, connect a 12-volt test light to the battery
such a s a wire conductor contacting metal case from battery B+, and then to the
through worn insulation. More often, shorts to battery case from battery B-. If the light
frame are resistive "leakage" paths caused by lights a t all, even momentarily, there is a
contamination and/or moisture. serious problem with the battery, either
external contamination or internal
These leakage paths can result in unwanted damage. DO NOT continue until this
electrical noise on the metallic truck structure, condition is corrected. Your meter may
and may result in improper operation. be damaged if you proceed before
correcting this condition.
Shorts to frame can be caused by: Install another battery in the truck and
Accumulation of dirt repeat this procedure from step 1.
Battery electrolyte leakage If the test light does not light, continue to
the next step.
Motor brush dust
3. With the battery disconnected from the
Motor brush leads touching the housing
truck, use a digital ammeter to measure
Breakdown in insulation the leakage current from the battery case
Bare wires to battery B+ and from the battery case to
battery B-. Begin measuring a t the highest
Pinched wiring harness ampere scale and work toward the lowest.
Improper mounting of circuit cards A reading of more than 0.00 1 A (1 mA)
indicates a serious short. DO NOT
Shorts to frame can occur a t numerous continue until this condition is
locations on a truck, including: corrected. Your meter may be damaged if
Batteries you proceed before correcting this
condition.
Motors
Install another battery in the truck and
Cables, wiring, and harnesses repeat this procedure from step 1.
Heat sinks If the current is less than 0.0002 A (0.2
Bus bars mA), go to step 4. If the current is greater
Solenoids than 0.0002 A (0.2 rnA) and less than
0.001 A (1 rnA), remove the battery from
Contactors the truck, then continue with step 4.
Terminal strips Ensure the battery case does not touch
Switches the truck frame during the remaining
tests.
Power panel insulation
4. With the battery disconnected (or removed
Circuit card mounts and disconnected) from the truck, use a
digital ohmmeter to measure the
To determine the source(s) of shorts to frame, resistance from truck frame to truck B+, to
begin by testing the battery for shorts to case. truck B- (NOT battery B+ and B-), and to
all fuses and motors. A reading of less
than 1000 ohms indicates a serious short.
00700-CL222-05, 1 5 March 2005

DO NOT continue until this condition is fuses and motor terminals. Begin
corrected. Your meter may be damaged if measuring a t the highest ampere scale
you proceed before correcting this and work toward the lowest. If the current
condition. is less than 0.001 ampere (1 mA), go to
step 7. If the current is more than 0.001
NOTE: Depending on the nature of the problem,
ampere (1 mA), continue with the step
it may also be necessary to measure for
below.
shorts to frame, B+ (truck) or B- (truck)
a t specific circuits associated with the a. To identify the cause of the short to
problem. frame, disconnect circuit components
until the leakage current reads less than
a. To identify the cause of the short to 0.001 A (1 mA). Do not reconnect
frame, disconnect circuit components components one a t a time, but leave
until the low resistance condition them disconnected until the leakage
disappears. Do not reconnect current reads less than 0.001 ampere
components one a t a time, but leave (1 mA). Prevent disconnected terminals
them disconnected until the low or connectors from touching the truck
resistance reading disappears. Prevent frame or other conductive surfaces.
disconnected terminals or connectors
from touching the truck frame or other b. The most likely areas to check are:
conductive surfaces. Motors
b. The most likely areas to check are: Heat sinks
Motors Power cables
Heat sinks Power circuit components
Power cables Control circuit components
Power circuit components c. Repair or replace the component(s)
Control circuit components causing the leakage current.
Repeat step 6.
c. Repair or replace the component
causing the low resistance condition, d. Reconnect all other components
Then repeat Step 4. previously disconnected, measuring
current between steps. If a reading is
d. Reconnect all other components more than 0.001 A (1 mA) when
previously disconnected, one a t a time, reconnecting a component, that
measuring resistance between steps. If a component or its wiring is defective.
reading is less than 1000 ohms when Repair or replace a s appropriate.
reconnecting a component, that
component or its wiring is defective; 7. When, after all components are
repair or replace a s appropriate. reconnected, you get a reading less than
0.001 ampere (1 mA) there is no short to
e. When, after all components are frame condition with the truck or the
reconnected, you get readings greater battery. If you previously removed the
than 1000 ohms, continue with the next battery from the truck, re-install the
step. battery.
5. Reconnect the battery connector to the
truck and turn the key switch ON. If the
battery was previously removed, ensure
the battery case does not touch the truck
frame.
6. Use a volt/ohm/ammeter on the current
function meter to measure leakage current
to the truck frame from B+, B-, and all
00700-CL222-05, 1 5 March 2005

With battery connector

Turn the key switch
disconnected, measure
OFF and disconnect
leakage current from battery
the battery
case to battery B+ and to
connector.
current setting
.
of meter, then
Connect a 12V test

light from battery
case to battery B+,
then from case to
battery B-.
Yes I
Install another Remove battery

battery. -A serious from truck.
problem exists
with the battery.
DO NOT
continue until
this condition is
corrected, or
meter damage
may result.
- 1 Go to Chart 1
00700-CL222-05, 1 5 March 2005

. With battery connector

disconnected (or
disconnnected/removed) ,
measure resistance from
Do NOT
continue until
resistance
measures
greater than
truck frame to truck B+,
1000 ohms, or
to truck B-
meter damage
(NOT battery B+/B-),
& to all fuses & motors.
Disconnect a circuit
Reconnect the battery component and
connector. Turn key measure current
switch ON. again. (Do not
reconnect previously
disconnected
components.)
Disconnect a circuit Measure leakage

component and current to truck
measure resistance frame from B+, B-, all
again. (Do not fuses and motors.
.
reconnect previously
disconnected
components.)
Yes
Repair or replace the

component last
disconnected. Reconnect
all components one at a
time, measuring current
between steps.
Yes Yes
Repair or replace the

component last
disconnected. Reconnect all
A Truck has no
shorts to frame. Reinstall
battery if previously
components one at a time, removed.
-
measuring resistance
between steps.
I
I
00700-CL222-05, 1 5 March 2005

Troubleshooting Wiring Problems

move a harness, cut a cable tie, or remove the
Troubleshooting Wiring wire from a bracket. Note carefully the location
Problems of the wire and all protective or securing
attachments before moving the harness.
Visually inspect all wiring and electrical After repair, return or replace all protective
components for: and/or securing hardware to its original
Loose connections or connectors condition. Protective materials are necessary for
Loose or broken terminals the interconnect system to perform reliably.
Damaged terminals, blocks, or strips Examine and maintain any added materials
Exposed wire a t terminations, excessive used to dress or protect the wire. This includes
strip gap spiral wrap, brackets, cable ties, fasteners,
Abrasions, scrapes, nicks in the wire, flexible conduit, etc.
damage from overheating or burns, or
other general insulation damage Do not attach tie wraps tight enough to pinch or
deform cable harnesses. Avoid tie wrapping
Broken wire strands and shorted hydraulic hoses which expand with pressure to
conditions (especially those that are close hinder extra pinching of tie wrapped electrical
to metal edges or surfaces) cables.
Power Cables Use a digital ohmmeter to check for wiring

continuity.
Inspection
Wiring Harness
Power cables should be checked for damage,
including: Terminology
Evidence of overheating
Burned spots in the cable The term "connector JPCx" or "connector JPTx"
means a mated connector consisting of two
Nicks or cracks in the insulation connector halves. One half contains male
Damaged or overheated terminal lugs connectors, or pins (P);the other half contains
Damaged mounting hardware or brackets female connectors, or jacks (J).The third
character references the relative location of the
Repair or replace damaged cables or mounting Connections On the carriage
hardware a s necessary. manager are designated by a (C). Connections
on the steer/tractor manager are designated by
Power cables are marked on the terminal lug (T). Hanging connections are designated by (H).
with the location where they belong. If the
marking is missing or is not readable, remark When you a mated JP connector.
the cable with the correct information. you will have two connector halves. The
individual connector halves are designated by
The terminal lugs should be crimped tightly and "Jx" and "Px."
securely on the wire. Replace the lug if
overheating is evident. Repair or replace faulty JPT3 is the mated
connectors a s necessary. connector for steer position feedback. 53
represents the jack connections, P3 represents
the pin connections and T designates the
Guidelines steer/tractor manager.
During troubleshooting and repairs, it is

sometimes necessary to unplug a connector,
00700-CL222-05, 1 5 March 2005

Troubleshooting Wiring Problems
Use the "Electrical Connector Locator Chart" on
page 5-18 to locate electrical connectors on the
truck.
Inspection
Whenever working on the truck, use care

around wiring harnesses.
Do not pull on wires.
Carefully mate and unmate all connectors.
Do not pry apart connectors with
unspecified tools.
Examine and maintain any added
materials used to dress or protect the wire.
This includes spiral wrap, brackets, cable
ties, fasteners, flexible conduit, etc.
Check harness wires for abrasions,
scrapes, nicks, damage from overheating
or burns, or other general insulation
damage.
Replace terminations with exposed wire
visible a t the connectors. Damaged
terminations, exposed wires or damaged
connectors can cause operational failure of
the truck.
During troubleshooting and repairs, it is

sometimes necessary to unmate a connector,
move a harness, cut a cable tie, or remove the
wire from a bracket. Note carefully the location
of the wire and all protective or securing
attachments before moving the harness.
After repair, return or replace all protective or

securing hardware to its original condition.
Protective materials are necessary to provide
reliable performance of the interconnect
system.
There should be a wire marker a t each

termination. If the marker is missing or
unreadable, remark the wire for easier
identification.
NOTE: I t is normal to find unused connectors
for uninstalled options that have had
heat shrink applied over them and have
been strapped to the harness.
00700-CL222-05, 1 5 March 2005

Switches (General)
Switches (General) the switch assembly and can only be seen if the
switch is disassembled.)
Examine the switch for signs of arcing,

overheating, discoloration, cracking, or other
physical damage. Replace the switch if you see
such damage.
To test a switch, isolate it from the electrical

circuit. Do this by removing all the connections
from the switch, making sure all wires are
labeled and identified for reconnection.
Use a n ohmmeter set to a low resistance scale

to measure the resistance across the switch. In
a closed position, the switch should be less Figure 5-2. Typical Hall Effect Switch
than 1 ohm. In a n open position, the switch

The switch is powered a s follows:
should show a resistance greater than 10
megohms. +6 to +12 volts is applied to the positive (+)
"1 q:; 1 ;,lD~dman

terminal.
Battery negative is applied to the negative
$ (-) terminal.
As shown in Figure 5-1, when a magnet is not

present, the transistor is OFF and the output
DGND lead (Deadman # 1) is in a high state.
Figure 5- 1 . Hall Effect Switch Schematic When a magnet is present, the transistor is
turned ON creating a path from the DGND (-)
terminal to the Deadman # 1 terminal. Terminal
Hall Effect Switches Deadman # 1 will now be a negative (-) potential,
or active.
The limit switches and deadman switches used
on this truck are Hall Effect switches. These
switches consist of a transistor that is turned Key Switch
on when a magnet is positioned next to the
base. (Keep in mind that the magnet is part of Inspection
With the battery plugged in and key switch in
the ON position, battery voltage B+ should be
present on both terminals of the switch. Test
the key switch with a n ohmmeter after
removing it from the electrical system. In the
OFF position, the ohmmeter should read
greater than 10 megohms, and in the ON
position, the ohmmeter should read less than 1
ohm. If not, replace the switch.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting
Electric Motor Tests
A permanent magnet steer motor uses

Electric Motor Tests permanent magnets a s fields and has only
two external connections.
NOTE: Field connections may be labeled S.
Shunt-Wound Motor Shunt-wound motor field connections
may be labeled E. Series-wound motor
S2lE2lD2 field connections may be labeled D.
Open Circuit Motor Test

A1 S1lEIlDI An open circuit is one in which the electrical
circuit within the motor has been broken. This
can be caused by:
Series-Wound Motor Bad brushes or brush springs
Broken wire in the field or armature
sl? winding
Loose or bad connection
Refer to Figure 5-3 for the following procedure:

1. Isolate the motor from the truck circuit by
removing the power cables. Use two
wrenches to avoid twisting the terminal
stud.
I
2. With the motor a t room temperature,

Permanent Magnet
-
connect the leads of a digital ohmmeter
between the individual circuits in the
Motor motor.
Figure 5-3. Motor Circuits
Motor Types
Refer to Figure 5-3.
A shunt-wound or series-wound drive
motor has four external connections: two
armature (A) and two field (S, E, or D).
A series-wound lift motor has only two
external connections because the
armature and field windings are connected
internally.
00700-CL222-05, 1 5 March 2005

Electric Motor Tests
3. YOU should observe the following Short-circuited Armature or
measurements:
Field Winding
Motor Probe Points
1 Resistance 1 A short rirclriterl winding is one in which the
Drive Motor
1 S1 to S 2
(shunt) 1 0.9 to 1.5
ohms
insulation on the field o; armature has broken
down a t two or more points. The breakdown
creates a low resistance path, allowing current
S1 to S 2 < 1 ohm
to flow from one turn of the coil to another
A1 to A2 < 1 ohm adjacent coil turn, without actually flowing
through the coil wire. The result is a decrease in
A1 to S 1 ; A1 to
A2 t o S l ; A 2 to
1 > 100,000
ohms
> 100,000
total resistance of the motor winding and a n
increase in the current flow. The severity of the
short circuit depends on its location.
A1 o r A 2 to > 100,000 A shorted motor may be indicated by:
Frame
Slow or sluggish operation
Lift Motor < 1 ohm
Running faster than normal (suggests a
A to Frame > 100,000
short in the field)
Steer Motor Overheating
A1 o r A2 to > 100,000 Blowing a power fuse
Frame Burning of brush wires
Severe burning or discoloration on
4. If the meter indicates high resistance in armature coil
the armature, check the condition of the Severe burning or discoloration on one or
brushes before replacing the motor. two commutator segments every 90" of
5. If you find a n open circuit in a rotation.
series-wound motor, the motor must be
disassembled by a motor rebuilding facility These symptoms can be caused by problems
to isolate the problem to the field or other than the motor itself:
armature circuit. Brake too tight or dragging
Wheel bearings too tight
Grounded Motor Test Faulty transmission
In a grounded motor, a n electrical circuit exists Binding in a related pump, hose, or
between the current-carrying conductors and solenoid valve
the motor housing. This can be caused either by Load wheels not aligned properly
direct contact or through conductive foreign Rail guided with drive tire not aligned
material. properly
The ground may be caused by: Testing a motor for short-circuited windings
Insulation breakdown requires special equipment a t a motor
Brush leads touching the motor housing
Buildup of carbon dust or other materials
To test for a grounded motor, see "Shorts to

Frame Test" on page 5-4.
00700-CL222-05, 1 5 March 2005

Battery Discharge lndicator (BDI)
Battery Discharge resets the Operator Display to show the

replacement battery's charge.
Indicator (BDI) b. Example 2: A battery in the lift truck is
at 20% charge and lift cutout has not
occurred. The replacement battery has
Theory a state-of-charge equal to 50%.
Because the difference is only 30%, the
Battery Discharge Indicator (BDI)is a feature display will remain a t 20% until the
that monitors and remembers the charge level replacement battery has discharged to
of the battery connected to the lift truck and 20%. Then the display will begin
helps to prevent excessive discharging of that counting down.
battery. Operating a lift truck using a
discharged battery can damage both the battery c. Example 3: A battery in the lift truck is
and the electrical components of the lift truck. at 20% charge and lift cutout has
occurred. The replacement battery has
At power-up, BDI tests the battery to determine a state-of-charge equal to 50%.
if it is the same battery that was installed at Because the difference is only 30%, the
power-down. If it is the same battery, it display will remain at 20% and lift
continues to monitor the battery for discharge cutout will remain in effect until a
and updates the Operator Display as required. battery with a charge of a t least 70%
and a state-of-charge exceeding the
If a different battery is detected, BDI tests to configured BDI setting is installed in
determine the state-of-charge of the the lift truck.
replacement battery. The replacement battery 2. BDI looks at the configured reset point.
must meet both of the following criteria before BDI reset is programmable from 55% to
the display will be reset and lift restored. 100% of total battery charge and can be
1. The replacement battery must have a changed by entering the Configure Mode
charge level at least 50% different from the using the Superword. The new battery
previously installed battery, must be equal to or greater than the
configured percent of charge before the
2. The charge value of the replacement BDI will change. Example - BDI
battery must be greater than or equal to configured at 95%. Plugging in a battery at
the configured BDI setting. anything below 95% charge will not
change the Operator Display. Older
The criteria are determined in this way: batteries or applications providing
1. BDI compares the charge of the battery inadequate charging time could require a
that was connected to the lift truck with lower configured value for BDI since older
the new battery's charge. A charge batteries might be unable to reach a
difference of at least 50% between the two higher percent charge. Therefore, some
batteries resets BDI to show the batteries could require BDI configured as
state-of-charge of the replacement battery, low as 55% before lift cutout will reset and
that is, the measured state-of-charge of the Operator Display shows the charge of
the replacement battery minus the the replacement battery.
remembered state-of-charge of the old
battery must equal or exceed 50%. This The following example describes installing a
reset can be higher or lower than the old new battery when the Operator Display does
battery. not reset. Assume the following:
a. Example 1: A battery in the lift truck is BDI configured at 95%, the battery
a t 10% charge; the replacement battery connected is at 45% charge, and the new
is at 95%. With more than a 50% battery is at 92% charge.
difference in the charge levels, BDI
00700-CL222-05, 1 5 March 2005

Battery Discharge Indicator (BDI)
Since the new battery charge has not changed
by a t least 50% and the state-of-charge of the
new battery is not greater than the BDI reset
configured value, the Operator Display
continues to show the old battery's charge of
45% (even though the new battery is a t 92%).
What occurs is that the Operator Display
remains a t 45% until the charge of the new
battery declines to 45%. Then the display
resumes its normal descent.
One final example. Assume the following:

BDI configured a t 95%, the battery
connected is a t 65% charge, and the new
battery is a t 20% charge.
Again, the change in charge is not a t least 50%

and the new battery is not above the configured
BDI level. The Operator Display continues to
show 65%, but then descends rapidly a s the lift
truck operates until the Operator Display
shows the original charge of 20%. Once the
display shows 20%, it resumes a normal
descent.
Setting Battery State-of-Charge

Cutout
1. Fill, charge, and install a battery that is
typical of the batteries normally used in
this application.
2. Have a customer operator use the lift
truck in normal application until cutout
occurs.
3 . Permit the battery to cool and stabilize for
a t least two hours.
4. Before filling the battery, either take
specific gravity readings or measure open
circuit voltage of the battery cells.
5. Compare the measurements with the
battery manufacturer's recommendations
for maximum discharge.
6. Adjust the cutout value a s needed and
repeat the previous steps until battery
cutout occurs a t the desired discharge
level.
00700-CL222-05, 1 5 March 2005

Contactors
Contactors
Testing Resistance
Visually inspect the contactor for any signs of Examine the fuse for signs of overheating,
burning or physical damage. discoloration, cracking, or other physical
1. Turn key switch OFF and disconnect damage. You should be able to see if the fuse is
battery connector. blown through the fuse window. Replace the
fuse if you find damage.
2. Disconnect two wires marked X and Y
contactor. To test a fuse, remove it or isolate it from the
3 . Connect one lead of ohmmeter to X electrical circuit. Do this by removing the fuse
contactor lead and one to the Y contactor from the truck or by removing all the
lead. connections from one side of the fuse.
4. The reading should be between 20 and 40
ohms. If resistance is outside that range, Use a n ohmmeter set to Rxl scale and measure
replace contactor. the resistance across the fuse. The resistance
should be less than 1 ohm.
Table 5- 1 . Fuse Chart
Fuse Amps Location Function

FU1 15 Contactor/Fuse Panel Control Fuse for B+ PC
FU2 15 Contactor/Fuse Panel Control Fuse for B+
FU3 350 Relay/Control Fuse Panel Power fuse for TM
FU4 40 Relay/Control Fuse Panel Power fuse for SM

FU5 350 or Relay/Control Fuse Panel Power fuse for Lift Pump Motor
500
FU7 2 Contactor/Fuse Panel Control fuse for RF Terminal B+
FU8 2 Contactor/Fuse Panel Control fuse for RF Terminal B-
FU9 6 Contactor/Fuse Panel Control fuse for Lights & Fan B+

FUlO 6 Contactor/Fuse Panel Control fuse for Lights & Fan B-
Full 10 Aux Power Fuse Panel Control fuse for carriage heater (CS Option)
FU12 10 Aux Power Fuse Panel Control fuse for tractor heaters (CS Option)
FU13 10 Aux Power Fuse Panel Control fuse for carriage heaters (CS Option)
FU14 2 Aux Power Fuse Panel Control fuse for GM, B+ ESTOP (WG Option)
00700-CL222-05, 1 5 March 2005

Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
After elevating the carriage for

troubleshooting, be sure to use blocks to
secure the carriage.
Use extreme care when blocking the

mast for any reason. Never remove a
block when it is supporting the mast.
Lower the carriage fully.
Stabilize the top of the mast with a n overhead

chain hoist.
When you measure voltage a t solenoids, make

sure hydraulic lines and components are fully
installed.
Whenever possible, keep the key switch OFF

and the battery connector disconnected.
Cap open hydraulic lines to prevent

contamination.
00700-CL222-05, 1 5 March 2005

Definitions
Definitions Overtemperature (Traction Power

Amplifier)
Continuity Overtemperature of the traction power amplifier
is 85" C (185" F) and above. Overheating is
A continuous and uninterrupted path between unusual, but can occur if the traction power
two or more locations in a n electrical circuit, amplifier is installed incorrectly or overloaded.
typically having a resistance of less than 1 ohm.
At overtemperature the drive current limit is
Deadman Switches linearly decreased from full set current down to
zero. Plug current is not reduced by any
The switches in the truck that must be closed to thermal conditions to allow full plugging
allow truck operation. The Orderpicker Model strength a t all times.
7BPUE15 has two deadman switches under the
deadman pedal. Both switches must be Pulse Width Modulation
functional for the truck to travel, lift or steer.
Stepping on the pedal on the operator platform Pulse Width Modulation (PWM),also called
activates these switches. The deadman function "chopping," controls the speed of the motor by
acts to protect against travel while the brake is switching the battery voltage to the motor on
applied. and off very quickly.
M 3 and M 4 Accel Rate Short Circuit or "Short"

The time necessary to reach full output (PWM) A short circuit is a n unspecified path in a
from zero output in M3 or M4 (high speed, circuit that provides unwanted full or partial
PMC-3 on) mode. See Table 5-7 on page 5-24. continuity between two or more locations in a n
electrical circuit.
M3 and M 4 M a x Speed
Example: Two insulated wires are physically
Maximum speed (PWM duty factor) in M3 or M 4 next to each other and the insulation has been
(high speed) mode. worn off each of the wires. Because the
conductors inside each wire are now touching
each other, there is a short circuit.
Mode Select Inputs
Example: A power cable from the battery to a
The traction power amplifier is capable of four
junction post in the truck has had the
modes of operation that are determined by two
insulation worn away. Because the wire
mode select inputs (MM1 and MM2) from the
conductors are touching the tractor frame,
steer/tractor manager. See Table 5-4 on
there is a short circuit of the battery cable.
page 5-22.
Neutral Braking Undertemperature
When the amplifier is operating a t less than

The plugging force applied to the drive motor by
-25" C (-13" F), the current limit is cut back
the power amplifier when the throttle is in
resulting in reduced travel speed and
neutral with the deadman switches closed.
acceleration.
Open Circuit
A lack of a continuous path between two or
more electrical connections.
00700-CL222-05, 1 5 March 2005

Electrical Connector Locator Chart
Electrical Connector
Locator Chart
JPT4 (Spare digital) Steer/tractor manager

JPT5 Mast limit switches, lift limit switches Steer/tractor manager
JPT6 Steer feedback encoder Steer/tractor manager
Table 5-2. Electrical Connector locator Chart
00700-CL222-05, 1 5 March 2005

Connector Function or Routing Location

JPT7 (Spare digital) Steer/tractor manager
JPT8 Steer power head Steer/tractor manager
JPTS Mast cable 1 (signals) Steer/tractor manager
JPTlO Mast cable 1 (power) Steer/tractor manager
JPTl 1 Traction power amplifier Steer/tractor manager
JPT12 Power and drivers Steer/tractor manager
PS1 Steer/power head connector Steer/tractor manager
J S1 Filter card and steer controller interface Guidance manager
J T1 MULTI (Memory Update Link and Test Steer/tractor manager
Interface)
JPW 1 Filter card connector to load sensor Guidance manager
JPW2 Filter card connector to tractor sensor Guidance manager
Table 5-2. Electrical Connector locator Chart
00700-CL222-05, 1 5 March 2005

Programmable Maintenance Tool
Programmable
Maintenance Tool
Figure 5-5. Connection for PMT to Traction Power A m p
Diagnostic History
You can use the Programmable Maintenance
Figure 5-4. Programmable Maintenance Tool Tool to access the diagnostic history file of the
traction power amplifier.
The optional Programmable Maintenance Tool
(PMT) (P/N 00590-4998 1-71) allows you to test The PMT will read out all the faults that the
and diagnose the traction power amplifier in amplifier has experienced since the last time
this lift truck. the diagnostic history file was cleared. The
faults may be intermittent faults, faults caused
The PMT is powered by the host amplifier by loose wires, or faults caused by operator
through the four-pin connector on the error.
amplifier. See Figure 5-5.
For example, an overtemperature fault may be
When the PMT is first plugged into the caused by operator habit or overloading.
amplifier, the PMT displays the amplifier's
model number, date of manufacture, and NOTE: Each fault is listed only once, regardless
software revision code. Following this initial of the number of times it occurred.
display, the PMT displays a prompt for further
instruction. Access
NOTE: Follow the prompt a t the top of the PMT 1. Turn the key switch OFF and disconnect
screen, not the blinking icon, to choose the battery connector.
the correct setting. 2. Remove the tractor cover.
3. Connect the PMT to the traction power
amplifier.
4. Connect the battery and turn the key
switch ON.
5. Hold the more info key, and press the
diagnostics key.
00700-CL222-05, 1 5 March 2005

Clear Test Mode

After you have diagnosed and corrected the This section shows you different modes you can
problem, you should clear the diagnostic use on the PMT to troubleshoot this lift truck.
history file. This allows the traction power
amplifier to accumulate a new file of faults. By Access
checking the new history file a t a later date, you
can easily determine whether the problem was 1. Turn the key switch OFF and disconnect
completely fixed. the battery connector.
1. Hold the more info key, and press the 2. Remove the tractor cover.
program key. Release both keys after you 3. Connect the PMT to the traction power
enter the Special Program mode. amplifier.
2. Scroll through the mode using the scroll 4. Connect the battery and turn the key
display keys until "CLEAR DIAG HIST" is switch ON.
the top line in the display.
5. Press the test key on the PMT.
3. Press the more info key again. The PMT
will prompt you to acknowledge or cancel. 6. Scroll through the line items using either
scroll display key. When the item you want
4. Press the value u p key to clear the is the top line on the display, press the
diagnostic history. Press the value down more info key for a full screen display.
key to cancel.
Table 5-3: Test Mode
Display Explanation
THROTTLE% Throttle reading, in percent of full: 1- 100%
FIELD CURRENT Motor field current, in amps: 6-20A
ARM CURRENT Motor armature open, in amps: 80-300A
FIELD PWM Motor field applied duty cycle, as %: 0- 100%
ARM PWM Motor armature applied duty cycle: 0- 100%
BATT VOLTAGE Battery voltage across the internal capacitors: 20-25V
HEATSINK "C Heatsink temperature, in "C: 22-70" C
FORWARD INPUT Forward switch: on/off
REVERSE INPUT Reverse switch: on/off
MODE INPUT A Mode Select 1 (MM1):on/off. See Table 5-4.
MODE INPUT B Mode Select 2 (MM2):on/off. See Table 5-4.
INTERLOCK Interlock switch (deadman): on
MAIN CONT PC drive (output):on/off
AUX DRIVER Auxiliary driver (not used): on/off
NOTE: The traction power amplifier is capable (MM1 and MM2) from the steer/tractor
of four modes of operation that are manager. See Table 5-4.
determined by two mode select inputs
00700-CL222-05, 1 5 March 2005

Table 5-4: Modes of Operation
it is replace the TPA. If it shows being activated,

fork-first travel would allow a full speed of 6.0
MPH. The throttle percent input will be varied
The table below lists messages you may see

displayed when the PMT is operating in either
the Diagnostic Mode or the Diagnostic History.
The messages are listed in alphabetical order
for easy reference.
Table 5-5. Diagnostics and Special Diagnostics list
Display Explanation
ANTI-TIEDOWN Mode 1 select switch closed a t start-up
CONT COIL/FLD SHORT Contactor driver overcurrent or field winding short
CURRENT SHUNT FAULT Current sensor error
FIELD OPEN Motor field winding open
HW FAILSAFE Hardware fail-safe activated
LOW BA?TERY VOLTAGE Battery voltage too low (<16 volts)
M- SHORTED M- shorted to B-
5-2 2 00700-CL222-05, 1 5 March 2005

Table 5-5. Diagnostics and Special Diagnostics list
Display Explanation
NO KNOWN FAULTS No known faults
OVERVOLTAGE Battery voltage too high (>45volts)
THERMAL CUTBACK Thermal cutback due to over/under temperature
THROTTLE FAULT 1 Throttle wiper input fault
Table 5-6. Special Program Mode

Special Program Mode
The chart below shows you line items in the
Special Program Mode.
Access
1. Turn the key switch OFF and disconnect Load programming settings
the battery connector. SETTINGS+
2. Remove the tractor cover.
3. Connect the PMT to the traction power
amplifier.
4. Connect the battery and turn the key CONTRAST Adjust display contrast
switch ON. ADJUSTMENT
5. Press and hold the more info key; press
the program key.
6. Scroll through the line items using either Display PMT information
scroll display key until the item you want
to change is the top line on the display.
See Table 5-6 on page 5-23.
7. Press either change value key until you
reach the value you want.
00700-CL222-05, 1 5 March 2005

Programming 7. Press either change value key until the

setting you want is displayed. The
You can change certain parameters using the parameter is now set a t the value you
PMT. See Table 5-7. All changes occur in "real selected.
time"; the parameters can be changed while the 8. If the display stops changing and you want
truck is in operation. to go further, press the more info key. If
1. Turn the key switch OFF and disconnect the display shows "Min. Limit" or "Max
the battery connector. Limit," you have reached the factory set
limit for that parameter.
3. Connect the PMT to the traction power NOTE: The parameter may be dependent on
amplifier. another parameter. If so, the display will
show this information. Changing the
4. Connect the battery and turn the key related parameter may allow you to
switch ON. change the setting further.
5. Press the program key to enter the
Program mode. See "Definitions" on page 5-17.
6. Press either scroll display key until the
parameter you want is the top line of the
display. See Table 5-7.
Table 5-7. Traction Power Amplifier Parameters
neutral with the deadman switches closed.

M 3 RESTRAINT With neutral braking set a t 0%, the truck coasts
to a stop when the throttle is in neutral
(released).There is no plugging force applied.
When set to loo%, the power amplifier applies
ing force when the throttle is in neutral
00700-CL222-05, 1 5 March 2005

Drive Unit Troubleshooting Guide
Drive Unit
Troubleshooting Guide
Symptom Probable Cause Required Action
Oil leaks Damaged sealing rings Replace sealing rings, bearing shims, and
drive shaft bearings
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft
Housing/cover joint Reseal
Worn or damaged housing Replace drive unit
Drive wheel Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and
wobbles drive shaft bearings
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft
Loose wheel mounting hardware Inspect housing and drive shaft for damage;
Re-torque mounting hardware
Noise Worn or damaged drive shaft bearing Replace sealing rings, bearing shims, and
drive shaft bearings
1 Worn or damaged pinion bearings I Replace pinion bearing and pinion shaft n u t
Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
in good condition) shaft bearings, pinion bearings, pinion shaft
nut, and gear set
Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
worn or damaged) shaft bearings, pinion bearings, pinion shaft
nut, gear set, and drive shaft
Worn or damaged helical gear and pinion Replace helical gear and pinion
Steering Inadequate bearing lubrication Grease steering bearing
binds
Worn or damaged steering bearing Replace complete drive unit upper section
00700-CL222-05, 1 5 March 2005

Drive Unit Troubleshooting Guide
00700-CL222-05, 1 5 March 2005

Troubleshooting Flowcharts
T S 1: START TROUBLESHOOTING
Message or
Yes
v
Fault Code
displayed?
1 M e s s E t r Code
listed in symptom
tables in
Follow symptom
table directions
/
in Section 5
7. Chart GEN-1
00700-CL222-05, 1 5 March 2005

c GEN1: General Troubleshooting
I Gather as much 1
information as you Eliminate unlikely
What is the problem?
can about causes.
7- Where did it happen?
When did it happen?
Select and prioritize

What functions are affected? the most likely
causes.
What conditions trigger the problem?
Check each likely

Talk directly to the
cause, using the tests
operator or foreman.
in this manual.
Check all other truck

Operate the truck functions before
yourself. returning the truck
to service.
if necessary and
identify
all components which
could cause the
problem.
00700-CL222-05, 1 5 March 2005

(ENDL: End of Troubleshooting Procedure )
Operate the truck a s it

Make sure ALL wires,
was being operated when
hoses, and cables that
the problem occurred.
you removed have been
Verify the problem does
re-attached correctly.
not recur.
Have the driver operate

Make sure all covers are
the truck. Verify the
properly reinstalled.
problem does not recur.
Make sure any

component that was
Fill out any required
drained has been refilled
forms.
with the correct level of
fluid.
If you contacted your This is especially

Create the same Authorized Toyota Dealer important if the
conditions that occurred to discuss the problem, solution you
when the problem first call them again to let found is not in the
happened. them know what fixed the troubleshooting
problem. chart.
iEnd of Troubleshooting
00700-CL222-05, 1 5 March 2005

00700-CL222-05, 1 5 March 2005

Symptom Tables: Hydraulic Functions

NOTE: If you determine that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed
the hydraulic system.
Lift/Lower System
Lift Function
-
No Lift Motor Runs, No Codes
2. Inspect L/L solenoid for binding.
-
No Lift Motor Does Not Run, No Codes
ctor closed. Test for B- to the

lift motor. If voltage is
Slow Lift - Empty
1. Measure voltage to lift/lower solenoid.

3 . Inspect lift pump for low output.
4. Inspect pressure relief valve for binding
00700-CL222-05, 1 5 March 2005

Unable to Pick Up a Load; Lift Pump Runs; Travel OK
check cutout adjustment:

1. Allow battery to set unused for two
hours. Check SG and compare to battery
manufacturer's recommendations.
FIG until proper
rollers, and rails.

If pressure is low:
1. Measure voltage to lift/lower solenoid.
3 . Inspect pressure relief valve for binding
or weak spring.
Lower Function
No Lower, Lift and Travel OK

NOTE: Verify operation of lower/lift switches
(S4, S5). See "Maintenance Mode" on
page 6-4.
Load Drifting/Settling
00700-CL222-05, 1 5 March 2005

Symptom Tables: Travel Functions
Symptom Tables: Travel Functions

Slow or Sluggish Acceleration
1. Allow battery to set unused for two

hours. Check SG and compare to battery
manufacturer's recommendations.
Slow Travel; Lift/Lower OK; No Fault Codes
00700-CL222-05, 1 5 March 2005

Symptom Tables: Electrical Symptoms
Symptom Tables: Electrical Symptoms

Electrical Motors
Motor Overheating
Dead Lift Truck

Display is Dark; Lift Truck is not Operational
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 6. Codes and Tests
Section 6. Codes and Tests
00700-CL222-05, 1 5 March 2005

Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE 15 Service Manual
Operator Display Messages
Operator Display Table

Each steering
6-1. indicator message is explained in
Messages
The operator display has two sections, the I1 All LEDsDisplay Truck Condition
steering indicator and the battery indicator. See

Figure 6-1. I scroll in
side-to-side pattern
Left LED on steady
Drive unit position is
unknown
Drive unit in left,
end-of-travel zone (more
than 65"
counter -clockwise)
l
Mid-Left LED on steady Drive unit in left zone
(10-65"
counter-clockwise)
I Center LED on steady
Mid-Right LED on
Drive unit in center zone
(within 10" of center)
Drive unit in right zone
steady (10-65" clockwise)
Steering Battery Right LED on steady Drive unit in right

Indicator Indicator end-of-travel zone (more
than 65" clockwise)
All LEDs blink in In maintenance mode
Figure 6- 1 . Operator Display unison a s the horn
beeps
Steering lndicator Messages Table 6- 1 . Steering Indicator Display Messages 1
The steering indicator has five LEDs and shows
the current steering direction based on the
position of the drive unit. See Figure 6- 1. Battery Indicator Messages
When the truck is in maintenance mode, the The battery indicator has five LEDs used in
steering indication is overridden, and the LEDs three prioritized modes of operation (3 is the
flash as the horn "clicks". See "Maintenance highest priority).
Mode" on page 6-4.
priority Display
Mode
Fault Code 3 Series of blinks for each
(highest) digit (all 5 blink
together); see "Operator
Display Fault Codes" on
page 6- 15
Info Blinks a single LED to
Display indicate a particular
condition; seeTable 6-3,
"Info Display Messages,"
on page 6-3.
Battery 1 Single, steady LEDs
State-of- (lowest) represent the current
Charge I
I state-of-charge.
Table 6-2. Battery lndicator Messages
00700-CL222-05, 1 5 March 2005

Operator Display Messages
The battery indicator will always show the mode displayed. Once these codes are resolved, the
with the highest priority that is active. For next highest codes are displayed until they are
example, a n Info Display message will override resolved.
a battery state of charge message.
Each code is explained later in this section. See
Fault Code "Operator Display Fault Codes" on page 6-15.
All five LEDs flash in series to identify the fault lnfo Display
code. Each series (code) has two digits. If more
than one code is present ("stacked codes"), Each LED represents a different condition. The
there are rapid flashes between codes. table on the following page shows the cause and
how to clear each display.
There is no limit to the number of stacked
codes, but only the highest priority codes will be
Display Cause How To Clear

I Top LED blinking
I EPO depressed
Pull out EPO switch and reset kt
switch.
2nd LED from top Deadman pedal must be depressed before 1. Return controls to neutral.
blinking you request motion. 2. Step on deadman pedal.
Steering wheel was not turned (initialized) Turn steering wheel.
after key switch turned ON.
(If optional sidegate Sidegate u p when requesting travel or Lower sidegate.
with interlocks is lift/lower.
attached) 3rd LED from
top blinking
I11 4th LED from top

blinking
Bottom LED blinking. . I
Carriage reached lift limit (if equipped).
Battery charge
. . is too low. I
Press lift limit bypass switch to
continue lifting.
Use fullv-charged
.. battery.
I
Table 6-3. lnfo Display Messages
Battery Discharge Indicator (BDI)

On the BDI display, each LED represents a Full Full
different level. See Figure 6-2.
3/4 2nd
3rd
4th
Recharge Bottom
Figure 6-2. Battery State-of-Charge
00700-CL222-05, 1 5 March 2005

Maintenance Mode
Maintenance Mode 5. Wait for the BDI display to clear. A clear

display indicates the first digit was
accepted.
Maintenance mode allows you to test individual
circuits of switches and inputs while the lift NOTE: You must enter the second digit within 3
truck is stationary or under normal operation. seconds of entering the first digit.
6. Press and release the horn button once
For example, if you suspect the lift switch is more.
bad, you can verify the switch circuit input to
7. Wait a few seconds for the BDI display to
the steer/tractor manager.
clear again. All the BDI LEDs will flash to
indicate the password was accepted and
Enter the maintenance mode. See "Enter"
the truck is in Maintenance Mode.
below. There are two methods for entering
Maintenance Mode, using the deadman pedal or
using the horn button. After you enter General Testing
maintenance mode, follow the instructions in
"General Testing." 1. Enter maintenance mode. See "Enter" on
page 6-4.
2. Request a n operation. e.g.-travel, lift, etc.
When the switch turns on or off, or an
analog input crosses a threshold, the
Deadman Pedal Method truck determines whether the circuit is
1. Turn the key switch ON. The horn beeps good or bad.
three (3)times after self-diagnostics is If the circuit is good, the horn clicks and
complete. the heartbeat LEDs on the steer/tractor
2. Within 10 seconds after the three (3)horn manager and carriage manager, and the
beeps, step on and off the deadman pedal steer indicator LEDs on the operator
3-6 times. The horn will start clicking display blink during the operator request.
when the truck is in maintenance mode. If the circuit is bad, the horn does not
NOTE: The deadman circuit must be click and the LEDs do not blink during the
transitioned 12 times to enter operator request.
maintenance mode. If both switches (S2
and S23) are working properly, you only The following standard switches can be tested
need to step on and off the pedal 3 in maintenance mode:
times. If one is not working, you need to Steer Home Switch (S8)
step on and off 6 times. Deadman (S2 and S23)
Horn (S3)
Horn Button Method
24" Limit (S6);see Note below
1. Turn the key switch OFF. 60" Height (S7);see Note below
2. Hold the horn button and turn the key 120/ 150" Height (S29); see Note below
switch ON. Do not release the horn button.
Emergency power off (S21)
3. When the BDI display clears, release the
horn button. NOTE: To test S6, S7, S24, S25, S29 and S60,
4. While the BDI display is clear, press and step on deadman pedal and lift the
release the horn button once. Each time operator platform. Each switch is tested
you press the horn button, one BDI LED a s it passes its activation rail.
lights.
The following optional switches can also be
tested in maintenance mode:
00700-CL222-05, 1 5 March 2005

Maintenance Mode
Lower limit (S60);see Note on previous NOTE: This test will not work if you step on the
Page deadman pedal.
Auto manual (S61) 2. Rotate the steering wheel.
Lift limit (S24) 3. See Table 6-4 below for test results. This
180" Height (S25); see Note on previous velocity-sensitive feedback tells you if the
Page. system is receiving steering requests from
the steer encoder.
Throttle Potentiometer Test
1 . Entcr maintenance mode. See "Enter" on Horn and LED Corrective
Diagnosis
Response Action
-page
- 6-4.
Horn clicks Steer encoder None required.
2. Rotate the throttle (via the control handle)
and LEDs is good. Do not
from neutral to maximum speed in each blink a t the continue
direction. same rate you through the
The horn should click and the 2nd BDI rotate the steer encoder
LED should blink 3-4 times for each steering wheel. test.
direction. Horn clicks Steer encoder Test the
and LEDs is missing one individual
If the horn does not click and the LED
blink a t a channel. channels. Go
does not blink, the analog voltage is
different rate to step 4.
outside the acceptable range. Test the than you
resistance of the throttle potentiometer. rotate the
steering wheel.
Learning Throttle & Lift Potentiometer Horn and Steer encoder Replace the
LEDs do not or cable is bad. steer encoder.
There are two methods for learning the neutral respond when
position of the throttle potentiometer. You can you rotate the
use the procedure in the following table or use steering wheel.
the MashWare program. See "Flashware Table 6-4. Steer Encoder Test Results
4. Measure the voltage a t PC 2-1 (Channel A)
Step Technician Action
and PC 2-4 (Channel B) with respect to
1 Key ON, EPO in, Deadman pedal down PC 2-2 (DGND) a s you rotate the steering
2 Key OFF wheel.
3 Key ON, wait for 3 horn chirps 5. The voltage should vary a s the steering
4 EPO out, EPO in wheel is rotated.
5 EPO out, EPO in
Rate of Rotation Voltage
6 EPO out, horn chirps 10 times when
truck h a s learned neutral position of Slow Toggle 0-5V
throttle potentiometer Fast Approximately 2.5V
7 Deadman pedal u p
8 Key OFF, Key ON 6. If the voltages do not match the table
above, replace the steer encoder.
Steer Encoder Test
1. Enter maintenance mode and step OFF
the deadman pedal. See "Enter" on
page 6-4.
00700-CL222-05, 1 5 March 2005

Traction Power Amplifier Fault Codes
Traction Power Am ifie An internal microcontroller automatically
checks the function of the traction power
Fault Codes amplifier. When this microcontroller detects a
fault, it signals the appropriate fault code
- - -
through the light emitting diode (LED) on the

front of the traction amplifier. These are
not the codes that appear on the operator
display and tractor manager.
Under normal operation, the LED flashes a

single flash a t approximately one flash per
second (a "heartbeat" indicator). A two-digit
flash code signals the power amplifier has
detected a fault within itself. The code
continues flashing until corrected.
Figure 6-3. Traction Power Am p lifier
TPA Code LED Off

Code Title No power or defective amplifier
Amplifier has no power or is 1)atl. Check cal~leat power

Reason
am~~lificr
System Response Systcm shutdown, lowcring cnal~lcd
Alarm Sounds No
TPA LED Display
1 PC Contactor I Open I
1) Speed Limit
I
1 0 mph 1
How to Clear Replace or repair bad component
Corrective Actions and Checks
Action/
Step Meter Setting (+) Lead (-) Lead Expected Results Step Passed Step Failed
1 DCV JPT11-10 B- cable B+ Step 2 Replace STM

a t TPA
2 DCV 51-16 B- cable B+ Replace TPA Troubleshoot

a t TPA wire from STM
00700-CL222-05, 1 5 March 2005

TPA Code LED Solid On
TPA Code LED Solid On
TPA Code Heartbeat
None. System functioning properly.
00700-CL222-05, 1 5 March 2005

Section 6. Codes and Tests Toyota Orderpicker Model 7BPUE15 Service Manual
TPA Code 1,1
TPA Code 1,l
TPA Code 1,2
Action/
Step (+) Lead (-) Lead Expected Results Step Passed Step Failed
Meter Setting
1 Replace the TPA
00700-CL222-05, 1 5 March 2005

TPA Code 1,3
TPA Code 1,3
TPA Code 2,l
00700-CL222-05, 1 5 March 2005

TPA Code 2,6
Action/
Full speed request = Step 2 Replace STM

approx. 4.25 volts
No travel request =
0 volts
Full speed request = Replace TPA Troubleshoot
approx. 4.25 volts wires from
No travel request = STM
0 volts
TPA Code 2,6
Action/
Step Meter Setting (+) Lead (-) Lead Expected Results Step Passed
Approx. 5 volts I Step 2 Replace CM 1

Neutral = 0.6 to 1.7
volts
Full lower = less
Replace CM Adjust or
replace travel I
than 2.8 volts
Full lift = more than
0.2 volts
00700-CL222-05, 1 5 March 2005

TPA Code 3,3
TPA Code 3,3
Action/
1 S 1 and S2 wires S 1 wire S2 wire About 1 OHM Step 2 Troubleshoot

disconnected wires to motor
from TPA/OHMs and motor field
2 S 1 and S2 wires S 1 terminal S2 Turn key ON = 0 Step 1 Replace TPA
disconnected on TPA terminal volts
from TPA/OHMs on TPA Step on deadman
pedal = 12 to 13
volts for about one
second
00700-CL222-05, 1 5 March 2005

TPA Code 4,1
TPA Code 4,l
NOTE: After one minute of inactivity, the PC contactor

will drop out. This will activate a blinking 4 , l
code. This is normal operation and should not be
considered a fault.
Action/
Meter Setting
1 DCV JPT11-10 TPA B- More than 17 volts Step 2 Test battery. If
OK replace
STM
2 DCV J 11-16 TPA B- More than 17 volts Replace TPA Troubleshoot

wire to STM
TPA Code 4,2
00700-CL222-05, 1 5 March 2005

TPA Code 4,3
TPA Code 4,3
been parked in a
freezer for an
hours, take it amount of time

out of the freezer
00700-CL222-05, 1 5 March 2005

TPA Code 4,3
Action/
Park the truck Code clears Inspect the Replace the

and allow it to mounting of TPA
cool down for a the TPA to the
few hours truck frame. It
must be tight
against the
from to
dissipate heat
properly. If
tight,
investigate the
duty cycle use
of the truck.
00700-CL222-05, 1 5 March 2005

Operator Display Fault Codes
Operator Display Fault

Codes
00700-CL222-05, 1 5 March 2005

Code 1,3
Code 1,3

NOTE: Use step 1 if the contactor tips do open
when the lift request is removed. Use
steps 2 and 3 if the contact tips do not
open when the request is removed.
Contactor for
00700-CL222-05, 1 5 March 2005

Code 1,4
Code 1,4

NOTE: Use steps 1 and 2 if the contactor tips
do close when a lift is requested. Use
steps 3 and 4 it the contact tips do not
close when a lift is requested.
00700-CL222-05, 1 5 March 2005

Code 1,5
Code 1,s
Code Title Mast switches disagree
1 . Mast switches (S6. S7. S25. S29) wcrc dctcctctl out ol'
which indicates there is a problem with a switch
sccl~~cncc
Reason or rail.
2. Sol'twwrc is not conligurctl correctly or is conligurctl for

the wrong tr~rck.(Looking for a switch not on the tnlck.)
System Response Travcl speed limited
1 Alarm Sounds I yes 1

1 Operator Display 1 i? DDDDD
1 PC Contactor I Closed 1
1 Speed Limit I Limited 1
Corrective Actions and Checks Check all mast switches per Figure 5-2 on
page 5-10 and the steps in the chart below.
NOTE: Not opening the 24 in. switch with lift
request and motor running more than
10 seconds, will cause this code.
connects to.
00700-CL222-05, 1 5 March 2005

Code 1,6
Code 1,6
Action/
1 1 DCV I JPC11-2 1 JPC12-22 I B+ I step 2 I Replace CM

2 1 DCV 1 step 3 1 Troubleshoot
3 DCV JPC9-3 JPC12-11 B+ Step 4 Replace CM
4 DCV JPT10-3 TP4 B+ Replace STM Replace over
mast cable
00700-CL222-05, 1 5 March 2005

Code 1,8
Code 1,8
00700-CL222-05, 1 5 March 2005

Code 2,1
Code 2,l
Action/
1 1 DCV J P C 13-7 Approx 5 volts Step 2 Replace CM
2 DCV J P C 13- I Neutral = 1.0 to 2.1 Replace CM Adjust or

volts replace travel
Full F/F = greater pot
than 0.4 volts
Full T/F = less than
3.2 volts
00700-CL222-05, 1 5 March 2005

Code 2,2
Code 2,2
Action/
1 Check TPA for NA NA Code Mashing Troubleshoot Replace STM

code displayed per the TPA
code
00700-CL222-05, 1 5 March 2005

Code 2,3
Code 2,3
00700-CL222-05, 1 5 March 2005

Code 2,4
Code 2,4
should close.
contactor for
00700-CL222-05, 1 5 March 2005

Code 2,5
Code 2,5
1. If the code does not clear, follow the
Encoder a t rest = 0
00700-CL222-05, 1 5 March 2005

Code 2,6
Code 2,6
Full lower = less

than 2.8 volts
Full lift = more than
00700-CL222-05, 1 5 March 2005

Code 3,1
Code 3,l
disconnected
00700-CL222-05, 1 5 March 2005

Code 3,2
Code 3,2

NOTE: If the drive unit will steer left and right,
start with step 1. If the drive unit will
not turn in one or both directions, start
with step 4.
Action/
JPT3 10.5 to 13 volts Step 2 Replace STM

disconnected /
DCV
JPT3 PT3-1 Approx. 5 volts Step 3 Replace STM
disconnected /
DCV
DCV JPT3- 1 Prox not over metal Step 4 Replace home
= Approx. 5 volts prox sensor
Breakout cable JPT8-1 At rest = 4.81volts Step 5 Replace STM
connected Turning tiller fast
between STM Right = 0 volts
and Steer Power
Head/DCV
Breakout cable JPT8-10 At rest = 4.81volts Step 6 Replace STM
between STM left = 0 volts
and Steer Power
Head/DCV
Breakout cable JPT8-6 At rest = 0 volts Step 7 Replace STM
between STM left = 4.7 volts
and Steer Power
Head/DCV
6-2 8 00700-CL222-05, 1 5 March 2005

Code 3,2
Turning tiller fast

right = 4.7 volts
and Steer Power
and Steer Power
Motor + and Troubleshoot
wires to motor
00700-CL222-05, 1 5 March 2005

Code 3,3
Code 3,3
Operator Display 111111 111111

NOTE: Steering with the drive tire off the floor
will cause this code.
Action/
Step Meter Setting
1 Breakout cable JPT8-1 At rest = 4.81 volts Step 2 Replace STM
between STM Right =O volts
and Steer Power
Head/DCV
2 Breakout cable JPT8-10 At rest = 4.81 volts Step 3 Replace STM
between STM Left =O volts
and Steer Power
Head/DCV
3 Breakout cable JPT8-6 At rest = 0 volts Step 4 Replace STM
between STM Left = 4.7 volts
and Steer Power
Head/DCV
4 Breakout cable JPT8-15 At rest = 0 volts Step 5 Replace STM
between STM Right = 4.7 volts
and Steer Power
Head/DCV
00700-CL222-05, 1 5 March 2005

Code 3,3
and Steer Power
and Steer Power
At rest = 0 volts
Fast t u r n = about
1.5 volts. If truck
and Steer Power h a s a fault and will
00700-CL222-05, 1 5 March 2005

Code 3,4
Code 3,4
head senses current in the steer motor circuit.
between STM
and Steer Power
and Steer Power

not steer test fails if
jacked up/ DCV 0 volts is not seen.
00700-CL222-05, 1 5 March 2005

Code 3,5
Code 3,s
mn nnnnn
PC Contactor
Action/
Step Meter Setting (+) Lead
1 Breakout Cable JPT8-5 Approx. 4.85 volts Replace STM 1. Remove

connected Steering or not. If steer motor
between STM low, 0 volts truck and gear box
and Steer Power thinks it is current and make sure
Head / DCV limit and step failed it will turn with
power.
2. With steer
motor removed
make sure
drive unit
turns freely.
3 . Replace
Steer power
head.
00700-CL222-05, 1 5 March 2005

Code 3,6
Code 3,6
feedback encoder circuit.
00700-CL222-05, 1 5 March 2005

Code 3,7
Code 3,7
= 0 or 5 volts
00700-CL222-05, 1 5 March 2005

Code 4,l
Code 4,l
1 second or vice versa.

NOTE: Disconnect S2 and step on the deadman
pedal. If the code still appears
troubleshoot the S2 circuit starting with
step 1. If the truck does not recognize
the deadman pedal being depressed
troubleshoot S23 starting with step 6.
Action/
Meter Setting
JPC7 PC7-2 10.5 to 13 volts Step 2 Replace CM
Disconnected /
DCV
JPC7 JPC7- I Approx 5 volts Step 3 Replace CM

Disconnected /
DCV
DCV 10.5 to 13 volts Step 4 Repair or

Replace wires
to CM
DCV Switch closed = 0 Step 5 Replace S2

volts
Switch open =
approx 5 volts
DCV Switch closed = 0 Replace CM Repair or

volts replace wires
Switch open = to CM
approx 5 volts
JPC7 PC7-5 10.5 to 13 volts Step 7 Replace CM

Disconnected /
DCV
00700-CL222-05, 1 5 March 2005

Code 4,1
00700-CL222-05, 1 5 March 2005

Code 4,2
Code 4,2
Action/
If contactor tips N/A Check contactor for Step 2 Repair or

are closed with burnt tips and replace the
Key OFF mechanical binding contactor
Key on PC JPT12-20 0 volts when Step 3 Replace STM
closed, wait for contactor should be
30 seconds and closed. B+ when
see if contactor contactor should be
opens/DCV open
Key on PC JPT12-2 0 volts when If OK and code Troubleshoot
closed/DCV contactor should be still appears wire a t
closed. B+ when replace STM JPT12-2 for
contactor should be shorts to B+
open
00700-CL222-05, 1 5 March 2005

Code 4,3
Code 4,3
after the PC contactor was commanded closed.
Action/
One side of Other 0 Ohms Step 2 Replace fuse

fuse side of
fuse
2 PC tips closed by B+ with tips closed Step 3 Inspect PC
hand/DCV 0 volts with tips contact tips.
open Troubleshoot
wire a t
JPT12-2 for an
open.
3 DCV Step 4 Troubleshoot
circuit from
JPT12-21 B+
ESTOP relay
4 DCV B+ when PC should Step 1 Replace STM
be open. 0 volts
when PC should be
closed.
00700-CL222-05, 1 5 March 2005

Code 4,6
Code 4,6

1. If a communication failure occurs, the
steer/tractor manager microprocessor will
continue to attempt communication. This
communication will be evident by viewing
the RECEIVE (IL3/IL10) and TRANSMIT
(IL9/IL4)LEDs on the carriage manager
and the steer/tractor manager. The carriage
manager will then send (initiate)a message
to the steer/tractor manager and it will
acknowledge the message by flashing its
TRANSMIT LED. It is possible to determine
the faulty module (carriage manager or
steer/tractor manager) by viewing the
LEDs. See Figure 7-5 on page 7-8 and
Figure 7-8 on page 7-9.
2. If the failure is on the carriage manager, the
RECEIVE LED (IL3) will be flashing but the
TRANSMIT LED (IL4)will not. Check
over-the-mast cable. If cable is OK, replace
carriage manager.
3. If the failure is on the steer/tractor
manager, the RECEIVE LED (IL10)will be
flashing but the TRANSMIT LED (IL9)will
not. Check over-the-mast cable. If cable is
OK, replace steer/tractor manager.
00700-CL222-05, 1 5 March 2005

Code 4,8
Code 4,8
00700-CL222-05, 1 5 March 2005

Code 5,l
Code 5,l
0 Meter Setting
Cable 10.8 to 13 volts Replace CM Step 2

disconnected
from PT7/DCV
Remove wire 10.8 to 13 volts Step 4 Step 3
from
JPTS-6/DCV
Disconnect all 10.8 to 13 volts Connect Replace STM
devices using the devices to the
12 volts on the STM one at a
STM /DCV time.
Troubleshoot
the wiring and
device that
pulls down the
12 volts.
Disconnect all PT7-1 10.8 to 13 volts Connect Test overmast

devices using the devices to the cable for
12 volts on the CM one at a shorts. If OK
CM/DCV time. replace CM
Troubleshoot
the wiring and
device that
pulls down the
12 volts.
00700-CL222-05, 1 5 March 2005

Code 5,2
Code 5,2
Action/
1 Replace STM 1 N/A 1 N/A 1 N/A 1 N/A I N/A

NOTE: If this code is intermittent check truck
for shorts to frame and verify static
straps are clean and contacting the
floor.
00700-CL222-05, 1 5 March 2005

Code 5,3
Code 5,3
12 volts on the STM one at a
Troubleshoot
12 volts on the
Troubleshoot
00700-CL222-05, 1 5 March 2005

Code 5,4
Code 5,4
Action/
1 Load new N /A N/A Clear codes N/A Replace STM

software to the
truck
00700-CL222-05, 1 5 March 2005

Code 5,5
Code 5,s
Operator Display 1113131313 1313131313
Action/
1 Replace CM N /A N/A N /A N/A N/A
NOTE: If this code is intermittent check truck

for shorts to frame and verify static
straps are clean and contacting the
floor.
00700-CL222-05, 1 5 March 2005

Code 6,1
Code 6,l
1 DCV 22 to 36 volts Step 2 Check FU14 if

OK
Troubleshoot
wiring to STM
22 to 36 volts Step 3 Troubleshoot
wiring to TP4
10.5 to 13 volts If Code 6 , l is Step 4
gone
DCV troubleshoot
wires and
speed encoder.
Is code is still
present
proceed to step
7
4 Filter card and 10.5 to 13 volts Step 5 Replace Steer

JPS 1 Controller
disconnected
from steer
controller/DCV
00700-CL222-05, 1 5 March 2005

Code 6 , l
disconnected /
that causes 12
00700-CL222-05, 1 5 March 2005

Code 6,2
Code 6,2
the code shown

on the Steer
Controller card
NOTE: Check adjustment of the line driver.

Check for mechanical binding in the
Drive Unit and steering gear box. Run
Learn for Guidance. Check setting for
Heading Angle and Distance from Wire
in configure. If intermittent check for
shorts to frame.
00700-CL222-05, 1 5 March 2005

Code 6,3
Code 6,3
Action/
Meter Setting
1 Troubleshoot per N/A
the code shown
on the Steer
Controller card
display
NOTE: Check adjustment of the line driver. Check for mechanical binding in the Drive Unit and
steering gear box. Run Learn for Guidance. Check setting for Heading Angle and Distance
from Wire in configure. If intermittent check for shorts to frame.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 7. Component Procedures
Section 7. Component Procedures
00700-CL222-05, 1 5 March 2005

Section 7. Component Procedures Toyota Orderpicker Model 7BPUE15 Service Manual
List of Component Procedures
Covers. Tractor . . . . . . . . . . . . . . . . . . 7-11
List of Component Cylinders
Procedures Center . . . . . . . . . . . . . . . . 7-69 to 7-70
Side . . . . . . . . . . . . . . . . . . 7-65 to 7-68
Air Gap Adjustment. Brake . . . . . . . . . . 7-27 Decals . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Amplifier. Traction Power . . . . . . . . . . . 7-45 Display. Operator . . . . . . . . . . . . . . . . . 7-16
Drive and Brake
Brake . . . . . . . . . . . . . . . . . . . . . . . 7-27
Drive Unit . . . . . . . . . . . . . . . . . . . . 7-24
Battery . . . . . . . . . . . . . . . . . . . 7-32 to 7-34 Drive Wheel . . . . . . . . . . . . . . . . . . 7-25
Cleaning . . . . . . . . . . . . . . . . . . . . . 7-33 Drive Motor . . . . . . . . . . . . . . . . . . . . .7-39
Install . . . . . . . . . . . . . . . . . . . . . . . 7-33 Drive Tire . . . . . . . . . . . . . . . . . 7-25 to 7-26
Remove . . . . . . . . . . . . . . . . . . . . . . 7-32 Drive Unit . . . . . . . . . . . . . . . . . . . . . . 7-24
Rollers Drive Wheel . . . . . . . . . . . . . . . 7-25 to 7-26
Inspect . . . . . . . . . . . . . . . . . . . 7-33
Replace . . . . . . . . . . . . . . . . . . . 7-33
Testing. Charging. Maintenance . . . 7-34
Bearings. Mast . . . . . . . . . . . . . . . . . . . 7-85 Electrical Components
Bleeding the Hydraulic System . . . . . . . 7-64 Battery Procedures . . . . . . . . . . . . . 7-32
Brake . . . . . . . . . . . . . . . . . . . . 7-27 to 7-29 Circuit Cards (General) . . . . . . . . . . 7-52
Air Gap Adjustment . . . . . . . . . . . . . 7-27 Contactor Tip Replacement . . . . . . . 7-48
Assembly . . . . . . . . . . . . . . . . . . . . 7-29 Contactors . . . . . . . . . . . . . . . . . . . 7-46
Disassembly . . . . . . . . . . . . . . . . . . 7-28 Drive Motor . . . . . . . . . . . . . . . . . .7-39
Friction Plate . . . . . . . . . . . . 7-28 to 7-29 Fuses . . . . . . . . . . . . . . . . . . . . . . .7-50
Inspection. Disassembled . . . . . . . . 7-28 Lift Motor . . . . . . . . . . . . . . . . . . . . 7-41
Brushes. Motor . . . . . . . . . . . . . 7-35 to 7-37 Motors (General) . . . . . . . . . . . . . . . 7-35
Steer Motor . . . . . . . . . . . . . . . . . . 7-42
Switches (General) . . . . . . . . . . . . . 7-53
Traction Power Amplifier (TPA) . . . . 7-45
Carriage Warning Light . . . . . . . . . . . . . . . . . 7-55
2-Stage . . . . . . . . . . . . . . . . 7-82 to 7-83 Emergency Lowering m o b . . . . . . . . . . 7-61
3-Stage . . . . . . . . . . . . . . . . 7-74 to 7-76
Center Cylinder . . . . . . . . . . . . . 7-69 to 7-70
Chains
2-Stage . . . . . . . . . . . . . . . . . . . . . . 7-93 Mow Control Valve . . . . . . . . . . . . . . . . 7-71
Center Cylinder. 3-Stage . . . . . . . . . 7-91 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Side Cylinders. 3-Stage . . . . . . . . . . 7-91 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Circuit Cards . . . . . . . . . . . . . . . . . . . . 7-52
Circuit Cards (General) . . . . . . . . . . . . . 7-52
Commutator. Motor . . . . . . . . . . . . . . . 7-38
Contactors . . . . . . . . . . . . . . . . 7-46 to 7-49 Guard. Mast . . . . . . . . . . . . . . . . . . . . . 7-13
Inspecting . . . . . . . . . . . . . . . . . . . . 7-46
Tip Replacement . . . . . . . . . 7-48 to 7-49
Control Handle . . . . . . . . . . . . . . . . . . . 7-17
Cover. Operator Console . . . . . . . . . . . . 7-12 Handle. Control . . . . . . . . . . . . . . . . . . 7-17
Covers and Finish Hydraulic Components
Decals . . . . . . . . . . . . . . . . . . . . . . . 7-14 Bleeding the Hydraulic System . . . . 7-64
Mast Guard . . . . . . . . . . . . . . . . . . . 7-13 Flow Control Valve . . . . . . . . . . . . . 7-71
Operator Console Cover . . . . . . . . . . 7-12 Fluid . . . . . . . . . . . . . . . . . . . . . . . 7-60
Tractor Covers . . . . . . . . . . . . . . . . . 7- 1 1 Lift Pressure Adjustment . . . . . . . . 7-63
7-2 00700.CL222.05, 1 5 March 2005

Lift Pump . . . . . . . . . . . . . . . . . . . . 7.62 Brush Spring Tension . . . . . . . . . . . 7-37

Manifold, Hydraulic . . . . . . . . . . . . .7-58 Brushes . . . . . . . . . . . . . . . 7-35 to 7-37
Reservoir . . . . . . . . . . . . . . . . . . . . .7.59 Commutator . . . . . . . . . . . . . . . . . .7-38
Side Cylinder . . . . . . . . . . . . . . . . . 7 . .65 Terminal Nuts . . . . . . . . . . . . . . . . .7-38
Solenoid Valves . . . . . . . . . . . . . . . .7-61
Hydraulic Fluid . . . . . . . . . . . . . . . . . . .7-60
Cold Storage . . . . . . . . . . . . . . . . . .7-60
Hydraulic Manifold . . . . . . . . . . . . . . . .7-58 Operator Display . . . . . . . . . . . . . . . . .7-16
Hydraulic Reservoir . . . . . . . . . . . . . . . .7.59 Outer Mast . . . . . . . . . . . . . . . . . . . . . .7-81
Inner Mast . . . . . . . . . . . . . . . .7-78 to 7-81 Pallet Clamp . . . . . . . . . . . . . . . . . . . . .7-95

Pump. Lift . . . . . . . . . . . . . . . . . . . . . .7-62
Lift Chains
2-Stage . . . . . . . . . . . . . . . . . . . . . 7
..93 Reservoir. Hydraulic . . . . . . . . . . . . . . . 7-59
3-Stage . . . . . . . . . . . . . . . .7-91 to 7-92 Rotor. Brake . . . . . . . . . . . . . . . 7-28 to 7-29
Lift Motor . . . . . . . . . . . . . . . . . . . . . . 7
..4 1
Lift Pressure Adjustment . . . . . . . . . . . .7-63
Lift Pump . . . . . . . . . . . . . . . . . . . . . . 7..62
Light, Warning . . . . . . . . . . . . . . . . . . .7-55 Side Cylinder . . . . . . . . . . . . . . 7-65 to 7-68
Load Wheels . . . . . . . . . . . . . . . . . . . . 7 ..96 Skid Pads . . . . . . . . . . . . . . . . . . . . . . . 7-97
Solenoid Valves . . . . . . . . . . . . . . . . . . 7-61
Steer Motor . . . . . . . . . . . . . . . . . . . . . 7-42
Steering and Controls
Manifold. Hydraulic . . . . . . . . . . . . . . . .7-58 Control Handle . . . . . . . . . . . . . . . . 7-17
Mast Operator Display . . . . . . . . . . . . . . . 7-16
2-Stage . . . . . . . . . . . . . . . . . . . . . . 7-84 Switches
Inner . . . . . . . . . . . . . . . . . . 7.78 to 7-81 Deadman . . . . . . . . . . . . . . . . . . . . 7-53
Outer . . . . . . . . . . . . . . . . . . . . . . . . 7.81 Emergency Power Off . . . . . . . . . . . 7-53
Mast Bearings . . . . . . . . . . . . . . . . . . . . 7-85 General . . . . . . . . . . . . . . . . . . . . . . 7-53
Mast Disassembly and Shimming . . . . . 7-87 Key . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Mast Section
2-Stage Carriage . . . . . . . . . . . . . . . 7-82
2-Stage Mast . . . . . . . . . . . . . . . . . .7-84
3-Stage Carriage . . . . . . . . . . . . . . . 7-74 Terminal Nuts. Motors . . . . . . . . . . . . . 7-38
Disassembly and Shimming . . . . . . . 7-87 Tire. Drive . . . . . . . . . . . . . . . . 7-25 to 7-26
Forks . . . . . . . . . . . . . . . . . . . . . . . . 7.94 Traction Power Amplifier (TPA) . . . . . . . 7-45
Inner Mast . . . . . . . . . . . . . . . . . . . . 7.78
Lift Chains, 2-Stage . . . . . . . . . . . . . 7-93
Lift Chains, 3-Stage . . . . . . . . . . . . .7-91
Load Wheels . . . . . . . . . . . . . . . . . . 7.96 Valves . . . . . . . . . . . . . . . . . . . . . . . . .7-61
Mast Bearings . . . . . . . . . . . . . . . . . 7-85 Flow Control . . . . . . . . . . . . . . . . . . 7-71
Outer Mast . . . . . . . . . . . . . . . . . . . 7.8 1
Pallet Clamp . . . . . . . . . . . . . . . . . . 7.95
Skid Pads . . . . . . . . . . . . . . . . . . . . 7.97
Motor, Drive . . . . . . . . . . . . . . . . . . . . . 7-39 Warning Light . . . . . . . . . . . . . . . . . . . .7-55
Motor, Lift . . . . . . . . . . . . . . . . . . . . . . . 7.41 Wheels
Motor, Steer . . . . . . . . . . . . . . . . . . . . . 7-42 Drive . . . . . . . . . . . . . . . . . .7-25 to 7-26
Motors . . . . . . . . . . . . . . . . . . . 7-35 to 7-44 Load . . . . . . . . . . . . . . . . . . . . . . . .7-96
00700.CL222.05. 1 5 March 2005

00700-CL222-05, 1 5 March 2005

Component Locator Photos
Side Cylinder Chains Mast Guard

Page 7-9 1 , page 7-93 Page 7- 13
Side
Cylinders
Page 7-65 \ Center Cylinder
Page 7-69
Forks pallet Clamp

Page 7-94 Page 7-95
Figure 7- 1 . Tractor View
00700-CL222-05, 1 5 March 2005

Hydraulic
Reservoir
Page 7-59
Lift Motor
Page 7-41
Lift Pump
Page 7-62
Solenoid
Valves 4
Page 7-61
Hydraulic
Manifold
Page 7-58
Power
Cables
Figure 7-2. Inside Tractor
00700-CL222-05, 1 5 March 2005

Electrical Panel Cover Removed
Traction Power
Amplifier
Page 7-45
Figure 7-3. Electrical Panel
1 5 0 Limit
Switch (S29)
Page 7-53
Figure 7-4. Mast Switches
00700-CL222-05, 1 5 March 2005

Figure 7-5. Carriage Manager lEDs
00700-CL222-05, 1 5 March 2005

LED IL6 Representing

1 IL6-1 I Warning Light 1
I IL6-2 1 Not Used I1
I IL6-3 1 Hour Meter I1
I IL6-4 1 Brake I1
I IL6-5 1 Pump I1
I IL6-6 1 Horn I1
1 1L6-7 1 Lift/Lower Solenoid I1
IL6- 10 Deadman Switch 1 (S2)

Figure 7 -7 : Steer/Tractor Manager lEDs
Figure 7 - 6 . Steer/Tractor Manager lEDs

Figure 7 -8 : Steer/Tractor Manager LEDs
00700-CL222-05, 1 5 March 2005

Figure 7-9. Steer Power Head LED
00700-CL222-05, 1 5 March 2005

Covers and Finish Tractor Covers
Covers and Finish

Tractor Covers
Figure 7- 10. Top Cover Removal
Removal
1. Press in the two latch buttons then lift the
top cover straight up and out. See
Figure 7-10.
2. Pull out the tractor cover from the top.
Installation
1. Position the bottom of the tractor cover
inside the bumper and push in from the
top.
2. Position the top cover over the two latch
buttons and push down until they snap
into place.
00700-CL222-05, 1 5 March 2005

Operator Console Cover Covers and Finish
Operator ConsoleCover Installation

1. Position cover over console components
and secure to the platform with-the two
captivating knobs.
Make sure the operator platform is fully

lowered before placing any part of your
body between the masts.
Figure 7- 1 1 . Operator Console, Cover Installed
Removal
Figure 7- 12. Operator Console, Cover Removed
1. Lower platform to the floor. Turn key

switch off and disconnect battery.
2. Loosen the two captivating knobs located
on each side of the cover.
00700-CL222-05, 1 5 March 2005

Covers and Finish Mast Guard
Mast Guard
Figure 7- 13. M a s t G u a r d
Removal
1. Lower platform fully to floor. Turn key
switch OFF and disconnect battery.
2. Loosen four screws in each mounting
bracket to gain clearance for mast guard.
3. Lift u p mast guard until notches in mast
guard clear the mounting brackets.
4. Pull screen guard forward to remove.
Installation
1. Insert screen guard over the 4 mounting
brackets.
2. Lower guard until brackets align just
above the opening. See Figure 7-13.
3. Tighten all 6 mm socket head screws
using a n Allen wrench.
00700-CL222-05, 1 5 March 2005

Decals Covers and Finish
Decals Location
Refer to the Parts Manual Finish Instructions
Replace any missing decals. Remove and Section to locate decals on the truck.
replace any decals which are damaged.
NOTE: Clean the surface thoroughly and allow
it to dry before attaching new decals.
Touch u p the paint a s required.
0
Emergency Lower
Turn knurled knob
CCW slowly to lower
platform.
After lowering, turn
knob CW until closed.
00590 03512 i l
Emergency lower
inside compartment
00590-03513-71
Figure 7- 14. Safety Decals
00700-CL222-05, 1 5 March 2005

00700-CL222-05, 1 5 March 2005

Operator Display Steering and Controls
Operator Display
Figure 7- 15. Replacing Operator Display
Replace
1. Turn key switch OFF and disconnect
battery.
2. Remove operator console cover.
3. Disconnect the JPC 1 from carriage
manager. See Figure 7- 15.
4. Peel failed operator display from console
bezel.
5. Place new operator display in cut-out on
console bezel.
6. Connect JPC 1 to carriage manager. See
Figure 7-15.
7. Install operator console cover.
00700-CL222-05, 1 5 March 2005

Control Handle
NOTE: Carefully slide the two spacer washers,
lift/lower spring, and third spacer
Control Handle washer off of the lift pot shaft. See
Figure 7- 16.
For replacement parts, refer to the parts
manual for the truck the handle is installed on.
Removal
2. Disconnect JPC9 and remove the Control
Handle from the truck.
NOTE: Observe orientation of switches/
potentiometers and routing of
cables/wires a s the handle is Figure 7- 16. Spacer Washer and L/L Spring Removal
disassembled to make reassembly
easier. 3. Remove the three 3mm socket head cap
screws from the handle assembly. See
Figures 7-17 and 7- 18. Separate the cover
from the handle.
Be sure to observe proper precautions
against electrostatic discharge. See
"Static Safety" on page 2-9.
Before disassembly, determine which

components require replacement:
Lift/Lower Potentiometer (Pot),Lift Spring,
and/or Horn Switch
Travel Pot and/or Gear
Travel Spring, Shaft Gear, and so on
Figure 7- 17. Cover Retaining Screws - Bottom
Lift/Lower Knob
Lift/Lower Pot (VRZ), Lift Spring

and/or Horn Switch
Replacement
Disassembly
1. Remove the two 3/32 socket head nylon
set screws in the lift/lower knob (thumb
lever). If stripped, use a small 1 / 8 in.
blade flat screwdriver and carefully back
out the set screw. Figure 7- 18. Cover Retaining Screw - Top
2. Loosen the two metal set screws in the NOTE: Before sliding the pot bracket off the pot
lift/lower knob two full turns and remove shaft, identify which slot in the pot
the lift/lower knob. bracket is used to hold the pot
anti-rotate tab. The anti-rotate tab
00700-CL222-05, 1 5 March 2005

Control Handle
should be located in the slot furthest 7. Carefully unsolder the harness wires from
from the pin in the pot bracket. the lift/lower pot.
4. Remove the lift/lower pot and bracket
from the cover. See Figure 7-19. Assembly
1. Carefully solder harness wires to the
proper terminals on the new lift/lower pot.
,Tab Refer to "Hand Soldering Procedures" on
page 7-22.
Install horn switch assembly into the
handle cover by snapping the pin into the
plastic detents.
Slide lift/lower pot bracket onto the shaft.
Make sure the anti-rotation tab is inserted
into the proper slot on the bracket. See
Figure 7- 19.
Press the lift/lower pot and bracket into
the handle cover. Make sure the key on the
bracket engages the keyway in the handle
Figure 7- 19. Anti-Rotate Tab cover.
5. Make sure all wires are routed properly.
5. Carefully pry the horn switch from the Tuck the common ground wire into handle
cover using a small screwdriver. See between the bottom of the potentiometer
Figure 7-20. and the screw boss to prevent the wire
from being pinched or interfering with the
horn button. See Figure 7-2 1.
Figure 7 - 2 0 . Horn Switch Removal
NOTE: The button, pin, and spring can easily

slide apart. Identify the proper position Figure 7 - 2 1 . Control Handle W i r e Routing
of these components before
disassembly. 6. Install the cover onto the handle assembly
with the three socket head cap screws.
6. If replacing the lift/lower pot, carefully Torque to 15-20 in. lb. (1.7-2.25 N*m).
remove heat shrink tubing from the
7. Install a fiber washer and lift/lower spring
terminals. Identify the wires so they can
(lightly greased with P/N 00590-04836-71)
be installed in the same location on the
on the liftllower pot shaft. Install the
new pot.
00700-CL222-05, 1 5 March 2005

Control Handle
spring with the tangs straddling the pot pull the travel pot/bracket assembly from
bracket pin. See Figure 7-16. the enclosure. See Figures 7-23 and 7-24.
NOTE: Replace the spring if the tangs are not
parallel. Do not bend the spring.
8. Install the two remaining fiber washers.
9. Install the lift/lower knob. See "Lift/Lower
Knob Installation/Adjustment" on
page 7-21.
Travel Pot (VR 1 )

Disassembly
1. Remove the four hex head cap screws from Figure 7-23. Travel Pot Bracket Screws
the front of the travel pot enclosure and
remove cover. See Figure 7-22.
R e m o v e screws
Figure 7-24 Travel Pot Enclosure (Cover Removed)
Figure 7-22. Travel Pot Cover Removal 3. Loosen the set screw on the gear two full
2. Remove the two pan head machine screws Figure 7-25.

-
turns and slide the gear off the shaft. See
from the back of the enclosure. Carefully

4. Remove retaining nut and lock washer
from pot and separate from the bracket.
See Figure 7-25.
Figure 7-25. Travel Pot/Bracket Disassembly
5. Carefully remove heat shrink tubing from

the terminals and identify the wires so
they can be installed in the same location
on the new pot.
00700-CL222-05, 1 5 March 2005

Control Handle
6. Carefully unsolder the harness wires. 2. Use a pin removal tool and pull pins 3 thru
6 from JC-9. These wires pass through the
Assembly shaft to the lift/lower pot and horn switch.
1. Slide 3/8 in. (9.5 mm) long shrink sleeving NOTE: The washer and shims can easily slip off
over previously sleeved wires. of the shaft gear. Observe the proper
2. Solder all electrical components to the position of these components before
harness. See "Hand Soldering Procedures" disassembling them.
on page 7-22. 3. Remove the button head screw from the
3. Shrink sleeving a s necessary. shaft gear and slide shaft out of enclosure.
4. Assemble pot and bracket and install See Figure 7-24.
retaining n u t and lock washer. When 4. Carefully rotate the shaft gear assembly to
installing the travel pot into the bracket, disengage the spring tangs from the pin.
leave the mounting n u t finger tight. See Remove the shaft gear assembly from the
Figure 7-25. enclosure.
5. Install the gear on the pot shaft, aligning
the set screw with the flat portion of the Assembly
shaft.
1. Slide the shaft gear assembly back into
6. Install the travel pot/bracket assembly enclosure. Engage the travel pot gear with
into the enclosure. Engage the travel pot the shaft gear (there is one large tooth that
gear with the shaft gear (there is one large is used to align the gears).
tooth that is used to align the gears).
Tighten the pot gear set screw and torque a. Make sure the spring tangs straddle the
to 3 to 4 in. lb. (0.3 to 0.4 N*m). pin (tangs should be parallel). If the
spirol pins were replaced, make sure
they are installed such that when the
ACAUTION spring is installed, the spring sits on a n
even edge of the pin and not on the gap.
It is very easy to over-torque and ruin
the gear. NOTE: Replace the spring if the tangs are not
parallel. Do not bend the spring.
7. Tighten the two pan head machine screws
on the back of the enclosure while moving b. Make sure the washer and shims are
the handle to ensure there is no binding. properly aligned to allow the handle
See Figure 7-23. shaft to slide easily through the
enclosure. See Figure 7-26.
8. Install the handle in the truck.
9. Adjust the travel pot to the correct voltage
values.
10. Tighten the retaining nut.
11. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-22.
Travel Spring and Pinion

Disassembly
1. Remove the four hex head cap screws from
the front of the travel pot enclosure and Figure 7-26. Travel Pot/Bracket Assembly installation
remove cover. See Figure 7-22.
7-2 0 00700-CL222-05, 1 5 March 2005

Control Handle
2. Route the lift/lower pot and horn wires 4. Check the potentiometer for proper
through the enclosure. Carefully slide the operation and spring return to neutral.
shaft through the enclosure, passing Correct any binding.
through the shaft gear assembly, washer, 5. Install and tighten two nylon set screws on
and shims. top of the metal set screws.
3. Align the screw hole in the handle shaft 6. Verify the potentiometer reference
with the hole in the shaft gear. Apply voltages.
thread locking compound (Loctite #425) to
the threads in the shaft and on the button
head screw. Install the screw and torque Cleaning and Inspection
to 8 to 12 in. lb. (0.9 to 1.3 N*m).
4. Reinstall the wire pins into the connector.
5. Inspect the tab on the plate ground to
ACAUTION
When cleaning plastic parts, use a dry
ensure that it is in contact with the bronze rag or a cleaner that is safe on plastics.
handle shaft bushing. See Figure 7-27. Most chemicals can damage plastic.
While performing a repair on the Control

Handle, clean and inspect the parts listed in
Table 7-1.
Table 7- 1: Control Handle Checks
Part Cheek for:
I
Horn button Cracks or deformation

assembly
(button, pin,
& spring)
Lift/lower Cracks, deformation, loose dowel

pot bracket pin, over round or oversized shaft
hole
Figure 7-27. Plate Ground
Travel pot Cracks, gear deformation,
stripped threads
6. Install the cover on the travel pot
enclosure with the four hex head cap Travel shaft Cracks, gear deformation or loose
screws. See Figure 7-22. gear spirol pin
assembly
Lif t/Lower Knob

Installation/Adjustment
1. Rotate the lift/lower potentiometer shaft
fully counterclockwise.
r Travel pot
enclosure
Handle
halves
Cracks, loose spirol pin, stripped
threads, deformation or indents
on external stops
Cracks, damage or
deformation/indents on external
2. Install the lift knob on the potentiometer stops
shaft. The pin on the knob must fit
between the tangs of the potentiometer
return spring. 1 ~/,'"wer
Cracks, deformation, stripped
threads, loose dowel pin I
3. Rotate the lift/lower knob fully Plate ground Check for continuity between the
counterclockwise and tighten the metal set control handle shaft and the truck
screws to 6 to 8 in. lb. (0.7 to 0.9 N*m). frame
Other Stripped threads. All screw

hardware threads should be cleaned.
00700-CL222-05, 1 5 March 2005

Control Handle
Hand Soldering Procedures

When hand soldering is performed on solid
state potentiometers, the following is
recommended:
Flux - rosin base
Solder - 60/40 rosin core or equivalent
Solder Iron - 55 watt max.
TipSize - 0.118 in. (3mm) dia. x 1.182in.
(30 mm) long screwdriver
Tip Temperature - 500°F (260°C) max.
Terminal Contact Time - 6 seconds max.
NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.
ACAUTION
Contact contamination can occur if
cleaning solvent is allowed to enter
switches or potentiometers.
After soldering, clean terminals with a brush

dampened with a n alcohol-based cleaner. Make
sure cleaner does not seep into the electrical
component.
NOTE: Components damaged due to solvent
saturation will not be covered under
warranty.
Installation
1. Install control handle on truck. Connect
JPC9.
2. Reconnect the battery connector and turn
the key switch ON.
3. Perform LEARN and test truck operation
before returning to service.
00700-CL222-05, 1 5 March 2005

Drive and Brake
Drive and Brake
00700-CL222-05, 1 5 March 2005

Drive Unit Drive and Brake
Drive Unit
Use extreme care whenever the truck is
jacked up. Never block the truck
between the mast and the floor. Keep
hands and feet clear from vehicle while
jacking the truck. After the truck is
jacked, place solid blocks beneath it to
support it. DO NOT rely on the jack
alone to support the truck. For details,
See "Jacking Safety" on page 2-1 1.
6. Drain fluid from drive unit. See

Figure 7-28.
7. Remove 6 bolts (use 10 mm socket head
cap screw wrench) holding drive unit to
Figure 7-28. Drive Unit Drain Plug tractor. See Figure 7-29.
8. Attach a suitable hoist to drive unit
Remove assembly and lift assembly out of truck.
1. Remove tractor covers.
2. Remove drive motor. See "Drive Motor" on Installation
page 7-39. 1. Using a suitable hoist, lower drive unit
3. Remove center bumper plate (19 mm assembly into tractor.
socket). 2. Secure drive unit to tractor with six bolts
4. If truck has wire guidance, remove cable and adhesive (P/N 00590-4609 1-71). (Use
from sensor on front bumper. 10 mm socket head cap screw wrench.)
5. Jack and block tractor so drive wheel is Torque to 120 ft. lbs. (162.8 Nm).
just off floor. 3. Refill gear box with fluid. See "Lubrication
Specification Chart" on page A-2.
4. Install drive motor. See "Drive Motor" on
page 7-39.
5. Install dipstick plug and dipstick.
6. Install prox. switch activation bracket and
secure motor to drive unit with cap
screws.
7. Connect power cables to drive motor.
8. Install steer motor and connect wires to
steer power head. See "Steer Motor" on
page 7-42.
9. Connect brake wires.
10. If truck uses wire guidance, connect wire
Figure 7-29. Drive Unit Mounting Bolts (Four Shown) guidance sensor cable.
11. Install bumper plate.
12. Install tractor covers, connect battery and
test truck operation before returning to
service.
00700-CL222-05, 1 5 March 2005

Drive and Brake Drive Wheel
Drive Wheel 2. Install drive wheel mounting bolts. Torque

to 100 ft. lbs. (135.7 Nm).
3. Install bumper plate.
4. Remove block and lower tractor with jack.
5. Connect power and test operation before
returning truck to service.
Drive Tire Replacement
ACAUTION
Any misalignment of the tire and hub
while the tire is being pressed onto the
hub can damage the hub. For this
reason, chamfers are provided on the
outside edge of the hub and on the end
Figure 7-30. Drive Wheel Mounting Bolts of the insiae diameter of the tire's metal
insert. The chamfers help to center the
Removal hub and tire during the pressing
operations and reduce the possibility of
1. Turn steering wheel all the way to the right misalignment. To prevent damage, the
so you can access drive wheel mounting hub must be installed on the circular
bolts. See Figure 7-30. ram with its chamfered side up.
battery connector.
Outside of Hub
/and Tire Assembly

alone to support the truck. For details,
see "Jacking Safety" on page 2-1 1. I I w Circular Ram
3. Jack and block truck under tractor frame.

See "Tractor" on page 2- 11. ' Press Table
4. Remove bumper plate.
5. Remove drive wheel mounting bolts. See Figure 7-3 1 . Drive Tire lnstallation
Figure 7-30.
1. Check inside surface of metal insert on
6. Remove drive wheel. new tire. Use sandpaper to remove any
scaling or rust. Clean inside of metal
Installation insert and lubricate it with a soap
solution.
1. Install drive wheel on drive wheel shaft.
2. Place circular ram on the press table. See
Figure 7-31. The length of ram must be
00700-CL222-05, 1 5 March 2005

Drive Wheel Drive and Brake
longer than width of old tire to allow
complete removal of old tire. The outside
diameter of ram must be small enough to
fit loosely in the insert of tire but must be
large enough to rest squarely on flat
surface on outer edge of hub.
3. If outside edge of hub is not flush with
edge of metal insert in old tire, measure
how far hub is recessed inside tire. The
new tire must be placed in the same
position the old tire was installed on hub.
You can use a spacer (slightly smaller in
diameter than inside diameter of tire insert
and same thickness a s depth of recess) to
obtain proper amount of recession.
4. Position hub assembly with old tire on top
of circular ram so outside of wheel is
positioned upward. The outside edge of
hub has a chamfer to help guide new tire
onto wheel. The chamfered edge must
always be leading edge when a tire is
pressed onto hub.
5. Center hub assembly on top of ram and
make sure that they mate squarely.
6. Position new tire with its chamfered insert
facing hub. Align new tire and hub so that
they are concentric.
7. Begin pressing new tire onto hub and old
tire off wheel. Run press slowly for the first
few inches of travel, because this is the
critical stage of the operation. If tire begins
to cock to one side, stop press and realign
tire. A sharp jar with soft-headed mallet
will usually realign tire on hub.
NOTE: If new tire does not press on with a
minimum of 5 tons (68,947 kPa)
pressure, replace hub.
8. Release press. Remove wheel, tire
assembly, and old tire from press table.
Inspect wheel and tire assembly.
9. Install drive wheel. See "Drive Wheel" on
page 7-25.
00700-CL222-05, 1 5 March 2005

Drive and Brake Brake
Brake Installation
1. Install brake assembly on drive motor.
2. Align cable bracket on brake assembly and
install bolts (3).
3. Connect PH5 and place cables in cable
bracket. Secure cable ties around cables.
4. Remove blocks and test brake before
Figure 7-32. Brake Assembly, installed
Removal
battery.
Figure 7-33. Measuring Brake Air Gap

Brake Air Gap Adjustment
During normal use, the friction plate will wear
(get thinner). This causes the air gap to
increase.
With the brake energized, measure the total air
gap with a feeler gauge. The total air gap should
alone to support the truck. See "Jacking
be 0.010 to 0.015 inch (0.25 - 0.38 mm) and
Safety" on page 2- 1 1.
uniform all the way around the armature disc.
A total gap greater than 0.015 inch (0.38 mm)
3. Jack and block truck under tractor frame.
indicates brake wear.
See "Tractor" on page 2- 11.
4. Disconnect electrical cable (PH5)to brake If the air gap is too large, the brake may not
assembly. work properly; this is especially true when the
5. Cut cable ties and pull cables from brake is hot or the battery charge level is low.
bracket. See Figure 7-32.
6. Remove brake (3 screws). See Figure 7-32.
NOTE: Note the location of the shims.
7. Remove brake release screws from tractor
(near steer motor) and install in brake.
Tighten screws until brake releases
completely.
00700-CL222-05, 1 5 March 2005

Brake Drive and Brake

~f the air gap is too small, the brake friction Brake Friction Plate (Rotor)
plate may drag.
Replace the brake friction plate if the thickness
is less than 0.236 inch (6 mm). See Figure 7-34.
Figure 7-34. Brake Assembly Components
Various shims and spacers are available for Figure 7-35. Disassembling the Brake
adjusting the air gap.
Adjustments can be made without removing the

Disassembly
brake coil assembly from the truck. 1. Remove assembly screws (3) from brake.
See Figure 7-35.
Shims and spacers should be added or removed
equally at each of the three assembly screws. NOTE: Keep track of the number and thickness
See Figure 7-34. of shims under each spacer.
2. Lift coil assembly off friction plate.
The air gap should be uniform [within 0.005
3. Remove old friction plate.
inch (0.127 mm)]when measured at various
points around the brake.
Inspection
When the correct air gap is obtained, torque the
assembly screws to 9 ft. lbs. (12 Nm). Check the mounting plate and the brake coil
assembly for signs of wear. If either part has
severe gouging or wear exceeding 0.010 inch
(0.25 mm), replace the brake.
00700-CL222-05, 1 5 March 2005

Drive and Brake Brake
Assembly 1. Position new friction plate in center of

mounting plate. See Figure 7-36.
2. Install a 0.020 inch (0.508 mm) shim
between a 0.709 inch (18 mm) spacer and
mounting plate on each assembly screw.
See Figure 7-36.
3. Place brake coil assembly on top of friction
plate. See Figure 7-36.
4. Tighten assembly screws (3).See
Figure 7-35.
5. Check the air gap. See "Brake Air Gap
Adjustment" on page 7-27.
Figure 7-36. Brake Assembly Components
Mounting
Plate
Friction
Plate
Figure 7-37: Brake Assembly, Detail View
00700-CL222-05, 1 5 March 2005

Brake Drive and Brake
00700-CL222-05, 1 5 March 2005

Electrical Components
Electrical Components
00700-CL222-05, 1 5 March 2005

Battery Procedures Electrical Components
Battery Procedures
ACAUTION When replacing battery cable ends,

remove only one end at a time from the
Before working on the battery, review connector, to avoid the cable ends
Battery Safety, beginning on page 2-6. touching and causing a short circuit. Do
Batteries for this lift truck weigh not allow the metal cable end to touch
between 920 and 2000 Ib. (418 to 908 the battery. Use insulated tools and
kg). Use extreme care during avoid contact with battery case or cable
replacement. Use a suitable battery ends.
moving device or hoist for lifting. Do not
extend a battery more than 1/3 of its 1. To remove a cable from the connector, you
length outside the battery compartment must push this retainer down while
without being attached to a pulling the battery cable towards the rear
battery-moving device. and out of the connector. See Figure 7-39.
NOTE: The distance from the floor to the top of

the battery rollers is 12.25 inches (31.12
cm).
Battery Connector/Cables
Location
The battery connector is located a t the
front-right of the tractor, above the battery.
Removal, Replacement, and

Installation
Figure 7-39. Removing Battery Cable from Connector
The cables to either half of the connector have a
lip on their forward end. This lip snaps over a 2. Do not attempt to repair battery cables by
spring-loaded retainer which is part of the crimping new terminals. Replace the
connector. cable.
Battery Removal
1. Turn key switch OFF.
2. Disconnect battery connector.
3. Remove tractor cover. See 'Tractor Covers"
on page 7- 11.
4. Position battery replacement device
according to manufacturer's
recommendation.
5. Remove battery gate by lifting straight up.
See Figure 7-40.
Figure 7-38. Battery Cable and Connector
00700-CL222-05, 1 5 March 2005

Electrical Components Battery Procedures

6. Remove battery with replacement device. Inspect Battery Rollers
Make sure the battery rollers turn freely. Clean
off any electrolyte with a solution of 1 lb. (.45
kg) of baking soda added to 0.5 gal. (1.9 liters)
of hot water. See Figure 7-41.
Replace Battery Rollers

Lift the damaged roller from its slot and replace
with a new one. See Figure 7-41.
Battery Exterior Cleaning

1. Read, understand, and follow procedures,
recommendations and specifications in the
Figure 7-40. Installed Battery with Spacer
battery and battery charger
manufacturer's manuals.
Battery Installation
1. Load a fully charged and tested battery on
replacement device.
2. Position replacement device with lift truck
battery compartment according to
replacement device manufacturer's
recommendation.
3. Install battery in compartment. Make sure
battery moves no more than 1 / 2 inch (13
mm) in compartment. Adjust spacer if
necessary. See Figure 7-40.
2. Wear personal protective equipment. See
4. Install battery gate. See Figure 7-40.
"Battery Safety" on page 2-6.
5. Move lifting device from area.
6. Connect battery connector, turn key the battery connector. Remove the battery
switch ON and test truck operation. from the lift truck.
Inspect the battery cables to make sure
they are not frayed or loose. Inspect the
battery connector to ensure there is no
foreign material inside the connector.
Figure 7-4 1 . Battery Rollers
00700-CL222-05, 1 5 March 2005

Battery Procedures Electrical Components
Make sure the filler plugs are tight and the Testing, Charging, and
vent holes in the filler plugs are open. Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the
battery manufacturer's specifications and
instruction manual.
ACAUTION
NEVER plug the battery charger into the
lift truck. This will severely damage the
lift truck's electrical system. Plug the
charger ONLY into the connector from
the battery.
Figure 7-42. Battery Filler Plugs and Vent Holes
5. Keep the top of the battery clean and dry

Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create shorts to ground.
ACAUTION
Do not clean the top of the battery with
the soda solution i h i l e it is instalied in
the truck. Water can seep into the
electrical compartments and cause Battery Discharge Indicator
serious damage.
Battery Discharge Indicator (BDI) is a feature
6. Wash dirty batteries (or any that have had that monitors and remembers the charge level
electrolyte spilled on them) with a solution of the battery connected to the lift truck and
of 1 lb. (0.45 kg) of baking soda added to prevents excessive discharging of that battery.
0.5 gal. (1.9 liters) of hot water. Operating a lift truck using a discharged
7. Use a brush with flexible bristles to clean battery can damage both the battery and the
the entire top of the battery with the soda electrical components of the lift truck.
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
Reconnect the battery connector.
00700-CL222-05, 1 5 March 2005

Electrical Components Motors (General)
Motors (General)
ACAUTION
Never use a chemical solvent to clean a
Motor Cleaning motor, as it can carry carbon dust to
inaccessible areas and cause shorts
within the motor.
ACAUTION
Cleaning a motor with solvents requires
complete disassembly and drying, and
should only be performed by an
authorized motor repair shop.
Figure 7-43. Motor Cleaning with Compressed Air
Periodic cleaning is essential to prevent

overheating and shorts-to-frame. To clean a
motor properly:
1. Wear safety glasses or goggles to protect
your eyes from dust and debris.
2. Using a n OSHA approved air nozzle, use
clean, dry, low pressure (30 psi or 207 kPa
or 2.1 kg/cm2) compressed air to blow
carbon dust and other foreign matter
from:
Motor housing
Brush holders
Commutator
Field and armature windings (if Figure 7-44. Motor Brush Location
accessible)
Motor Brushes
Location
Drive motor brushes, see Figure 7-45.
Lift motor brushes, see Figure 7-46.
Steer motor brushes, see Figure 7-47.
Inspection
Conduct a partial inspection of the motor after

every 500 hours of truck operation. If you work
in a n abnormally severe or caustic environment
or if you have a rigorous duty cycle, inspect the
motor more frequently.
00700-CL222-05, 1 5 March 2005

Motors (General) Electrical Components
Set up and rigidly adhere to a strict inspection 2. Check brush spring tension. See "Motor
schedule to obtain the maximum efficiency Brush Spring Tension" on page 7-37.
from the electrical equipment. 3. Clean brushes and holders. Wipe the
commutator with a dry, lint-free cloth. DO
NOT USE lubricants of any kind on or
around the commutator.
4. Check brush holders for solid connection
to the mounting support. Tighten the
mounting screws a s necessary.
5. Check the cap screws holding the brush
cross connectors to the brush holder body.
Figure 7 -4 5 . Drive Motor Brushes, location
Each partial inspection of the motor should

include the following:
1. Inspect the brushes for wear and for
proper contact with the commutator.
Record the level of wear on the brushes.
This history will give you a n indication of
whether a brush should be changed or if it
can wait until the next inspection. Refer to
Page 7-37 for acceptable brush length and Figure 7 -4 7 . Steer Motor Brushes, location
general
- motor information.
6. Make sure the motor terminals are
NOTE: Overloading a unit is ultimately reflected
secured tightly to the motor frame. Be
in the motor and brush wear; therefore,
careful not to strip the threads or crush
you must take this into account when
the insulating parts. See "Terminal Nuts"
considering brush replacement.
on page 7-38.
7. Check all the cap screws around the frame
for tightness.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.
Replacement
If one brush needs replacement, always replace
the entire set of brushes.
Use only genuine Toyota brushes. Using

another type of brush could damage the
Figure 7-46. lift Motor Brushes, location commutator or cause excessive brush wear and
will void your warranty.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE 1 5 Service Manual Section 7. Component Procedures
Electrical Components Motors (General)
If the end of the brush is not already contoured Motor Brush Spring Tension
to fit the commutator:
Inspection
3 . Slide the brush up slightly in its holder.
4. Insert a paper strip between the brush
face and the commutator.
5. Place a small leather loop around the coil
spring for the brush. If the brush spring
has a loop a t the brush, hook the spring
scale directly to the spring.
6. Attach a 5 lb. (2.27 kilogram) spring scale
Figure 7-48. Motor Brush, Steer Motor to the leather loop.
7. While gently pulling the scale outward,
NOTE: Form the brush contour using a brush
slowly pull the paper strip in the direction
seating stone.
that the commutator normally rotates.
8. When the paper strip begins to move
Spring freely, the spring scale will read the spring
Scale brush tension.
9. Refer to the table below for proper spring
tension:
10. Repeat steps 3 through 9 for the

- Rotation
\
remaining brushes.
Pull paper in direction of rotation
Figure 7-49. Motor Brush Spring Tension Inspection
00700-CL222-05, 1 5 March 2005

Motors (General) Electrical Components
Commutator terminal securing nut to avoid twisting the

stud.
Motor Cable
Securing Nut
Fiber
Securing
Nut
Figure 7-50. View of Steer Motor Commutator
Inspection Figure 7-5 1 . Motor Terminal - Double Nut
Stud terminal securing nuts should be torqued

The commutator should be inspected for
to 140-160 in. lbs. (15.8-18.1 Nm) and motor
surface condition and high mica.
cable securing nuts to 100- 120 in. lbs.
(11.2-13.6 Nm). Check these torques each time
The commutator must be smooth and clean to
you check motor brushes.
provide maximum brush wear. When
-
commutators are not properly maintained,
Two different methods are used to connect
carbon dust can collect in the grooves between
power leads on this truck. The double nut
the segments. This can lead to a short circuit in
method is shown in Figure 7-51. The triple nut
the armature.
method is shown in Figure 7-52. The torques
listed in the paragraph above apply to both
Good commutation will be indicated by a
methods.
dark-brown, polished commutator and an
evenly polished brush wearing surface.
Motor Cable Terminal Stud
If the commutator appears rough, pitted, or has

Securing Nut \
Cable Lug
signs of burning or heavy arcing between the
/Fzminal
commutator bars, the motor should be removed
for servicing.
I Washer
Terminal Nuts 1 or2
Whenever you disconnect and reconnect any

power leads to a motor, always tighten the
motor cable securing nuts with a torque wrench
to prevent over-tightening them and damaging
Stud
Terminal
Securing
&- - A Housing
the motor. Use a second wrench on the stud Nut
Figure 7 -52. Motor Terminal - Triple Nut
00700-CL222-05, 1 5 March 2005

Electrical Components Drive Motor
9. Break seal between drive motor flange and
Drive Motor drive unit. Use 2 screws from steer motor
mounting plate. See Figure 7-54.
Figure 7-53. Removing Dipstick

Figure 7-54. Breaking Seal Between Motor and Drive Unit
Removal 10. Attach a suitable hoist to drive motor and
1. Remove tractor covers. See "Tractor lift motor out of truck.
Covers" on page 7-11.
2. Turn drive unit using steering wheel so installation
you can reach power cables. 11. Clean sealant from motor flange and cap
3. Turn key switch OFF and disconnect screws for drive motor. See Figure 7-55.
batterv.
4. Remove brake from drive motor (if the
motor is to be replaced). See "Brake" on
page 7-27.
5. Disconnect power cables from drive motor.
Note location for installation and label if
necessary.
6. Remove steer motor. See "Steer Motor" on
page 7-42.
7. Remove dipstick and plug. See
Figure 7-53.
8. Remove the bracket that activates the
home prox switch.
Figure 7 -5 5 . Bottom of Drive Motor
00700-CL222-05, 1 5 March 2005

Drive Motor Electrical Components
12. If pinion needs to be installed:
a. Clean threads using thread primer (P/N
00590-04963-71).
b. Install the key and gear.
c. Apply adhesive (P/N 00590-04964-71)to
the threads.
d. Torque the n u t to 4 5 ft. lbs. (63 Nm).
13. Install a new gasket to the motor flange.
14. Install drive motor.
15. Install cam rings (if previously installed)
and secure motor to drive unit with cap
screws (13 mm socket). See Figure 7-56.
16. Install dipstick. See Figure 7-56.
17. Install steer motor and connect wires to
steer power head.
18. Install brake if previously removed and
connect wires.
19. Connect power cables to drive motor. See
Figure 7-56.
20. Install tractor covers. See "Tractor Covers"
on page 7-11.
21. Connect power and test truck operation
before returning to service.
Figure 7-56. Connecting Drive Motor to Truck Systems
00700-CL222-05, 1 5 March 2005

Electrical Components Lift Motor
Lift Motor
Removal
battery.
2. Remove tractor covers. See "Tractor
Covers" on page 7- 11.
NOTE: In the next steps you will need a 5 gallon
(19 liter) capacity container.
3. Drain hydraulic fluid. See "Hydraulic Figure 7 -5 8 . Pump-to-Motor Connection
Fluid" on page 7-60.
4. Disconnect hoses from pump. installation
5. Use two-wrench method to disconnect 1. Add anti-seize compound (P/N
power cables from lift motor. See 00590-04836-71) to spline shaft of pump
Figure 7-57. before mounting - to motor. See
Figure 7-59.
2. Mount pump to motor. See Figure 7-58.
3. Install four bolts to fasten the motor to its
bracket on the tractor frame.
Figure 7 -5 9 . Bottom of Pump
4. Connect power cables. See Figure 7-57

Figure 7-57. lift Motor Connections
5. Attach hoses.
6. Remove the four bolts that hold motor to 6. Replace hydraulic filter. See Figure 7-57.
bracket. See Figure 7-57.
7. Insert drain plug in drain hose and fill the
7. Lift out motor and pump assembly. hydraulic reservoir with new fluid. See
NOTE: Rest the motor on the bracket lip. "Lubrication Specification Chart" on
page A-2.
8. Remove pump from motor. See
Figure 7-58. 8. Connect battery and turn key switch ON.
-
9. Test lift functions.
10. Install tractor and top covers.
00700-CL222-05, 1 5 March 2005

Steer Motor Electrical Components

9. Install new steer motor assembly on pivot
Steer Motor ring. Secure with four bolts and adhesive
(P/N 00590-04964-71). See Figure 7-6 1.
Inspection
Check brushes. Once brushes are removed,

check commutator. See Figure 7-60.
Figure 7 -6 1 . Steer Motor Mounting
10. Install steer switches.

11. Connect M+ and M- to steer/tractor
Figure 7 -6 0 . Steer Motor Commutator, Brushes Removed manager.
12. Install circuit card cover.
Replace
1. Turn key switch OFF and disconnect returning truck to service.
battery.
Covers" on page 7- 1 1.
3. Remove circuit card cover.
4. Disconnect wires M+ and M- from
steer/tractor manager.
5. Remove proximity switches and
disconnect encoder.
6. Remove four mounting bolts and pull steer
motor assembly off pivot ring. See
Figure 7-61.
7. Remove six mounting bolts that secure
motor to mounting Figure 7-62. Separating Steer Motor from Gear Box
8. Install mounting plate to steer motor using
six bolts. Disassembly
1. Remove steer motor. See "Steer Motor" on
page 7-42.
2. Remove eight screws in the gear box. See
Figure 7-62.
3. Replace parts a s necessary. See
Figure 7-63.
00700-CL222-05, 1 5 March 2005

Electrical Components Steer Motor
Figure 7-63. Steer Motor and Gear Box, Disassembled
Pinion Gear 2. Remove mounting bolt from pinion gear.

See Figure 7-64. Note the number of
shims located above and below the gear.
Replace
3 . Loosen the set screw and remove the
1. Remove steer motor assembly. See "Steer pinion gear. See Figure 7-64.
Motor" on page 7-42.
Figure 7-65. Steer Motor Mounting Shaft

Figure 7-64. Steer Motor Pinion Gear 4. Install shims a s removed in step 3 , pinion
gear with key in keyway, shims as
00700-CL222-05, 1 5 March 2005

Steer Motor Electrical Components
removed in step 3, and secure with the
mounting bolt. Apply adhesive (P/N
00590-04964-71) on steer motor shaft.
See Figure 7-65.
5. Install steer motor assembly. See "Steer
Motor" on page 7-42.
00700-CL222-05, 1 5 March 2005

Electrical Components Traction Power Am p lifier
Traction Power Am ifier 6. Remove traction power amplifier. See

Figure 7-67.
Remove
battery.
2. Remove top and tractor covers.
3 . Remove control panel cover. See
Figure 7-66.
Figure 7-67. Traction Power Amplifier
Install
1. Install traction power amplifier on top of
power panel on top of tractor. See
Figure 7-67.
2. Secure traction power amplifier with three
Figure 7-66. Top of Tractor bolts.
3 . Connect cables and b u s bars. See
4. Disconnect the following cables and bus Figure 7-67.
bars:
4. Install control panel cover. See
S1 Figure 7-66.
S2 5. Install tractor and top covers.
J1 6. Connect battery and turn key switch ON.
B+ 7. Test truck operation.
B-
M-
5. Remove three bolts.
00700-CL222-05, 1 5 March 2 0 0 5
Contactors Electrical Components
C~ntcl~t~r~ Remove Assembly
This lift truck has two contactors, the PC and

pump (P) contactors. The following procedtzres
ACAUTION
When repairing contactors, use only
apply to either one. Toyota authorized contactor kits.

battery.
Covers" on page 7- 11.
3 . Remove control panel cover. See
Figure 7-69.
Figure 7-68. Severely Pitted Contactor Tips
Tip Inspection
When you inspect contactor tips, follow these
guidelines:
Disconnect the battery before inspecting
or servicing contactor tips.
Figure 7-69. Top of Tractor
Darkened points do not indicate burning.
Burning indicates a loss of contact point 4. Identify contactor to be removed. See
material. Figure 7-71.
Replace the contact tips if there is not
enough contact point material to last until
the next regular inspection or severe
pitting is evident. See Figure 7-68.
The silver alloy part of the point is usable
contact material; the copper backing is
not.
Do not file contact tips to remove
discoloration or minor irregularities. This
practice produces a surface more
susceptible to sticking.
If a cone and crater appear, remove the
cone with a file; Do not use sandpaper or
emery cloth.
Figure 7-70. Control Panel, Top View
5. Disconnect appropriate cables and fuses

by removing hex nuts. Note their location
00700-CL222-05, 1 5 March 2005

Electrical Components Contactors
and label if necessary for proper
reinstallation. See Figure 7-71.
6. Remove bus bars between contactors. See
Figure 7-70.
7. Remove contactor coil wires (X and Y) by
pulling wire connector. Note their locations
and label if necessary.
8. Remove contactor from mounting panel (2
hex nuts).
Install Assembly
1. Position the contactor on the threaded
studs of the mounting panel and attach
with hex nuts. See Figure 7-71.
Figure 7-71. Contactors
NOTE: P contactor is intermittent duty; PC

contactor is continuous duty.
2. Attach coil wires (X and Y) by sliding
connector onto appropriate spade
terminal.
3. Install bus bars on contactor lugs.
4. Install fuses. Match location to
corresponding tractor frame label.
5. Attach cables to appropriate lugs and
tighten securely.
00700-CL222-05, 1 5 March 2005

Contactor Tip Replacement Electrical Components
Contactor Tip Disassembly
Replacement
Figure 7-73. Pump Contactor Components
7. Remove nylon nuts (2) securing upper

retaining blocks (2).See Figure 7-73.
Figure 7-72. Contactor Components 8. Remove upper retaining blocks.
For the PC and pump contactors, use the 9. Remove stationary tips (2).
proper contactor tip replacement kit 10. Remove nut on top of core and rod
(P/N 00590-02782-71). It contains the following assembly shaft. See Figure 7-73.
items: 11. Remove fiber washer.
2 stationary contact tips 12. Remove contact spring.
1 movable contact tip 13. Remove movable contactor tips.
1 contact spring 14. Remove insulator bushing.
1 fiber washer
insulator bushing
When replacing contactor tips, replace
all old parts with the parts supplied in
the kit, even if the old parts appear to be
good.
Figure 7-74. installing New Contactor Components
Replacement
1. Install new insulator bushing over core
and rod assembly shaft. See Figure 7-74.
2. Install new movable tips over insulator
bushing, with contact tip faces down.
00700-CL222-05, 1 5 March 2005

Electrical Components Contactor Tip Replacement
3. Install new contact spring over insulator

bushing.
4. Install new fiber washer over rod assembly
shaft.
5. Secure movable tip assembly with nut on
top of core and rod assembly shaft.
6. Install new stationary contactor tips (2),
with tips facing up.
Figure 7-75. Contactor Assembly
Make sure cable posts face up, and are

on same side as contactor coil spade
terminals.
Make sure studs on lower retaining
block lock into holes in contact tip bar.
7. Install upper retainer blocks (2).Studs on
blocks will lock into holes in contactor
tips. See Figure 7-75.
NOTE: Grooves on the retainer blocks face the
inside.
8. Secure upper retainer blocks with nylon
nuts.
00700-CL222-05, 1 5 March 2005

Fuses Electrical Components
Fuses Auxiliary Power Fuses
Replacement
When replacing fuses, make sure fuses are
installed in the proper order. See Figure 7-76.
Figure 7-76. Fuse Locations
NOTE: Refer also to "Fuses" on page 5-15.
Figure 7-78. Fuse Plate Mounting and Cable Routing
Installation
battery.
3. Remove the front plate under the console
from the operator platform.
4. Line u p the fuse block on decal and mark
top and bottom holes.
5. Punch out the holes.
6. Push the fuse block mounting screws
through the holes in the decal.
Figure 7-77. Control Fuses on Steer/Tractor Manager 7. Line up the screws with the mounting
holes on the plate and adhere the decal to
the plate.
8. Mount the fuse holder on the caution
decal. Secure with two pan head screws.
See Figure 7-79.
00700-CL222-05, 1 5 March 2005

Electrical Components Fuses
9. Mount the fuse holder plate with two
thread-forming screws to the inside of the
platform upright. See Figure 7-79.
Figure 7-79. Close-up of Auxiliary Power Fuse Holders
10. Install the fuses in fuse holder. Order of

fuses from top-to-bottom is a s follows:
2AMP
2AMP
GAMP
GAMP
11. Route the harnesses through the raceways
between the fuse holder and the carriage
manager.
12. Connect wires to fuses a s marked on
sleeves. Connect to carriage manager a t
JPC 10.
13. Install the fuse cover using the flat washer
and screw.
15. Install front plate on operator platform.
00700-CL222-05, 1 5 March 2005

Circuit Cards (General) Electrical Components
Circuit Cards (General) 2. Remove appropriate cover(s). See "Tractor

Covers" on page 7- 1 1.
-
3. If removing a circuit card from tractor,
remove circuit card cover.
4. Disconnect all connectors on this circuit
card.
5. Remove all screws holding circuit card to
frame.
Figure 7-80. Steer/Tractor Manager Circuit Card
Figure 7-82. Carriage Manager in Operator Console
Installation
1. Install new circuit card with the screws
you removed earlier.
Figure 7-8 1: Steer Power Head Circuit Cart
2. Attach connectors to circuit card.
3. Connect battery connector and turn key
ACAUTION switch ON.
Use proper precautions against 4. If installing a circuit card in the tractor,
electrostatic discharge. See "Static install circuit card cover.
Safety" on page 2-9. 5. Install appropriate cover(s).
NOTE: Before removing a good carriage 6. Connect power and test operation before
manager, use the Flashware Program to returning truck to service.
clear the memory. See "Clear Primary
Memory" on page 10-6.
Removal
battery.
00700-CL222-05, 1 5 March 2005

Electrical Components Switches (General)
Switches (General) 5. While holding the two return springs in

place, lift pedal straight up.
6. Remove the two screws mounting the
Refer to the electrical schematic in the
deadman switch to bracket.
Appendix to identify the electrical circuit
location of the switch. 7. Disconnect wires from switch(es). Note
location and mark if necessary for
recondition later.
Deadman Switches
8. Replace defective switch(es). See
There are two deadman switches (S2 and S23). Figure 7-83.
9. Reconnect wires.
Replacement 10. Align washers with holes.
11. While holding the two return springs in
place, install pedal assembly. See
Figure 7-83.
Use extreme care whenever the truck is 12. Install washer and lock n u t on bottom of
jacked up. Keep hands and feet clear deadman pedal post.
from the vehicle while jacking the truck. 13. Connect power and test truck operation
After the truck is jacked, place solid before returning to service.
blocks beneath it to support it. DO NOT
truck. See "Jacking Safety" on Emergency Power Off Switch
page 2-1 1.
The emergency power off (EPO) switch is S 2 1.
Removal
1. Disconnect battery, turn key switch OFF
and remove key.
2. Remove operator console cover. See
"Operator Console Cover" on page 7-12.
3. Disconnect wires EPO 1 and 2 from back
of EPO switch. See Figure 7-84.
Figure 7-83. Deadman Pedal Components
1. Raise operator platform high enough (at

least 3 feet [91.44 cm]) to access bottom of
deadman pedal from under platform.
2. Block operator platform with a 4 in. x 4 in.
(100 x 100 mm) block.
battery connector.
4. R~~~~~ lock nut and washer from bottom Figure 7-84. EPO Switch a n d Key Switch locations
of deadman pedal post.
00700-CL222-05, 1 5 March 2005

Switches (General) Electrical Components

4. Loosen two screws on backside of EPO 4. Reconnect battery connector and check
switch. operation.
5. Hold lower half of switch, push in and 5. Turn key switch OFF and disconnect
rotate top half 90" counterclockwise to battery connector.
unlock halves of EPO switch. 6. Install operator console cover.
NOTE: The switch may turn hard. 7. Connect battery and test operation before
6. Lift top half of EPO switch from bezel. returning truck to service.
Installation
1. Insert lower portion of EPO switch in its
hole in bezel.
2. Slide upper half of EPO switch over lower
half until it is seated. Rotate top half 90"
clockwise to lock.
3. Tighten screws on backside of EPO switch.
See Figure 7-84.
4. Reconnect wires to back of the EPO
switch.
6. Connect power and test truck operation
before returning truck to service.
Key Switch
This lift truck is equipped with a two position
(off/on) key switch (S1), which energizes all
truck operations.
Removal
battery connector.
3. Remove mounting n u t from stem of key
switch. See Figure 7-84.
4. Remove key switch.
5. Disconnect wires from bottom of key
switch.
Installation
1. Connect wires to terminals.
2. Install new key switch and tighten locking
nut.
3. Secure mounting nut on key switch stem.
00700-CL222-05, 1 5 March 2005

Electrical Components Warning Light
Warning Light
Figure 7-85. Warning light
Replace
battery.
2. Unplug warning light harness. See
Figure 7-85.
3. Cut cable ties.
4. Remove foam gasket and light.
5. Install new light and foam gasket.
6. Connect harness.
7. Connect power and test function of
warning light before returning truck to
service.
00700-CL222-05, 1 5 March 2005

Warning Light Electrical Components
00700-CL222-05, 1 5 March 2005

Hydraulic Components
Hydraulic Components
00700-CL222-05, 1 5 March 2005

Hydraulic Manifold Hydraulic Components
Hydraulic Manifold
Figure 7-86. Hydraulic Manifold location
ACAUTION
Lower the operator platform before
removing the hydraulic manifold.
Remove
battery.
3. Drain hydraulic reservoir. See "Hydraulic
Fluid" on page 7-60.
4. Remove hoses.
5. Remove the two bolts holding the manifold
to the bracket.
Install
1. Mount manifold to its bracket.
2. Replace the O-rings a t manifold openings.
NOTE: Lubricate O-rings with clean hydraulic
fluid before installing.
3. Connect the hoses to the manifold.
4. Fill reservoir. See "Lubrication
Specification Chart" on page A-2.
5. Install tractor covers.
6. Connect power and test lift system
function before returning truck to service.
00700-CL222-05, 1 5 March 2005

Hydraulic Components Hydraulic Reservoir

5. Install tube weldment.
Hydraulic Reservoir
6. Install strainer and filler breather cap. See
Figure 7-87.
Remove
NOTE: To help prevent the hoses from slipping
1. Turn the key switch to OFF and off the protrusions on the reservoir:
disconnect battery.
Clean and dry the hoses and
2. Remove top and tractor covers. protrusions
3. Drain the hydraulic fluid. See "Hydraulic Make a rough surface on the
Fluid" on page 7-60. protrusions
4. Disconnect the warning light and hour 7. Attach hoses. Tighten the clamp as close
meter wires. as possible to the top of the hose.
$ Reservoir
" Tube
Weldmeni
Figure 7-87. Hydraulic Reservoir, Installed
5. Remove the filler breather cap and strainer

from the top of reservoir. See Figure 7-87.
6. Remove the six screws that hold the
return line bracket to the reservoir.
7. Remove the tube weldment. See
Figure 7-87.
8. Remove the bracket located behind the
drain and suction hoses.
9. Slide the reservoir out of the tractor.
Install
1. Fit the grommet and protrusion in the
bottom of the tank and install the bracket
that holds the suction and drain hoses.
2. Slide the new tank in place in tractor.
3. Install the bracket behind the drain and
suction hoses.
4. Lubricate O-ring with clean hydraulic fluid

and install.
00700-CL222-05, 1 5 March 2005

Hydraulic Fluid Hydraulic Components
Hydraulic Fluid b. Drain hydraulic fluid. See Figure 7-89.

5. Insert drain plug in drain hose and fill the
hydraulic reservoir with new fluid. See
Replace "Lubrication Specification Chart" on
1. Lower carriage to floor to relieve hydraulic page A-2.
pressure. 6. Connect power and test lift functions
2. Turn key switch OFF and disconnect before returning truck to service.
battery. 7. Install tractor covers.
3 . Remove the tractor covers.
NOTE: In the next steps you will need a 5 gallon Cold Storage Hydraulic Fluid
(19 liter) capacity container.
4. Drain the hydraulic reservoir.
Filte
Figure 7-90. Hydraulic Unit

Figure 7-88. Drain Plug, Hydraulic Reservoir
Replace
a. Remove the drain plug from the drain 1. Drain the hydraulic reservoir.
hose. See Figure 7-88.
2. Open the bleed screws on all lift cylinders.
See "Bleeding the Hydraulic System" on
page 7-64.
3 . Drain the return hose (from the reservoir
to the manifold).
4. Open the emergency lower valve. See
Figure 7-88.
5. Drain the inlet hose (pump to reservoir).
6. Drain the outlet hose (to cylinders).
7. Drain the hose from the pump to the
manifold.
8. Change the filter on the manifold.
Figure 7-89. Draining Hydraulic Fluid
00700-CL222-05, 1 5 March 2005

Hydraulic Components Solenoid Valves
Solenoid Valves
Figure 7-9 1 . Solenoid Valves on Manifold
Emergency Lowering Knob

This knob allows you to lower the carriage
without using the lower switch.
1. Turn the emergency lower knob 1 SO0
counterclockwise. See Figure 7-91.
2. Allow the carriage to lower.
3. After the carriage is lowered to floor, push
in knob and turn 180" clockwise.
Replace
1. Lower operator platform completely.
battery.
3. Disconnect wires from solenoid valve.
4. Remove n u t holding coil to valve barrel
and pull off coil.
5. Remove the valve barrel.
6. If valve has O-ring, lubricate O-ring with
clean hydraulic fluid before installing
barrel.
7. Place new valve barrel in manifold and
secure. Tighten the valve until a torque
value of 22 ft. lb. (30 Nm) is achieved.
8. Place the coil on the valve barrel.
9. Secure nut holding coil to valve barrel.
Torque n u t to 5 ft. lbs. (7 Nm).
10. Reconnect wires to solenoid.
00700-CL222-05, 1 5 March 2005

Lift Pump and Motor Hydraulic Components
Lift Pump and Motor 6. Remove and replace both hydraulic fittings
on the lift pump.
Figure 7-93. Pump and Motor Connection
7. Apply molybdenum anti-seize compound

(P/N 00590-04836-71) to the mating
surfaces of the lift motor spline and pump.
Figure 7-92. Pump Location
8. Carefully mate the new lift pump spline to
the lift motor and attach the lift pump to
Replace the lift motor with the two mounting bolts.
1. Remove top and tractor covers. 9. Replace the filter on the manifold. See
2. Turn key switch OFF and disconnect Figure 7-92.
battery. 10. Connect hoses.
NOTE: In the next steps you will need a 5 gallon 11. Insert drain plug in drain hose and fill the
(19 liter) capacity container. hydraulic reservoir with new fluid.
3. Drain hydraulic fluid. See "Hydraulic 12. Connect power and test lift functions
Fluid" on page 7-60. before returning truck to service.
13. Bleed the hydraulic system a s necessary.
NOTE: Make sure hoses are disconnected from
pump. 14. Install tractor covers.
4. Remove the two mounting bolts securing
the lift pump to the lift motor. See
Figure 7-93.
5. Carefully separate the pump from the
motor, taking care not to damage the
toothed spline.
00700-CL222-05, 1 5 March 2005

Hydraulic Components Lift Pressure Relief Valve Adjustment
Lift Pressure Relief Valve required to lift maximum rated load

(value recorded earlier).
Adjustment b. TO increase pressure, turn adjusting
screw clockwise. To decrease pressure,
turn adjusting screw counterclockwise.
c. Tighten locknut on lift pressure relief
valve.
9. Check pressure again. If value has
changed, repeat this procedure until the
correct pressure reading is obtained.
10. Turn key switch OFF.
1 1. Disconnect pressure gauge and reinstall
cap on lift pressure test port (Gl).
Figure 7-94. Adjusting Lift Pressure
1. Install a calibrated pressure gauge [3000

psi (20,682 kPa) a t mid-range] in the lift
pressure test port (Gl).See Figure 7-94.
2. Loosen the locknut on the lift pressure
relief valve (RV1) to back out the
high-pressure relief.
3. Make sure emergency lower valve is
closed.
4. Place a maximum rated load + 200 lb.
(90.7 kg.) on the forks.
5. Start the lift system and turn the pressure
relief screw clockwise until the platform
starts to lift. Note the pressure required
when the platform starts to elevate. On
three-stage trucks, continue lifting until
the third stage of the mast starts lifting.
Record the pressure reading.
6. Lower the operator platform and remove
the load.
7. Chain the mast sections together and lift
or lift the operator platform until the
upper limit is reached.
8. To adjust pressure:
a. Continue trying to elevate, and turn lift
pressure adjusting screw (at RV1) to
obtain a pressure reading of 100 to 300
psi (689 to 2068 kPa) greater than that
00700-CL222-05, 1 5 March 2005

Bleeding the Hydraulic System Hydraulic Components
Bleeding the Hydraulic 4. cylinder.

Repeat the steps for the other side
System 5. Connect battery and turn key switch ON.

6. Lower operator platform all way down to
floor.
7. Fully lift and lower platform several times.
8. Clean up any spilled hydraulic fluid.
9. Check hydraulic reservoir level and fill a s
necessary. See "Lubrication Specification
Chart" on page A-2.
Center Cylinder
If the truck has a three-stage mast, it will have
a center cylinder. To bleed the center cylinder:
1. Elevate the operator's platform enough to
extend the center cylinder approx. 3 in.
(76 mm).
Figure 7-95. Side Cylinder Bleed Screw 2. Loosen, do not remove, the bleed screw.
(Use 3 mm Allen wrench for center
You must bleed the hydraulic system to remove cylinder.) Hold rag beneath the bleed screw
any trapped air whenever you: to keep hydraulic fluid from spraying out.
- - . -
Change a hydraulic line 3. When only hydraulic fluid starts flowing
Disconnect a hydraulic fitting from the cylinder, securely tighten the
Remove a hydraulic cylinder bleed screw.
Remove the hydraulic pump
Notice that the load is bouncing
Side Cylinder
1. Extend the cylinder then t u r n the key
switch OFF and disconnect the battery.
2. Loosen, do not remove, the bleed screw.
(Use 3 mm Allen wrench for side
cylinders.) Hold rag beneath the bleed
screw to keep hydraulic fluid from
spraying out.
ACAUTION
The bleed screw should only be
loosened enough to allow the air to
escape.
3. When only hydraulic fluid starts flowing

from the cylinder, securely tighten the
bleed screw.
00700-CL222-05, 1 5 March 2005

Hydraulic Components Side Cylinder
Side Cylinder 4. Remove the bolt in the top of the lift

cylinder that connects it to the bracket on
the mast.
5. Elevate the platform until it clears the ram
assembly enough to allow removal
Use extreme care whenever the truck is 6. Block the carriage and mast.
jacked up. Never block the truck 7. Remove the snap ring from the bottom of
between the mast and the floor. Keep the cylinder. See Figure 7-97.
NOTE: Using a mirror will enable you to see the

snap ring a t the bottom of each cylinder
housing in the following procedures.
Remove
1. Elevate the platform far enough to access
the tubing that connects to the bottom of
the lift cylinder but not far enough to Figure 7-97. Bottom View of Housing (Using Mirror]
extend the side cylinder. Block the carriage
in place. 8. Remove the bolt that attaches the cylinder
2. Remove the tubing from the bottom block housing to the main frame of the truck.
on the cylinder that is to be removed and See Figure 7-98.
cap both the tubing and the fitting to the
lift cylinder.
Figure 7-96. Hydraulic Connection, Side Cylinder, Bottom
3. Unblock and lower the platform to the Figure 7-98. Side Cylinder
floor.
9. Remove the lift cylinder from the truck.
00700-CL222-05, 1 5 March 2005

Side Cylinder Hydraulic Components
Installation 4. Pull piston until piston stop pushes

retaining ring, packing and adapter out of
1. Install cylinder in the truck. cylinder. See Figure 7-99.
2. Install the bolt that attaches the cylinder 5. Pull piston out of housing. Place piston on
housing to the main frame of the truck. cushioned stand. Do not damage piston
3 . Install the snap ring on the bottom of the surface.
cylinder housing. See Figure 7-97. 6. Push cushion into piston a t base of piston.
4. Unblock the mast and lower the platform
far enough to collapse the other outer
cylinder but still have access to the fitting
a t the bottom of the cylinder.
5. Block the platform in place. Connect the
tubing to the bottom of the cylinder.
6. Unblock and lower the platform to the
floor. Install the bolt in the top of the lift
cylinder that connects it to the bracket on
the mast.
7. Bleed hydraulic system. See "Bleeding the
Hydraulic System" on page 7-64.
8. Lift and lower carriage completely to check
lift function.
Figure 7- 100. Cushion, Removed
Cushion Service
1. Remove cylinder from truck. See "Side
Cylinder" on page 7-65.
ACAUTION
The cushion is under extreme pressure.
2. Remove snap ring and wiper. See Keep pressure on the cushion when
Figure 7-99. removing the items in the next step.
Failure to do so could cause injury from
projectile parts.
7. Remove snap ring and retaining ring. See

Figure 7- 100.
8. Release pressure on cushion and pull
cushion out of piston. See Figure 7-100.
9. Remove spring. See Figure 7- 100.
Figure 7-99. Piston Removal
3. Remove snap ring in cylinder housing.
00700-CL222-05, 1 5 March 2005

Hydraulic Components Side Cylinder
10. Remove seal from cushion. See 12. Install spring. Make sure it is fully seated
Figure 7-100. in cushion piston.
13. Install cushion piston.
14. Install retaining ring and snap ring.
15. Install cylinder in truck. See "Side
Figure 7- 10 1. Cushion Piston Seal Kit, listed In Order of

installation
Do not separate piston from piston plug Figure 7- 103. Cushion Assembly
unless necessary. If disassembly is
required, use a strap wrench only. Do Cleaning
not damage piston surface.
1. Flush inside of housing.
NOTE: When repacking the cylinder, replace all 2. Wipe piston with clean kerosene or
packings. See Parts Catalog for packing suitable industrial solvent.
kits. 3. Inspect all surfaces for galling or heavy
11. Install seal kit on cushion piston. See scratches. Remove minor defects with a
Figure 7-10 1. fine emery cloth.
4. Inspect all parts; replace a s necessary.
Tip: Twisting the fiber rings prior to installation
helps them retain their "memory." See
Figure 7-102.
Figure 7- 102. Twisting Fiber Rings
00700-CL222-05, 1 5 March 2005

Side Cylinder Hydraulic Components
Seal Repacking Service guide, P/N 00590-45416-71
1. Remove cylinder. See "Side Cylinder" on

page 7-65.
Figure 7- 105. Using C y linder Service Tools
5. Slide brass adapter on piston.

6. Install piston assembly into housing.
Figure 7- 104. Packing Components on Side Cylinder Install service guide. See Figure 7- 105.
Dip seal in oil and slide over piston, back
ACAUTION first.
Drive seal into assembly with driver. See
Do not damage chrome plating on
Figure 7- 105.
piston.
Remove service guide.
2. Remove snap rings, seals, backup ring and Install packing backup ring.
brass adapter. See Figure 7-104.
Install snap ring.
3. Dip all packings in clean hydraulic fluid.
Install wiper.
4. Lubricate inside of cylinder housing with
Install snap ring.
hydraulic fluid.
Install cylinder. See "Side Cylinder" on
NOTE: To prevent damage to packings at the page 7-65.
top of the cylinder, use the following
tools:
Service driver, P/N 00590-454 15-71
00700-CL222-05, 1 5 March 2005

Hydraulic Components Center Cylinder
Center Cylinder 4. Install carriage. See "Three-Stage

Carriage" on page 7-74.
5. Install end cap on center cylinder.
Removal
6. Connect power and test lift function before
Service of Cylinder with

Cushions
hands and feet clear from vehicle while Cushion Replacement
jacking the truck. After the truck is Refer to Figure 7-107 on page 7-70 for the
jacked, place solid blocks beneath it to following steps.
alone to support the truck. See "Jacking 1. Remove retaining ring (1) and top
Safety" on page 2- 1 1. bearing (2).
1. Remove carriage. See "Three-Stage NOTE: When the retaining ring is removed, a
Carriage" on page 7-74. spring behind the top bearing may push
the bearing" out of the housing.
"
Remove the spring (3)and pressure
ring (4).
Remove the three Torx screws (5) located
about 6 in. from the top of the housing.
Remove piston (6)from cylinder housing.
Remove the cushion assembly (7).
Coat the threads of the new cushion
assembly with thread-locking compound
primer (Loctite #T747) and apply
thread-locking compound (Loctite # 277).
Assemble the new cushion assembly (7) to
piston rod.
Figure 7- 106. Center Cylinder, Bottom View 8. Re-install piston assembly in cylinder
housing.
2. Remove snap ring and washer from
bottom of center cylinder. See 9. Re-install the three torx screws (5).
Figure 7- 106. 10. Lightly oil a new seal (8)and install in
3. Remove and cap hydraulic hoses. pressure ring (4). Check to make sure the
small orifice in the pressure ring is not
4. Remove U-shaped bracket.
obstructed.
5. Remove center cylinder.
11. Install spring (3).
12. Remove the bad parts from the top
Install
bearing.
1. Install center cylinder. Make sure the 13. Lightly oil new seal (9),O-ring (1O), backup
bushing is on the mounting bolt. ring (11) and wiper (12) and install into the
2. Install washer and snap ring to bolt under top bearing.
center cylinder. See Figure 7- 106. 14. Install the top bearing (2).
3. Install U-shaped bracket. 15. Install the retaining ring (1).
00700-CL222-05, 1 5 March 2005

Center Cylinder Hydraulic Components
1 I I II II I7- See View B See View A I
View B View A
Figure 7- 107. Center Lift Cylinder, Three-Stage with Cushions
Seal Replacement 8. Install the retaining ring (1).
Refer to See Figure 7-107 on page 7-70 for the

following steps. Installation
1. Reverse the removal procedure.
1. Remove retaining ring (1) and top
bearing (2). 2. Install cylinder. See "Side Cylinder" on
page
A - 7-65.
NOTE: When the retaining ring is removed, a 3. Reconnect the battery connector and turn
spring behind the top bearing may push the key switch ON.
the bearing out of the housing.
4. Bleed hydraulic system after reassembly.
2. Remove the spring (3)and pressure See "Bleeding the Hydraulic System" on
ring (4). page 7-64. Check for leaks.
3. Check to make sure the small orifice in the 5. Test all vehicle functions.
pressure ring is not obstructed.
4. Lightly oil a new seal (8)and install in
pressure ring (4).
5. Remove the bad parts from the top
bearing.
6. Lightly oil new seal (9),O-ring (1 01, backup
ring (11) and wiper (12) and install into the
top bearing.
7. Install the top bearing (2).
00700-CL222-05, 1 5 March 2005

Hydraulic Components Flow Control Valve
Flow Control Valve 7. Place the hydraulic fitting in the valve

housing block with the O-ring end first
and tighten.
Install hydraulic tubing.
Remove blocks and bleed the hydraulic
system. See "Bleeding the Hydraulic
System" on page 7-64.
Connect power and test lift function befc
Figure 7- 108. Flow Control Valve Location
Replace
1. Lift and block carriage enough to reach
valve housing block.
2. Turn key switch OFF and disconnect the
battery.
3. Remove hydraulic tubing. See
Figure 7- 108.
4. Remove fitting. See Figure 7-108.
5. Pull out flow control valve.
6. Place the new valve in the housing.
Figure 7- 109. Replacing Flow Control Valve
NOTE: Follow the directional arrow on the flow

control valve to install it correctly. It
should be pointing out of the housing in
the direction of flow. See Figure 7- 109.
00700-CL222-05, 1 5 March 2005

Flow Control Valve Hydraulic Components
00700-CL222-05, 1 5 March 2005

Mast Section
Mast Section
00700-CL222-05, 1 5 March 2005

Three-Stage Carriage Mast Section
Three-Stage Carriage
Do not dace hands between the masts
before blocking the carriage.
Use extreme care whenever the truck is 6. Feed cable through carriage to tractor.
jacked up. Never block the truck 7. Use 90" snap ring pliers to remove snap
between the mast and the floor. Keep ring holding chain rocker assembly to
hands and feet clear from vehicle while center cylinder. See Figure 7- 111.
Removal
battery.
3. Remove electrical over-the-mast cable
from bottom pulley on carriage. See
Figure 7- 110.
4. Disconnect cable tension spring from Figure 7- 1 1 1. Center Cylinder, Top View
carriage. See Figure 7-1 10.
Attach a suitable hoist to carriage and lift
approximately 1 ft. (30.5 cm).
Remove rocker assembly, its associated
hardware and chain from center cylinder.
Place chain on operator platform.
Remove end cap from center cylinder.
Remove carriage stops (2) from inner mast
and pound in locator pins until carriage
can clear the mast. See Figure 7-112 and
Figure 7- 1 13.
Figure 7- 1 10. Electrical Over-the-Mast Cable
5. Disconnect JPC8 and JPC9 from carriage

manager and cut cable tie from tractor
side.
00700-CL222-05, 1 5 March 2005

Mast Section Three-Stage Carriage
Figure 7- 1 12. lnner mast, Top Corner
Figure 7- 1 14. Underside of Carriage
4. Position platform 3 ft. (1 m) from floor.

5. Install rocker assembly, its associated
hardware and chain on center cylinder.
See Figure 7- 115.
6. Install endcap pulley on center cylinder.
7. Feed chains for center cylinder and
over-the-mast cable.
Figure 7- 1 13. lnner mast, Top Corner, Stops Removed
12. Remove operator platform.
Installation
1. With suitable hoist, lower bottom bearings
on carriage into channel on inner mast.
2. Make sure there are sufficient shims to
prevent side play. See "Mast Bearings" on
page 7-85.
3. Make sure 2 switches (S6 and S7) a t
bottom of carriage are riding their switch
rail properly. See Figure 7- 1 14. Figure 7- 1 15. Center Cylinder, Top View
8. Feed over-the-mast cable through back of

carriage to carriage manager and connect
to JPC8 and JPC9.
00700-CL222-05, 1 5 March 2005

Three-Stage Carriage Mast Section
9. Tie electric cables to platform. See NOTE: There are 6 in.(152 mm) from the top of
Figure 7- 1 16. the spring on the carriage to the center
bolt in the cable clam^.
12. Install carriage plate.
13. Install mast guard.
14. Lift and lower platform fully, and check
functions of lift system. Look for:
Oil leaks
Cables on pulleys
Switch actuation
Unusual bearing noise
Figure 7- 1 16. Tie Points for Cables on Platform, Backside Center Cylinder Ride Spring
Chain Anchors
- -
10. Install carriage stops a t top of inner mast.

See Figure 7- 1 17. Inspection of the chain anchors and pivot
Figure 7- 1 17. Inner mast, Top Corner 3. Place blocking under the operator's
platform. Lower the platform onto the
1 1. Lower carriage and install cable on bottom support.
pulley of carriage. Install cable retainer 4. Disconnect the battery connector and
spring. See Figure 7-118. open the emergency lower valve.
The center cylinder will move down and
the chains will go slack. If the center
cylinder does not go down far enough to
slacken the chains, push down on the c t
of the cylinder. This will allow the chain
anchor to be visible for inspection. See
Figure 7- 1 19.
Figure 7- 1 18. Electrical Over-the-Mast Cable, Front Side of

Platform
00700-CL222-05, 1 5 March 2005

Mast Section Three-Stage Carriage
Figure 7- 1 19: Before chain goes slack

Figure 7- 120: After chain goes slack
5' Inspect the anchor and pivot rocker 6. Reconnect the battely connector and close
for wear and replace if necessary. See
the emergency lower valve. Lift the
Figure 7-120.
platform slowly to take slack out of the
chains and to clear the safety stand from
beneath it.
7. Remove the stand and lower the platform.
8. Reinstall all covers.
00700-CL222-05, 1 5 March 2005

Inner Mast Mast Section
lnner Mast
mast

Removal
Figure 7- 1 2 2 . lnner mast, Chain Pulley Removed
1. Remove platform. See "Three-Stage
5. Remove center cylinder. See "Center
2. Attach hoist to inner mast and lift 2-3 Cylinder" on page 7-69.
inches (50-70 mm) to remove tension from
6. Remove hydraulic hose and pulley from
chain.
one side of inner mast.
3. Disconnect chains from bottom chain
anchor block of each side cylinder. Swing
chains over each pulley. See Figure 7- 121.
Figure 7- 123. Over-the-Mast Cable a n d H y draulic Hose
Figure 7- 12 1. Bottom Chain Anchor Block

7. Remove over-the-mast cable and pulley
from other side of inner mast. Note
4. Remove each chain pulley. See location of cable ties. See Figure 7-123.
Figure 7-122. 8. Raise inner and outer mast 1 ft.
(0.3 m) off floor. Block outer mast.
9. Remove flathead screws and upper roller
bearings on outer mast.
10. Use a hoist to the remove inner mast.
00700-CL222-05, 1 5 March 2005

Mast Section Inner Mast
installation 5. Apply adhesive (P/N 00590-04964-7 1) to

bolts and install chain pulleys. See
1. Line up bottom roller bearings in the outer Figure 7- 125.
mast channel and lower into main frame.
See Figure 7- 124.
Figure 7- 125. Attaching C y linder a n d lnner mast
6. Install chains and secure in chain

anchors. See Figure 7- 126.
Install upper roller bearings on the outer

mast.
Remove block from outer mast and lower
both masts.
Install bolt in the top of each piston. See
Figure 7- 125.
Figure 7- 126. lower Chain Anchor Block
7. Install center cylinder. See "Center

8. Install over-the-mast hose and cable
pulleys to outer mast.
9. Install hoist on outer mast and lift until
inner mast raises enough to expose cable
bracket.
00700-CL222-05, 1 5 March 2005

lnner Mast Mast Section
10. Install cables and hoses. Attach cable ties

to bracket on inner mast cable bracket.
See Figure 7-127.
Figure 7- 127. Tie Points for Cables a n d Hoses on lnner masf
11. Install carriage. See "Three-Stage

00700-CL222-05, 15 March 2005

Mast Section Outer Mast
Outer Mast 6. Remove top bearing on main frame.

7. With a suitable hoist, remove outer mast.
See Figure 7- 128.
Installation
1. With a suitable hoist, lower outer mast
into main frame.
hands and feet clear from vehicle while 2. Install top roller bearings.
jacking the truck. After the truck is 3. Install stops to outside, top of main frame.
4. Install pulleys.
alone to support the truck. See "Jacking 5. Install inner mast. See "Inner Mast" on
Safety" on page 2- 1 1. page 7-78.
6. Install operator platform. See "Three-Stage
Removal Carriage" on page 7-74.
7. Before returning truck to service, check
1. Remove operator platform. See
mast movement and adjust as necessary.
"Three-Stage Carriage" on page 7-74.
See "Adjustment" on page 7-81.
2. Remove inner mast. See "Inner Mast" on
page 7-78.
Adjustment
3. Remove both pulleys with cables. See
Figure 7- 128. Anytime you replace the outer mast, you must
adjust mast stop to make sure the mast hits the
stops evenly. See Figure 7- 129.
Figure 7- 129. Mast Stop
Figure 7- 128. Outer mast, Installed in Mast Frame
4. Remove bolt from top of each piston.

5. Remove stops from outside, top of main
frame. See Figure 7- 128.
00700-CL222-05, 1 5 March 2005

Two-Stage Carriage Mast Section
TWO-Stage Carriage 8. Remove finger guard. See Figure 7- 130.

Removal
1. Turn key switch OFF and disconnect Figure 7- 130. Finger Guard
battery.
2. Remove operator console cover. See 9. Disconnect inside chain anchors a t the
"Operator Console Cover" on page 7-12. bottom of the carriage. See Figure 7- 131.
3. Remove front carriage plate (below
console).
4. Disconnect JPC8 and JPC9 from carriage
manager and cut cable tie from tractor
side.
5. Feed electrical over -the-mast cable
through cable raceway.
ACAUTION
Do not place hands between the masts
before blocking the carriage.
6. Feed cable through carriage to tractor.

7 . ~ i fthe
t truck high enough to create slack Figure 7- 13 1. Inside Chain Anchor, View From Operator
on chains. Block carriage. Platform
10. Place disconnected end of chains over the

top of the mast, toward tractor. See
Figure 7-132.
00700-CL222-05, 1 5 March 2005

Mast Section Two-Stage Carriage
11. Remove both chain pulleys from top of 4. Install stop a t top of mast. See
cylinder. See Figure 7- 132. Figure 7- 133.
5. Install chain pulleys to top of piston. See
Figure 7- 132.
6. Feed chains over the pulleys and connect
chain anchors. See Figure 7- 131.
7. Feed over-the-mast cable through raceway
and into operator console. Connect cable
ties where necessary.
8. Install finger guard.
9. Feed over-the-mast cable through back of
carriage to carriage manager and connect
to JPC8 and JPC9.
1 1. Install carriage plate.
Figure 7- 132. Top of Mast, Outside
12. Lift and lower platform fullv, and check
12. Remove stop from top of mast. See functions of lift system. ~ o o for:
k
Figure 7- 133. Oil leaks
Cables on pulleys
Switch actuation
Unusual bearing noise
Figure 7-133. Top of Mast, Inside
13. Attach hoist and remove operator

platform.
Installation
1. With suitable hoist, lower bottom bearings
on carriage into channel on mast.
2. Make sure there are sufficient shims to
prevent side play. See "Mast Bearings" on
page 7-85.
3. Make sure the two switches a t bottom of
carriage are riding their switch rail
properly. See Figure 7- 1 14.
00700-CL222-05, 1 5 March 2005

Two-Stage Mast Mast Section
3. Install stops to outside, top of main frame.
Two-Stage Mast
4. Install pulleys.
5. Install inner mast. See "Inner Mast" on
page 7-78.
6. Install operator platform. See "Two-Stage
Use extreme care whenever the truck is Carriage" on page 7-82.
7. Before returning truck to service, check
mast movement and adjust as necessary.
See "Adjustment" on page 7-8 1.
support it. DO NOT rely on the jack Adjustment
Safety" on page 2- 1 1. Anytime you replace the mast, you must adjust
the mast stop to make sure the mast hits the
stops evenly. See Figure 7- 134.
Removal
1. Remove operator platform. See "Two-Stage
2. Remove pulley with cable. See
Figure 7-134.
Figure 7- 134. Top of Mast, Tractor Side
3. Remove bolt from top of each piston.

4. Remove stops from outside, top of main
frame. See Figure 7- 134.
5. Remove top bearing on main frame.
6. With a suitable hoist, remove outer mast.
See Figure 7- 134.
Installation
1. With a suitable hoist, lower outer mast
into main frame.
2. Install top roller bearings.
00700-CL222-05, 1 5 March 2005

Mast Section Mast Bearings
Mast Bearings If any marks are found within the masts or

main frame where the rollers have been
running, they should be removed with a
sanding disk with 80 grit paper. Do not attempt
to remove all marks, only the ridges.
Figure 7- 135. Mast Bearings and Shims
Shimming


battery.
2. Attach suitable hoist and lift carriage until Figure 7- 136. Staging of Mast Prior to Shimming Bearings
you can reach bearings.
A properly adjusted mast should show no more
3. Remove bearings and shims. than a 0.5 in. (13 mm) mark where the roller
4. Replace shims a s required. touches the respective mast or main frame. The
NOTE: Shim evenly on both sides until the
assembly should be shimmed to the tightest
smallest shim will not fit between the spot on the assembly (as the rollers run up and
bearing and the upright. Do not over down the rail). Small areas that are slightly
shim. higher than the rest of the web can be buffed to
avoid shimming the major portion of the rail too
Shimming a mast is done to ensure a smooth loose. While shimming the mast, the masts and
running unit which is not too tight or too loose. carriage must be loose enough to slide them in
Total movement between the bearings and mast and out by hand. Shimming the assembly in a n
should be between 0.030 to 0.045 in. (0.76 to upright position can result in shimming that is
1.14 mm). too tight and could cause premature wear.
00700-CL222-05, 1 5 March 2005

Mast Bearings Mast Section
The shims used under each roller bearing come NOTE: If the bearings are worn or damaged,
in the following sizes: thin, medium, and thick. replace them.
If the bearings are too loose, you should add
5. Install the same number of shims under
shims to the bearing. If the roller bearings are
the bearing that were removed.
shimmed too tight, causing wear along the
I-beam or mast shaving, reduce the shim 6. Make sure the roller bearing mounting
thickness. Although different combinations of bolts are clean before you install them.
shims may be used to obtain the proper 7. Apply thread-locking compound
adjustment, you should t r y to maintain equal (P/N 00590-04964-71) on the threads.
shim thickness on each side of the main frame Torque the bolts per Table 7-2.
and masts.
8. Reconnect the battery connector and turn
the key switch ON.
Upper Mast Bearing Replacement
9. Lift the carriage and mast and unblock the
mast.
10. Test the operation of the masts.
1 1. Return the truck to service.
Use extreme care when blocking the
mast for any reason. Never remove the Table 7-2: Mast Bearing Stud Retaining Bolt Torque Values
block when it is supporting the mast.
1. Slightly elevate the carriage to gain access

to the bearings.
2. Block the carriage before you attempt to

remove the roller bearing.
You may also use a lift hoist to pull the
carriage upward to gain access to the
roller bearing. Put a strap suitable to
handle the weight of the carriage around
the uppermost cross tie. Once the carriage
is raised in place, block it into position.
3 . Turn the key switch OFF and disconnect
ACAUTION
Do not damage the mast when prying
with the screwdriver.
NOTE: For the upper mast bearings, wedge a

screw driver between the roller bearing
and the mast to prevent the bearing
from falling.
NOTE: When removing the roller bearing, use
caution not to let the bearing fall down
into the mast assembly.
4. Remove the bolt securing the roller
bearing to the respective mast or mast.
00700-CL222-05, 1 5 March 2005

Mast Section Mast Disassembly and Shimming
9. Remove the main carriage by sliding it out
Mast Disassembly and the top of the inner mast. Set it aside for
Shimming later reassembly.
10. Disconnect and remove the lift cylinders
This section describes procedures for: from the masts.
Disassembling the three-stage mast 11. Attach the hoist to the inner mast.
Shimming main frame to outer mast 12. Remove the upper roller bearing bosses
and roller bearings from the outer mast.
Shimming outer mast to inner mast
13. Remove the masts and mainframe stops.
Shimming inner mast to carriage
NOTE: Two-stage masts require similar
procedures with the references to the
center lift cylinder and inner mast not Failure to properly balance load may
applying. result in personal injury. Use extreme
caution.
Mast Disassembly
14. Slide the inner mast out of the top of the
1. Remove the forks and mast guard. outer mast. Attach the hoist to the outer
2. Fully lower the carriage and make sure the mast.
pressure is out of the cylinders.
15. Remove the upper roller bearing bosses
3. Turn the key switch OFF and disconnect and roller bearings from the main frame.
the battery connector. Remove the battery.
4. Disconnect the over-the-mast cables and
hoses inside the tractor compartment and
plug the hoses. Disconnect the lift hose to Failure to properly balance load may
the side cylinders inside the tractor result in personal injury. Use extreme
compartment and plug. Disconnect all caution.
other cables that run from the tractor to
the mast. 16. Slide the outer mast out of the top of the
5. Secure the main carriage and masts so main frame.
they cannot move.
6. Remove the tractor from the mast and Shimming Main Frame to Outer
block each securely. Mast
7. Disconnect and remove the lift chains
from the center lift cylinder. Remove the 1. Install the mast roller bearings at the
over pulley cables and hoses. Remove the bottom of the outer mast.
center cylinder end cap assembly.
Mast assembly may swing free when

Mast assembly may swing free when lifting. Use extreme caution.
lowering. Use extreme caution.
2. Use a suitable lifting device and insert the
8. With a suitable hoist, carefully lay the outer mast into the main frame all the way
mast assembly down and block securely in to the bottom.
place. Remove the carriage stops from the 3. Using a pry bar, move the outer mast and
inner mast. roller bearing to one side.
00700-CL222-05, 1 5 March 2005

Mast Disassembly and Shimming Mast Section
4. Use spare shim(s)as a gauge to determine 16. With the outer mast fully nested, use a pry
the amount required to move the roller bar to check for bearing tightness. If more
bearings outward to make contact with the shims can be inserted between the bearing
main frame. and the outer mast, remove the roller
5. Remove the outer mast from the main bearing assembly and install the shim(s).
frame. Reinstall the bearing assembly.
6. Remove the roller bearings from both roller 17. Check for proper shimming by pulling the
bearing bosses at the bottom of the outer outer mast out and then pushing it in all
mast. the way. The outer mast should not hang
up while moving it in and out. Torque the
7. Install half of the total shim thickness bearing stud retaining bolts (refer to
required to each roller bearing boss at the Table 7-2 on page 7-86) .
bottom of the outer mast. (Applying one
half of the total shim thickness to each 18. Install the stops in the mainframe.
side of the mast maintains the center line
of the mast assembly.) Shimming Outer Mast to Inner
8. Reinstall the roller bearings. Torque the Mast
bolts per Table 7-2.
1. Install the mast roller bearings at the
9. Use a suitable lifting device and reinstall bottom of the inner mast.
the outer mast into the main frame. Check
for tightness while moving the outer mast
to the bottom of the main frame.
Add/remove shims as necessary to
maintain a snug, but free-running, fit. Mast assembly may swing free when
lifting. Use extreme caution.
NOTE: If the outer mast hangs up, a pry bar
may be used to move the mast. 2. Use a suitable lifting device and insert the
10. Assemble the two top mainframe roller inner mast into the outer mast all the way
bearings and bosses without shims. to the bottom.
11. Install the roller bearing assemblies, 3. Use a pry bar and carefully move the inner
attach with a retaining bolt, and snug up mast and bearings to one side.
to the main frame. 4. Use spare shim($ a s a gauge to determine
NOTE: Failure to snug the assemblies to the the amount required to move the bearings
main frame will result in the wrong outward to make contact with the outer
amount of shims, since the studs are mast.
canted.
12. With the outer mast fully nested, use a pry
bar and carefully move the outer mast to
the opposite side. Using spare shims Failure to properly balance load may
between the bearing and outer mast, result in personal injury. Use extreme
determine the amount of shims required caution.
to remove side play.
5. Remove the inner mast from the outer
13. Remove the roller bearing assemblies. mast.
14. Install half of the total shim thickness to 6. Remove the bearings from both roller
each roller bearing assembly. bosses at the bottom of the inner mast.
15. Install the roller bearing assemblies and 7. Install half the total shim thickness
attach with the mounting bolts and required to each roller boss at the bottom
tighten. of the inner mast.
00700-CL222-05, 15 March 2 0 0 5
Mast Section Mast Disassembly and Shimming
8. Reinstall the roller bearings. Torque the retaining bolt. (See Table 7-2 on
bolts per Table 7-2. page 7-86.)
9. Use a suitable lifting device and reinstall 18. Check for proper shimming by pulling the
the inner mast into the outer mast. Check inner mast out and then pushing it in all
for tightness while moving the inner mast the way. The inner mast should not hang
to the bottom of the outer mast. up while moving it in and out.
NOTE: If the inner mast hangs up, a pry bar 19. Install the outer lift cylinders.
may be used to move the mast. 20. Install the chain rollers and lift chains.
10. With the inner mast fully nested, use a pry 21. Install the center lift cylinders
bar to check for bearing tightness. If a thin
shim can be inserted between the bearing
and the outer mast, remove the inner mast
Shimming Inner Mast to
and install the shim between the bearing Carriage
and the roller boss. Torque the bearing 1. Install the mast roller bearings on the
stud retaining bolt (refer to Table 7-2 on carriage roller bosses.
page 7-86) . Leave the lifting device
connected to the outer mast. Do not apply 2. Use a suitable lifting device and insert the
excessive pressure to the bearings with the carriage into the inner mast all the way to
pry bar. the bottom.
11. Assemble the two roller bearings and NOTE: The carriage may have to be removed
bosses for the top inner mast without several times to obtain the proper fit.
shims. 3. Using a pry bar, move the bottom carriage
12. Insert the bearing/boss assemblies and bearings to one side.
attach with the retaining bolts. Draw the 4. Use spare shim($ a s a gauge to determine
bearing bosses up snug to the outer mast. the amount required to move the bearings
NOTE: Failure to snug the assemblies to the outward to make contact with the inner
main frame will result in the wrong mast.
amount of shims, since the studs are 5. Move the carriage to the top of the inner
canted. mast and repeat the process for the top set
13. Use a pry bar and carefully move the inner of bearings.
mast to the other side. Using spare shims 6. Remove the carriage from the inner mast.
between the bearing and inner mast, 7. Install half of the total shim thickness
determine the number of shims required required to each roller boss.
to remove side play.
8. Reinstall the roller bearings.
14. Remove the bearing/boss assemblies.
9. Use a suitable lifting device and reinstall
15. Install half the total shim thickness to the carriage into the inner mast. Check for
each bearing/boss assembly. tightness while moving the carriage to the
16. Install the bearing/boss assemblies into bottom of the inner mast.
the outer mast/inner mast. Attach with a 10. Use a pry bar to check for bearing
mounting bolt and tighten. tightness. If a thin shim can be inserted
17. With the inner mast fully nested, use a pry between the bearing and the inner mast,
bar to check for bearing tightness. If more remove the carriage and install the shim
shims can be inserted between the bearing between the bearing and the roller boss.
and the inner mast, remove the Do not apply excessive pressure to the
bearing/boss assembly and install the bearings with the pry bar.
shim($. Reinstall the bearing/boss 11. Use a suitable lifting device and reinstall
assembly. Torque the bearing stud the carriage, checking for tightness. Make
00700-CL222-05, 1 5 March 2005

Mast Disassembly and Shimming Mast Section
sure the carriage can be moved in and out
by hand.
12. When the correct fit is obtained, measure
the gap between the top of the platform Make sure all mast stops are installed
and the inner mast on both sides. If the and securely tightened before operating
gap between the platform and the inner the lift truck.
mast is not within 1 / 16 in. (1.59 mm) of
each other, remove the platform. 23. Reinstall the battery.
13. Take shims from the top roller on the side 24. Reconnect the battery connector and turn
that is farthest away and install them on the key switch ON.
the opposite side. Repeat this procedure 25. Adjust the lift chains.
until 1 / 16 in. (1.59 mm) is obtained. If all
26. Install the forks and mast guard.
shims are on one side of the top rollers,
remove shims from the bottom roller on 27. Check for proper operation.
the side that is farthest away and install 28. Grease the channels.
them on the opposite side.
29. Bleed the lift cylinders.
14. Repeat this procedure until the required
clearance a t the top of the platform is
obtained.
15. Install the carriage and the carriage stops.
16. Install the pulleys for the over mast hoses
and cables.
17. Secure the main carriage and masts in
place so that they do not move while
standing the assembly back up.
18. Install all the other items removed during
the disassembly process after laying the
assembly down.
Mast assembly may swing free when

lifting. Use extreme caution.
19. Attach the hoist to the mast assembly and

stand the mast back up. Install all the
other items removed during the
disassembly process prior to laying the
assembly down.
20. Attach the tractor to the mast.
21. Install the remaining components.
22. Connect the hoses and cables inside the
tractor compartment.
00700-CL222-05, 15 March 2 0 0 5
Mast Section Lift Chains, Three-Stage
Lift Chains, Three-Stage Side Cylinder Chains

Replace
1. Lift carriage enough to block between
carriage and inner mast.
jacked up. Never block the truck 2. Add block.
between the mast and the floor. Keep 3. Disconnect chain from chain anchors and
hands and feet clear from vehicle while feed off pulley. See Figure 7- 137 and
jacking the truck. After the truck is Figure 7- 138.
jacked, place solid blocks beneath it to 4. Replace chain as necessary. See
support it. DO NOT rely on the jack Figure 7-139.
Safety" on page 2- 1 1. 5. Feed chain over pulley and connect in
chain anchors. See Figure 7-137 and
Figure 7- 138.
Center Cylinder Chain
Replace
1. Attach suitable hoist and lift carriage
approximately 3 feet (.9 m) and block.
2. Disconnect chain from chain anchor and
feed out of truck.
3. Replace as necessary.
4. Feed chain over pulley and connect in
chain anchor.
5. Remove block and hoist.
returning the truck to service.
Figure 7- 138. Upper Chain Anchor and Pulley
Figure 7- 137. lower Anchor Block
Figure 7- 139. Master Link of Lift Chain
00700-CL222-05, 1 5 March 2005

Lift Chains, Three-Stage Mast Section
Figure 7- 140. Inside Chain Anchor, View from Operator

Platform

returning the truck to service.
00700-CL222-05, 1 5 March 2005

Mast Section Lift Chains, Two-Stage
Lift Chains, Two-Stage 8. Connect power and test lift function before

Figure 7- 142. Unbolting Forks
Figure 7- 14 1. Outside Chain Anchor, Side View
1. Attach suitable hoist and block carriage

just enough to gain slack on chains.
2. Disconnect chain anchors from both sides.
See Figure 7- 140 and Figure 7- 141.
3 . Replace chains as necessary.
4. Connect outside chain anchor. See
Figure 7- 141.
5. Feed chain over pulley.
6. Connect chain to inside anchor. See
Figure 7- 140.
00700-CL222-05, 1 5 March 2005

Forks Mast Section
Forks Install
1. Hold new fork in place underneath
Remove operator platform.
1. Raise operator platform high enough to

reach bottom of forks.
2. Block operator platform with 4 x 4" (10 x
10 cm) upright block.
3. Secure fork to hoist using a suitable strap
or chain.
4. Remove one socket head cap screw from
underneath fork a t tractor end. See
Figure 7- 142.
5. Remove snap ring from pivot pin in
mounting block of fork.
Figure 7- 144. Installing Forks and Shims
2. Install pivot pin through fork.

NOTE: Always use new snap rings when
assembling components.
3. Install new snap ring in pivot pin. See
Figure 7-143.
4. Install correct amount of washers or shim
a t back side of fork to maintain a level
fork. See Figure 7-144.
5. Install socket head cap screw a t tractor
end of fork.
Figure 7- 143. Snap Ring, Pivot Pin and Mounting Block
6. Remove block from operator platform.
7. Lower operator platform to floor and make
sure forks are level. If forks are not level,
add more shim to fork.
The fork will drop in step 6. It weighs
approximately 150 Ib. (68 kg).
6. Drive out pivot pin. The fork, washers or

shim will drop. See Figure 7-143.
7. Replace damaged fork.
00700-CL222-05, 1 5 March 2005

Mast Section Pallet Clamp
Pallet Clamp between the pallet clamp and the left hand
pallet support. Torque the remaining hex
nut to 21 ft. lbs. (29 Nm).
Figure 7- 145. Pallet Clamp Assembly, Underside
Install
1. Install the pallet clamp assembly on the
platform front plate. Secure it with four (4)
M10 X 20 screws. Torque to 30 ft. lbs. (41
Nm).
2. Install the pedal assembly to the platform
main support plate. Secure it with two (2)
M8 X 20 screws. Torque to 15 ft. lbs.
(20 Nm).
3. Hook the tension spring into the 1/4-inch
holes in the pivot bracket and pedal weld
in the pedal assembly. See Figure 7-145.
4. To extend the spring so you can connect
the cable assembly, slide a 2-inch-wide
block between the left hand pallet support
and the pallet clamp on the pallet clamp
assembly.
5. Install the cable bracket on the pedal
assembly. Secure it with the M8 X 10
shoulder bolt and M8 hex nut. Torque to
15 ft. lbs. (20 Nm).
6. Place the cable assembly in the cable
bracket and secure with the M6 hex nuts.
Finger-tighten the hex nut closest to the
pedal mounting and leave the other nut
loose.
7. Remove the 2-inch block you used in
Step 4.
8. Adjust the hex nut closest to the pedal
mounting until there is a 90' angle
00700-CL222-05, 1 5 March 2005

Load Wheels Mast Section
Load Wheels

jacked up. Keep hands and feet clear of
from the vehicle while jacking the truck.
truck. See "Jacking Safety" on
page 2-1 1.
Figure 7- 146. load Wheel
1. Raise operator platform approximately 1

ft. from the floor. Place a 4 x 4 inch (10 x
10 cm) block across top of baselegs
underneath platform.
battery.
3 . Jack up baseleg high enough to clear load
wheel from under baseleg. Block under
baseleg.
4. Remove snap ring from axle. See
Figure 7- 146.
5. Drive out axle. The load wheel will fall out
of baseleg. See Figure 7- 146.
6. Replace load wheel assembly.
7. Drive axle back through wheel and
baseleg.
8. Install snap ring.
9. Remove blocks.
00700-CL222-05, 1 5 March 2005

Mast Section Skid Pads
Skid Pads
Location
There are two skid pads on each truck.
Inspection
1. Check clearance between each skid pad
and floor.
2. If clearance is more than 3/4 inch
(19.1 mm) on either side, replace skid pad.
See procedure below.

jacked up. Keep hands and feet clear of
from the vehicle while jacking the truck.
truck. See "Jacking Safety" on
page 2-1 1.
Replacement
Weld new skid pad inside worn skid pad.

Clearance from floor should be 3/4 inch
(19.1 mm).
00700-CL222-05, 1 5 March 2005

Skid Pads Mast Section
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 8. Wire Guidance
Section 8. Wire Guidance
00700-CL222-05, 1 5 March 2005

Section 8. Wire Guidance Toyota Orderpicker Model 7BPUE15 Service Manual
System Overview
System Overview
Wire guidance is a means to automatically steer
the truck while traveling in a n aisle. I t offers
precise steering a t full-speed travel in very
narrow aisle (VNA)applications.
A wire guidance system consists of two

sub-systems.
Warehouse-installed equipment includes a
guide wire and line driver. The guide wire
is in the floor and emits a n alternating
current (AC) signal a t a specific frequency
and amplitude generated from the line
driver.
Truck-installed equipment includes:
Two guidance sensors, tractor end and
load end
Steer controller, behind steer motor
Filter card, on guidance manager
Travel speed feedback encoder, on top
of the drive motor
Steer feedback encoder, on top of the
steer motor
Auto/manual switch, on operator
console
Associated cables and mounting
brackets
The truck must learn the amplitude and
frequency of the guidance signal to
properly track the guide wire.
NOTE: This manual will cover all
truck-installed equipment.
To operate wire guidance, see the Model

7BPUEl5 Operator Manual.
00700-CL222-05, 1 5 March 2005

Install Kit Components

Before installing kit components, turn the key
switch OFF, disconnect the battery and remove
the appropriate covers.
NOTE: Once you install all the components,
complete the Set-Up Procedure
beginning on 8-9.
Guidance Manager (Steer

Controller Card and Filter Card)
The guidance manager is a n assembly
comprised mainly of a steer controller card and
a filter card. The wire guidance firmware is Figure 8-2. Guidance Manager, Installed
housed in the WSI module.
4. Install the power and ground cable (P/N
1. Wear a static strap and insert the WSI 00590-4588 1-71) to connector PS2 on the
module (P/N 00590-458 18-71) into the steer controller card. Route the wires
socket on the steer controller card. See through the wiring channel along the
Figure 8-1. steer/tractor manager to SPL3 and TP4 a s
shown on the schematic. (See Figure A-6
on page A- 13.) Use cable ties a s necessary.
5. Install the CAN bus wiring harness (P/N
00590-45881-71) to PS4 on the steer
controller card. Route the harness along
the existing wiring to the steer/tractor
manager connector PT2. Use cable ties a s
necessary.
Figure 8- 1 . Steer Controller Card
2. Install the steer controller card assembly

(P/N 00590-459 10-71) on the electrical
panel with four hex spacers (P/N
00590-02988-71). See Figure 8-2.
3. Install the filter card assembly (P/N
00590-45747-71) on the steer controller
card. Secure with four screws (P/N Figure 8-3. Load Sensor Assembly, Installed
00590-45925-7 1) in the hex spacers. See
Figure 8-2.
00700-CL222-05, 1 5 March 2005

Load Sensor Assembly 6. Connect the JW1 cable to the filter card.
1. Lift the platform, and securely place a

safety stand under the platform. Lower the
platform on the safety stand.
2. Turn key switch OFF and disconnect the
battery.
3. Secure the antenna frame assembly (P/N
00590-02772-71) to the cross tie between
the side cylinders with four hex head cap
screws. See Figure 8-3.
4. Connect the 1L cable assembly (P/N
00590-02911-71) to the connector on the
sensor assembly. See Figure 8-4.
Figure 8-5. JWI Cable Routing Under Battery to Tractor
Figure 8-4. JW I Cable Connection
5. Route the cable along - the lift hose to the

tractor. Add cable ties loosely as necessary Figure 8-6. Bumper Plate, location
to hold the cable to the hose. See
Figure 8-5. Tractor Sensor Assembly
NOTE: Tight cable ties will cause the shielded 1. Remove the bumper plate. See Figure 8-6.
sensor cable to break as the lift hose
expands when the platform lifts. 2. Place tractor sensor assembly (P/N
00590-02842-7 1) on the bumper plate
with the connector jack facing the top of
the bumper plate and secure with four
screws (P/N 00590-03085-7 1). See
Figure 8-7.
3. Connect cable assembly (P/N
00590-45746-71) to the sensor at
connector J1T. See Figure 8-7.
4. Feed the cable through the cutout in the
tractor frame along the right side of the
tractor frame drive unit housing. Secure
the cable to the tractor frame using the
cable straps (P/N 00590-03458-71) and
00700-CL222-05, 1 5 March 2005

bolts for the pre-drilled holes. Connect to

the filter card.
Figure 8-7. Tractor Sensor Assembly, lnstalled
5. Install the bumper plate.

6. Apply the bumper decal to the bumper
plate a s shown in Figure
- 8-8.
Figure 8-9. Kit Components for Steps 2-4
7. Use additional cable straps a s necessary.
Speed Encoder
NOTE: To perform step 1, we recommend using
a n impact gun.
1. Remove the nut off the shaft on top of the
drive motor.
2. Install motor/encoder stud
(P/N 00590-45879-71) on the shaft.
See Figure 8-9.
3 . Install the O-rings (P/N 00590-45949-71)
in the grooves on the motor/encoder stud.
See Figure 8-9.
4. Install the encoder mounting plate (P/N
Figure 8-8. Bumper Decal, location 00590-45855-7 1) on top of the brake with
the following hardware in the order listed.
See Figure 8-9.
00700-CL222-05, 1 5 March 2 0 0 5
a. 3 lockwashers (P/N 00590-02851-71) Feed the harness through the notch in the
housing. See Figure 8- 11.
b. 3 washers .(P/N 00590-03092-7 1)
,
8. Install the snap ring (P/N

c. 3 screws (P/N 00590-46033-71) 00590-46047-71) on top of the bearing in
the housing. See Figure 8- 11.
9. Use gasket flange sealant (Loctite Ultra
Black 598) and fill the notch in the
housing. See Figure 8- 11.
10. Connect PH6 of cable assembly (P/N
00590-45863-71) to the encoder harness
connector JH6, then route the harness
wires along the drive motor cables. Use
cable ties as necessary, but do not
overtighten.
11. Route the wires through the clamps on the
top deck then back over and down the
Figure 8- 10. Encoder Bearing as Shipp ed in Kit
wiring channel to PS1 on the steer
controller card. Use cable ties as
5. Install the bearing housing (P/N necessary.
00590-46054-71jon the mounting plate
with four screws (P/N 00590-03113-71).
See Figure 8-9.
6. Remove the snap ring from the encoder
bearing (P/N 00590-46055-71). See
Figure 8-10.
Figure 8- 12. Top of Steer Motor
Steer Encoder
Removal
1. Turn the drive unit counter clockwise to
the steering mechanical stops.
2. Remove the two mounting screws securing
the encoder cover to the top of the steer
motor.
3. Thread a 10-32 machine screw (1.5 in.
Figure 8- 1 1 . Kit Components for Steps 7-9 long) into the tapped hole in the top of the
encoder. Tighten the screw against the
7. Install the bearing into the housing encoder shaft and continue to tighten until
oriented so the harness is on the top end. the encoder is lifted from the shaft.
00700-CL222-05, 1 5 March 2005

Installation Auto/Manual Switch

1. Clean the encoder shaft. Apply retaining 1. Remove the operator console cover.
compound (Loctite609)to the encoder 2. Remove the bezel.
shaft.
3. From the backside of the bezel, use a hot
2. Install the steer encoder kit (P/N knife to cut out the detent for the
00590-45880-71) on the shaft. auto/manual switch. See Figure 8-14.
3. Install the encoder cover and the two 4. Place the rocker switch orange-side-up in
mounting screws. the bezel.
4. Secure the encoder to the motor with the 5. Install the connector housing (P/N
two screws provided with the steer 1-0 12-339/004) on the auto/manual
encoder. See Figure 8- 13. switch cable (P/N 00590-45865-71). See
5. Route the cable from the encoder down the Figure 8- 1 5.
side of the motor and connect to cable 6. Connect the cable to the auto/manual
JH7. switch. See Figure 8-15.Then connect to
the carriage manager.
Figure 8- 13. Steer Encoder, Installed
6. Route that cable along the existing wiring Figure 8- 15. Auto/Manual Switch Cable
to PT6 on the steer/tractor manager.
7. Place the auto/manual switch decal (P/N
7. Use cable ties as necessary. 00590-45783-71) on the front side of the
bezel. See Figure 8- 16.
Figure 8- 14. Cutting the Auto/Manual Switch Detenf
00700-CL222-05, 1 5 March 2005

Figure 8- 16. Auto/Manual Switch, Installed
00700-CL222-05, 1 5 March 2005

Set-Up Procedure
Set-Up Procedure 6. From the main menu, type s for Set

Configurable Items a t the prompt. Make
sure the settings are correct for the
NOTE: If you are setting up a truck with guidance application. Change settings if
factory-installed wire guidance, skip to necessary.
s t e 4.
~
NOTE: To change these settings:
1. Install the wire guidance kit components.
See "Install Kit Components" on page 8-3. Use the up and down arrows to select
2. If necessarv, flash the latest version of the options.
software through Flashware. See "Flash Use the left arrow to decrease values,
Memory Program" on page 10-6. and the right arrow to increase values.
3. Turn on the wire guidance option in 7. After changing the truck configuration:
Flashware. See "Enable Wire Guidance in Truck restarts automatically
FlashWare" on page 8-9.
Horn beeps when self-diagnostics is
4. Perform the Guidance Parameter Setup to finished
set the distance from wire and heading
-
angle ~ a r a m e t e r sSee
L
.
Parameter Setup" on page 8-9.
"Guidance
Screen returns to the main menu
8. Type x to exit FlashWare.
5. Learn the guide wire frequency. See "Learn
Guide Wire Frequency" on page 8- 10. Guidance Parameter Setup
6. Learn the guide wire offsets. See "Learn 1. Connect the FlashWare program to the
Wire Guidance Offsets" on page 8-10. truck.
7. Perform the Guidance Check to make sure 2. Make sure the Wire Guidance Option is
the truck can steer on the wire properly. turned on in FlashWare. See "Enable Wire
See "Guidance Check" on page 8- 11. Guidance in FlashWare" on page 8-9.
3. At the prompt on the Main Menu, type s
Enable Wire Guidance in for Setup Configuration Items and press
FlashWare Enter key.
NOTE: For complete instructions on FlashWare, 4. Set the following parameters in the Truck
See "Software Configuration" on Configure Menu.
page 10-1.
Distance From Wire Slow 1.6
1. Make sure the latest version of FlashWare
is installed in the truck. If not, flash load Distance From Wire Stop 3.0
the latest version. See "Flash Memory
Heading Angle Slow 1.6
2. From the main menu, type o for Options a t Heading Angle Stop 3.0
the prompt.
3. From the options menu, use your arrow NOTE: If wire guidance is turned off in
keys to move to the Wire Guidance prompt Flashware, the Truck Configure Menu
and press the enter key. will display the lift cutout threshold
4. In the box that appears on the left, type in only.
the 4-digit authorization code you 5. Type x to save these parameters and exit
obtained from the Toyota Parts this menu.
Distribution Center.
5. Type y a t the Wire Guidance prompt, and
follow the instructions a t the bottom of the
screen.
00700-CL222-05, 1 5 March 2005

Set-Up Procedure
Learn Guide Wire Frequency Learn Wire Guidance Offsets

NOTE: Make sure the line driver is set up and NOTE: Make sure the line driver is set u p and
adjusted properly. adjusted properly.
1. In manual steer mode, position the truck 1. In manual steer mode, position the truck
to center the tractor end and the load end to center the tractor end and the load end
sensors over the guide wire (+ 0.75" [19 sensors over the guide wire (+ 0.75" [19
mm]).Make sure the drive unit is mm]). Make sure the drive unit is
centered. centered.
NOTE: The horn chirps a t approximately 10 NOTE: The horn chirps a t approximately 10
chirps per second when the truck is chirps per second when the truck is
centered over the guide wire and if the centered over the guide wire and has
present frequency has been learned previously learned the present guide
previously. wire frequency.
2. Without moving the truck, turn the key 2. Without moving the truck, turn the key
switch off. switch off.
3. Enter horn code 3,3. 3. Enter horn code 3,4.
a. Hold down the horn button and turn the a. Hold down the horn button and turn the
key switch on. Do not release the horn key switch on. Do not release the horn
yet. yet.
b. Wait for the steer LEDs to stop flashing, b. Wait for the steer LEDs to stop flashing,
and release the horn button. and release the horn button.
c. Press and release the horn button 3 c. Press and release the horn button 3
times. Each time you press the button, times. Each time you press the button,
a n additional BDI LED will light. a n additional BDI LED will light.
d. Wait for the BDI LEDs to turn off. d. Wait for the BDI LEDs to turn off.
e. Press and release the horn button 3 e. Press and release the horn button 4
more times. more times.
f. Wait for the BDI LEDs to turn off. f. Wait for the BDI LEDs to turn off.
4. Wait 10-15 seconds for the truck to learn 4. Wait for the center steer LED to start
the guide wire frequency. During this time, flashing. (The LED should start flashing in
the following occurs: approximately 8 seconds.)
BDI LEDs scroll up and down 5. Step on the deadman pedal and wait for
Horn does not chirp the drive unit to center.
5. After the BDI stops scrolling, verify the 6. Flip the auto/manual switch to auto.
truck has learned the guide wire 7. Drive tractor-first for approximately 20
frequency. Observe the following pattern: feet (6.1 m) and coast to a stop.
Horn chirps a t approximately 10 chirps NOTE: Do not apply the brake, or drive
per second forks-first a t any time during this
Center steer LED flashes continuously procedure.
6. If the truck fails to demonstrate the Travel speed is limited to 2 mph
pattern listed in step 5, repeat the (3.2 kph).
procedure. The chirp pitch changes slightly.
Left and right steer LEDs flash.
8. Flip the auto/manual switch to manual.
00700-CL222-05, 1 5 March 2005

Set-Up Procedure
9. Drive the truck away from the guide wire. 9. Verify the horn chirps approximately 10
The truck has now learned the offsets and chirps per second and the center steer
stored them in memory. LED flashes.
NOTE: You must drive the truck completely off 10. Drive the truck completely off the guide
the guide wire for the truck to learn the wire.
offsets correctly. 11. Flip the auto/manual switch to auto.
If you need to re-learn the wire guidance 12. Verify the horn chirps approximately 20
offsets, you do not need to re-learn the chirps per second.
guide wire frequency, unless the 13. Drive forks-first toward the guide wire a t a
frequency has changed. very slight angle less than 3". Verify the
following:
Guidance Check The horn becomes silent a s the load
antenna reaches the guide wire.
Verify the truck can automatically steer by the The truck locks onto the guide wire
guide wire.
without operator assistance before
1. Make sure steps 1-6 of the Set-up traveling 20 feet (6.1 m).
Procedure have been completed. See All steer LEDs stay lit continuously to
"Set-Up Procedure" on page 8-9.
show the truck is locked on the wire.
2. Flip the auto/manual switch to manual
and drive away from the guide wire.
3. Flip the auto/manual switch to auto.
4. To prove that the frequency has been
learned correctly:
Verify the horn chirps approximately 20
chirps per second
One steer LED flashes in conjunction
with the drive unit position
5. Travel tractor-first a t full throttle. Verify
travel is speed-limited.
6. Travel forks-first a t full throttle. Verify
travel speed is slower than the tractor-first
travel speed.
7. Drive tractor-first toward the guide wire a t
a n approximate 20" angle. Verify the
following:
a. All steer LEDs flash and the horn
becomes silent a s the tractor sensor
reaches the guide wire.
b. The truck locks onto the guide wire
without operator assistance before
traveling 20 feet (6.1 m).
c. All steer LEDs stay lit continuously to
show the truck is locked on the wire.
8. Flip auto/manual switch to manual.
00700-CL222-05, 1 5 March 2005

Codes and Tests
Codes and Tests

Operator Display Fault Codes
The codes listed in this section that appear on
the operator display pertain only to wire
guidance. All other operator display codes are
listed in the Codes and Tests section.
Guidance Manager Operational

Codes
The following codes will appear on the guidance
manager display during normal operation of the
wire guidance. See "Corrective Actions and
Checks" on page 8-12.
Acquiring pause (drive unit is
Code I I I
Action/
1 GM operating N/A N/A N/A N/A N/A

correctly
00700-CL222-05, 1 5 March 2005

Code 0,1
Code 0,l
Action/

correctly
Code 0,2
Action/

correctly
Code 0,3
Motor Current /
Code 0,4
pen circuit with

switch in Auto
00700-CL222-05, 1 5 March 2005

Code 0,7
Code 0,7
Open circuit with

switch in Auto
Guidance Manager Fault Codes

The fault codes on the following pages appear
on the guidance manager display whenever a
code 6,2 or 6,3 appear on the operator display.
00700-CL222-05, 1 5 March 2005

Code 1 ,P
Code 1 ,P
Action/
1 Run Learn I Message goes away I N/A Install a new

Guidance I a n d truck tracks I Steer
Controller
Card
00700-CL222-05, 1 5 March 2005

Code 9,l
Code 9,l
Action/
DCV I JPT'3-2 10.5 to 13 volts Step 2 Replace STM

DCV Home prox over Troubleshoot Check
metal = 0 volts. per Code 3.6 adjustment of
Home prox not over prox. If OK
metal = approx. 5 Replace prox.
volts
00700-CL222-05, 1 5 March 2005

Code 9,2
Code 9,2

NOTE: Check the adjustment of the line driver.
Check for mechanical binding in the
Drive Unit and Steering Gear Box. Run
Learn for Guidance. Check settings for
Heading Angle and Distance from wire
in configure. If intermittent check for
shorts to frame.
antenna card
00700-CL222-05, 1 5 March 2005

Code 9,2
Action/
I
Sensor removed JPW1- I Centered: 32 mV step 7 Replace
/ mVAC (LR) 1.5inLeft; 1 5 m V Antenna Card
1.5 in Right; 76 mV
7 Bumper removed J P 1-A16 B- Centered: 1.1V step 8 Replace Filter

/ DCV (TR) (Filter Card) 1.5 in Left; 0.6V Card
1.5 in Right; 2.8V
8 Sensor JPW1-2 B- Centered: 70mV step 9 Replace

removed/ mVAC 1.5 in Left; 1OOmV Antenna Card
(LN) 1.5 in Right; lOOmV
9 Sensor removed JP1-A6 (filter B- Centered: 2.5V step 10 Replace filter

/ DCV (LN) card) 1.5 in Left; 3 . W card
1.5 in Right; 3.7V
10 JPW2andJPlT JPW2-lto15 JPlT-lto 0 Ohms step 11 Replace cable

disconnected / 15
ohms
11 JPT2 PW2-15 PW2-14 Approx. 1 1.5V step 1 3 step 12

disconnected /
DCV
12 Filter card JP1-Bl (filter JP1-A13 Approx. 1 1.5V Replace filter Replace Steer
removed / DCV card) (filter card Controller card
card)
13 Bumperremoved JPW2-3 B- Centered: 32mV step 14 Replace

/ mVAC (TL) 1.5 in Left; 15mV antenna card
1.5 in Right; 76mV
14 Bumper removed J P1 -A15 B- Centered: 1.1V step 1 5 Replace filter

/ DCV (TL) 1.5 in Left; 0.6V card
1.5 in Right; 2.8V
15 Bumper removed JPW2- I Centered: 32mV step 16 Replace

/ mVAC (TR) 1.5 in Left; 15mV antenna card
1.5 in Right; 76mV
16 Bumper removed J P1 -A16 B- Centered: 1.1V step 17 Replace filter

/ DCV (TR) (Filter card) 1.5 in Left; 0.6V card
1.5 in Right; 2.8V
17 Bumper removed JPW2-2 B- Centered: 70mV step 1 8 Replace

/ mVAC (TN) 1.5 in Left; lOOmV antenna card
1.5 in Right; 1OOmV
18 Bumper removed J P 1-A5 (Filter B- Centered: 2.5V Replace Steer Replace filter
/ DCV (TN) card) 1.5 in Left; 3.7V Controller Card card
1.5 in Right; 3 . W
00700-CL222-05, 1 5 March 2005

Code 9,3
Code 9,3
00700-CL222-05, 1 5 March 2005

Code 9,4
Code 9,4
00700-CL222-05, 1 5 March 2005

Code 9,6
Code 9,6
either the load or tractor sensors.
Action/
Meter Setting
1
2
1 JPW2 and J P l T
disconnected /
ohms
JPW2 PW2-15 PW2-14 Approx 1 1.5 volts

Step 2
Step 4
Replace cable
Step 3
disconnected /
DCV
3 Filter card JP1 -B 1 (filter J P1 -A13 Approx 11.5 volts Replace filter Replace Steer
removed / DCV card) (filter card controller card
card)
4 Bumper JPW2-2 Centered: 70mV step 5 Replace

removed/ mVAC 1.5 in Left; 1OOmV Antenna Card
(TN) 1.5 in Right; 1OOmV
5 Bumper removed JP1-A5 (filter B- Centered: 2.5V step 6 Replace filter

/ DCV (TN) card) 1.5 in Left; 3 . W card
1.5 in Right; 3 . W
6 JPWlandJPlL JPW1-lto15 JPlL-lto OOhms step 7 Replace cable

disconnected / 15
ohms
7 JPW 1 PW2-15 PW1-14 Approx.11.5V step 9 step 8

disconnected /
DCV
00700-CL222-05, 1 5 March 2005

Code 9,6
Controller card
00700-CL222-05, 1 5 March 2005

Code 9,8
Code 9,8

No troubleshooting steps required.
00700-CL222-05, 1 5 March 2005

Code 9,C
Code 9,C
Action/
Meter Setting
1
2
1 JPWl a n d J P l L
disconnected /
ohms
JPW 1
1 JPW1-1 to 15 J P l L - l t o
PW2-15
l 5
PW1-14
I Oohms
Approx 1 1.5 volts

Step 2
Step 4
Replace cable
Step 3
disconnected /
DCV
card)
4 Sensor JPW1-3 Centered: 32mV step 5 Replace

removed/ mVAC 1.5 in Left; 15mV Antenna Card
(LL) 1.5 in Right; 76mV

/ DCV (LL) card) 1.5 in Left; 0.6V card
1.5 in Right; 2.8V
6 Sensor removed JPW1 - I Centered: 32 mV step 7 Replace

/ mVAC (LR) 1.5 in Left; 15 mV Antenna Card
1.5 in Right; 76 mV
7 Bumper removed J P1 -A16 B- Centered: 1.1V step 8 Replace Filter

1.5 in Right; 2.8V
00700-CL222-05, 1 5 March 2005

Code 9,C
Antenna Card
00700-CL222-05, 1 5 March 2005

Code 9,E
Code 9,E
Antenna Card
8-26 00700-CL222-05, 1 5 March 2005

"
Code 9,E
Action/
Sensor Centered: 70mV step 9 Replace

G;""" mVAC 1.5 in Left; 1OOmV
1.5 in Right; 1OOmV
Antenna Card

/ DCV (LN) card) 1.5 in Left; 3 . W card
1.5 in Right; 3 . W
10 JPW2 and J P l T JPW2-1 to 15 J P l T - l to 0 Ohms step 11 Replace cable

disconnected / 15
ohms
11 JPT2 PW2-15 PW2-14 Approx. 1 1.5V step 1 3 step 12

disconnected /
DCV
12 Filter card JP1-B 1 (filter JP1 -A13 Approx. 1 1.5V Replace filter Replace Steer
removed / DCV card) (filter card Controller card
card)
13 Bumper removed JPW2-3 Centered: 32mV step 14 Replace

1.5 in Right; 76mV
14 Bumper removed JP1-A15 B- Centered: 1.1V step 15 Replace filter

/ DCV (TL) (filter card) 1.5 in Left; 0.6V card
1.5 in Right; 2.8V
15 Bumper removed Centered: 32mV step 16 Replace

/ mVAC (TR) 1.5 in Left; 15mV antenna card
1.5 in Right; 76mV
16 Bumper removed JP1-A16 Centered: 1.1V step 17 Replace filter

/ DCV (TR) (Filter card) 1.5 in Left; 0.6V card
1.5 in Right; 2.8V
17 Bumper removed JPW2-2 Centered: 70mV step 18 Replace

/ mVAC (TN) 1.5 in Left; 1OOmV antenna card
1.5 in Right; 1OOmV
18 Bumper removed J P1-A5 (Filter B- Centered: 2.5V Replace Steer Replace filter
/ DCV (TN) card) 1.5 in Left; 3 . W Controller Card card
1.5 in Right; 3 . W
00700-CL222-05, 1 5 March 2005

Code 9,F
Code 9,F
Figure 8- 17. Steer Controller Card and Filter Card,

Installed
Action/
DCV Filter card plugged Replace Steer If 5 volts is

in = 0 volts controller read all the
Filter card time, replace
unplugged = 4.5 to the filter card.
5.5 volts If 5 volts is
never read,
replace steer
controller card
00700-CL222-05, 1 5 March 2005

Code 9,H
Code 9,H
Action/
Meter Setting
1
2
1 JPW2 and J P l T
disconnected /
ohms
JPW2 PW2-15 PW2-14 Approx 1 1.5 volts

Step 2
Step 4
Replace cable
Step 3
disconnected /
DCV
card)
4 Bumper removed JPW2-3 Centered: 32mV Step 5 Replace

1.5 in Right; 76mV
5 Bumper removed J P1 -A15 B- Centered: 1.1V Step 6 Replace Filter

/ DCV (TL) (filter card) 1.5 in Left; 0.6V Card
1.5 in Right; 2.8V
6 Bumper removed JPW2-1 Centered: 32 mV step 7 Replace

/ mVAC (TR) 1.5inLeft; 15mV Antenna Card
1.5 in Right; 76 mV
7 Bumper removed J P1 -A16 B- Centered: 1.1V step 8 Replace Filter

1.5 in Right; 2.8V
00700-CL222-05, 1 5 March 2005

Code 9,H
Antenna Card
00700-CL222-05, 1 5 March 2005

Code 9,J
Code 9,J
Action/
2
1 JPWl and J P l L
disconnected /
ohms
JPW 1
0 ohms
Approx 1 1.5 volts

Step 2
Step 4
Replace cable
Step 3
disconnected /
DCV
3 Filter card JP1 -B 1 (filter JP1-A13 Approx 11.5 volts Replace filter Replace Steer
card)
4 Sensor removed Centered: 32mV Step 5 Replace

/ mVAC (LL) 1.5 in Left; 15mV antenna card
1.5 in Right; 76mV
5 Sensor removed J P1 -A7 (filter Centered: 1.1V Step 6 Replace Filter

/ DCV (LL) card) 1.5 in Left; 0.6V Card
1.5 in Right; 2.8V
6 Sensor removed Centered: 32 mV step 7 Replace

/ mVAC (LR) 1.5inLeft; 15mV Antenna Card
1.5 in Right; 76 mV
7 Bumper removed JP1-A16 Centered: 1.1V step 8 Replace Filter

/ DCV (LR) (Filter Card) 1.5 in Left; 0.6V Card
1.5 in Right; 2.8V
00700-CL222-05, 1 5 March 2005

Code 9,J
Antenna Card
00700-CL222-05, 1 5 March 2005

Code 9,K
Code 9,K
Action/
2
1 JPW2 and J P l T
disconnected /
ohms
JPW2
0 ohms
Approx 1 1.5 volts

Step 2
Step 4
Replace cable
Step 3
disconnected /
DCV
3 Filter card JP1 -B 1 (filter JP1-A13 Approx 11.5 volts Replace filter Replace Steer
card)
4 Bumper removed Centered: 32mV Step 5 Replace

1.5 in Right; 76mV
5 Bumper removed JP1-A15 Centered: 1.1V Step 6 Replace Filter

/ DCV (TL) (filter card) 1.5 in Left; 0.6V Card
1.5 in Right; 2.8V
6 Bumper removed Centered: 32 mV step 7 Replace

/ mVAC (TR) 1.5inLeft; 15mV Antenna Card
1.5 in Right; 76 mV
7 Bumper removed JP1-A16 Centered: 1.1V step 8 Replace Filter

1.5 in Right; 2.8V
00700-CL222-05, 1 5 March 2005

Code 9,K
Antenna Card
00700-CL222-05, 1 5 March 2005

Tests
9. If voltages are good in steps 7 and 8,

replace the guidance manager.
Speed Feedback Encoder Test Steer Feedback Encoder Test

This test should be r u n when the guidance This test should be run when the guidance
system is not functioning properly. system is not functioning properly.
1. Verify the speed feedback encoder is 1. Verify the steer feedback encoder is
mounted securely to the drive motor. mounted securely to the steer motor.
2. Jack and block the truck. 2. Enter maintenance mode. See
3. Enter maintenance mode and travel "Maintenance Mode" on page 6-4.
slowly. See "Maintenance Mode" on 3. Step on the deadman pedal and rotate the
page 6-4. The rate of horn chirps should steering wheel a t different rates of speed.
increase a s travel increases. Test the
4. The rate of the horn chirps should
encoder in both travel directions.
increase a s you turn the steering wheel
a. If the chirp rate does not change a s faster.
travel speed changes, or if there are no
a. If the chirp rate does not change, or
horn chirps, go to step 4.
the horn does not chirp, go to step 5.
b. If the chirp rate changes with the travel
b. If the chirp rate does change with the
speed, the speed feedback encoder is
steering rate, the encoder is good. Do
good.
not finish the test.
4. Manually flex the encoder wires and listen
5. Check the wiring from JH7 to JT6 for
to the chirp rate.
continuity or damage. Repair or replace
a. If there are inconsistencies in the chirp faulty wiring.
rate, check the wiring from JH6 to J S 1
6. Verify 5 volts is present a t JPT6-3. If not,
for continuity or damage. Repair or
change the steer/tractor manager.
replace faulty wiring.
7. Verify DGND is present a t JPT6-2. If not,
b. If there are no inconsistencies in the change the steer/tractor manager.
chirp rate, replace the encoder
assembly. 8. Measure the voltage a t JPT6- 1 with
respect to JPT6-2 and turn the steering
5. Verify 12 volts is available a t J P S1-19 on wheel. The voltage should cycle between
the steer controller. If not, replace the approximately 5 and 0 volts a s the encoder
steer controller. turns. If not, replace the steer feedback
6. Verify DGND is available a t JPS1- 12 on encoder.
the steer controller. If not, replace the 9. Measure the voltage a t JPT6-4 with
steer controller. respect to JPT6-2 and turn the steering
7. Rotate the speed feedback encoder while wheel. The voltage should cycle between
checking JPS1-8 with respect to JPS1 - 12. approximately 5 and 0 volts a s the encoder
As the encoder rotates, the voltage should turns. If not, replace the steer/tractor
change between approximately 12 and 0 manager.
volts. If the voltage does not change,
replace the encoder. Wire Guidance Sensor Test
8. Rotate the speed feedback encoder while
checking JPS1-7 with respect to JPS1- 12. This test should be run when the guidance
As the encoder rotates, the voltage should system is not functioning properly. This test
change between approximately 12 and 0 assumes that all other components of the
volts. If the voltage does not change, guidance system have checked good.
replace the encoder.
00700-CL222-05, 1 5 March 2005

Tests
1. Park the truck directly over the guide wire. NOTE: The steer LEDs indicate which coil is
2. Turn the key switch OFF. being tested. See Figure 8-18. To change
the coil being tested, press the horn
NOTE: To test each sensor, you must enter a button. The battery LEDs indicate the
horn code-one for the load sensor, one signal strength of each coil. See
for the tractor sensor. Once you enter Figure 8- 18.
the code, you can test coils individually
in each sensor. 4. Check the near wire coil pairs and verify
the signal strengths are approximately the
3. Enter the horn code to test the tractor or same.
load sensors. To switch between tests,
5. Check the 4 guidance coils (2 right, 2 left)
turn the key switch OFF before entering
and verify the signal strengths are
the other code.
approximately the same.
6. Drive the truck diagonally across the guide
wire to monitor the guidance channels.
Load Sensor The signal strength should increase a s the
coil approaches the wire, and decrease a s
Tractor Sensor
the coil moves farther away from the wire.
a. If one or more channels are low, re-learn
a. Hold down the horn button and turn the the guidance offsets (page -10) and
key switch ON. Do not release the horn repeat the test.
yet.
b. If one or more channels are still low,
b. Wait for the steer LEDs to stop flashing, swap the sensor input connectors on the
and release the horn button. filter card a t JPWl and JPW2.
c. Press and release the horn button the If the low channel stays the same,
number of times a s the first digit of the replace the filter card and re-learn the
horn code. Each time you press the guide wire frequency and offsets.
button, a n addition BDI LED will light. If the low channel stays the same after
d. Wait for the BDI LEDs to turn off. replacing the filter card, replace the
e. Press and release the horn button the steer controller.
number of times in the second digit of c. If the low channel changes to the other
the horn code. end of the truck, test the cable for
continuity shorts between wires, and
f. Wait for the BDI LEDs to turn off.
shorts to frame. Include the shield wire
a t pin 13 in PW1 and PW2. If the cable
Near Wire Coil tests good, replace the sensor.
Drive away from the wire and operate all
truck functions, including travel, lift,
steering, horn and any optional equipment
while checking the guidance coils. If the
guidance signal increases due to the
operation of any of these functions, there
is a short to frame in the truck or electrical
noise generated by motors due to bad
brushes, worn commutators or faulty
suppressors. The sensor coils are picking
up this noise.
8. Locate and repair the short to frame or
Figure 8- 18. Operator Display
faulty component.
00700-CL222-05, 1 5 March 2005

General Troubleshooting
General Troubleshooting
To troubleshoot poor performance of wire
guidance when no fault code is generated,
follow these corrective actions and steps.
NOTE: In the following step, consult the battery
manufacturer's recommendations for
the specific gravity. If unavailable, use
the value stated in step 1.
1. Check the battery for an adequate charge.
If the specific gravity is less than 1.145,
replace or charge the battery. Adjust the
BDI cutout correctly.
2. Check for shorts to frame.
3. Check the static strap. Clean or replace as
necessary.
4. Make sure both guidance sensors are
mounted on the truck centerline with no
physical damage.
5. Make sure the sensor cables are not
connected backwards to the guidance
manager.
6. Make sure the line driver is adjusted
according to the manufacturer's
specifications.
7. Relearn the wire guidance frequency and
offsets. See page 8- 10 and page 8-10.
8. Make sure the heading angle and distance
from wire settings are configured correctly.
See "Guidance Parameter Setup" on
page 8-9.
9. Check for bent base legs.
10. Make sure the load wheels are not
binding.
11. Check for excessive play in the drive unit
radial ring.
12. Make sure the steer motor is securely
mounted to its gear reducer.
13. Make sure the steer motor gear reducer is
not binding and its pinion gear is properly
engaging the drive unit.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 8. W i r e Guidance
Troubleshooting in Flashware
NOTE: Switching from manual to auto mode

clears the values for the parameters
above.
00700-CL222-05, 1 5 March 2005

Theory of Operation
The steer controller compares the strength of The HA and DFW settings may be changed in
four guidance signals (TL,TR,LL, RR) and the Truck Configure Menu using Flashware
determines the truck's distance from wire software. See "Options" on page 10-9.
(DFW) and heading angle (HA).The steer
controller uses the DFW and HA to correct the When the steer controller calculates the HA and
steering via the tractor steer manager.
- DFW, it sends a steering correction request to
the steer/tractor manager via the CAN-bus
(BUS+, BUS-). The steer/tractor manager then
tells the steer power head which direction to
steer. This command causes the drive unit to
turn.
For example, if the steer controller calculates

that the truck is 1" to the right of the wire, it
The heading angle is the angle between the tells the steer/tractor manager to turn the drive
direction the truck is pointed and the guide unit and move the truck toward the left until all
4 guidance signals (TL,TR, LL, LR) are equal
wire. The steer controller calculates the angle
by comparing the TL, TR, LL and LR signals. distance from the wire.
For example, if the TL and LR signals are
stronger than the TR and LL signals, the truck While the drive unit is turning, the steer
is pointed to the right of the guide wire. This feedback encoder reports the amount the drive
calculation is compared to the configured unit is turning. This encoder is mounted
settings of HA slow and HA stop. If HA slow is directly on the steer motor's armature shaft and
1.6" and if the heading angle is greater than rotates with the steer motor. As the encoder
1.6", travel speed is limited. If HA stop is 3" and turns, it sends two voltages, CHA and CHB, to
the heading angle is greater than 3", travel will the steer/tractor manager. The steer/tractor
come to a controlled stop. manager uses these voltages to track the drive
unit position, then sends the information to the
steerLcontrollervia the CAN bus. CHA and CHB
change state from approximately 5 volts to 0
volts and back a s the encoder rotates. The
resulting number of times the 2 channels
change state indicates how far the drive unit
has turned. When the required amount of
turning is sensed, the steer command is
removed.
The steer controller also verifies the direction

Distance from wire (DFW) is the distance the the drive unit is turning. CHA changing state
centerline of the truck is from the guide wire. before CHB indicates one direction. CHB
The steer controller calculates this distance by changing state before CHA indicates the
comparing the TL, TR, LL and LL. For example, opposite direction.
if the TL and LR are stronger- than the TR and
LR signals, the left guidance coils are closer to Since the truck travels in relationship to the
the guide wire than the right guidance coils. wire, once a steer request is carried out and the
The factory default settings for DFW slow is truck moves forward, the sensors' relationship
1.6". If this distance is greater than 1.6'', travel to the wire changes, therefore the steer request
speed is limited. The factory default setting for changes. The change in request will turn the
DFW stop is 3". If the distance is greater than drive unit the other way, monitored by the steer
3",the travel will come to a controlled stop. feedback encoder, until the truck is both
parallel to and directly over the wire.
00700-CL222-05, 1 5 March 2005

Theory of Operation
The steer controller monitors the direction of
travel (forward and reverse) by monitoring the
travel speed encoder. This encoder is mounted
on top of the drive motor and turns with the
armature shaft. As the encoder turns, it sends
two voltages, SPEEDFB A and SPEEDFB B, to
the steer controller. SPEEDFB A and SPEEDFB
B will change state from approximately 12 volts
to 0 volts and back a s the encoder is rotated.
SPEEDFB A changing state before SPEEDFB B

indicates one direction of travel. SPEEDFB B
changing state before SPEEDFB A indicates the
opposite direction of travel.
The steer controller must monitor both travel

directions to keep the truck on the guide wire.
The steer request for a truck traveling
tractor-first is opposite to the steer request
when the truck travels forks-first. The steer
controller reverses the steer request a s the
travel direction changes.
The travel speed encoder also indicates the

travel speed to the steer controller. The steer
controller monitors the speed to allow smooth
steering changes a t all travel speeds.
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 9. Theory of Operation
Section 9. Theory of Operation
00700-CL222-05, 1 5 March 2005

Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE15 Service Manual
NOTES
-3 REFERENCE POWER DISTRIBUTION DIAGRAM D20008910
DENT SHEET ZONE DESCRIPTION

B I C5 ELECTRICALLY RELEASED BRAKE
B+ I A3 BAnERY CONNECTOR
B I A4 BAnERY CONNECTOR
FUI I D5 CONTROL FUSE FOR B+PC, I 5 AMPS

FU2 I D5 CONTROL FUSE FORB+, 15 AMPS
FU3 I A3 POWER FUSE FOR TRACTION MOTOR, 350 AMPS
FU4 I 83 POWER FUSE FOR STEER MOTOR, 40 AMPS
FU5 I 83 POWER FUSE FOR LIFT PUMP MOTOR, 350 OR 500 AMPS
FU7 2 85 CONTROL FUSE FOR RF TERMINAL B+, 2 AMPS
FU8 2 86 CONTROL FUSE FOR RF TERMINAL B-, 2 AMPS
FU9 2 Bb CONTROL FUSE FOR LIGHTS & FAN B+, 6 AMPS
FUlO 2 Bb CONTROL FUSE FOR LIGHTS & FAN B~,6 AMPS
FUI 1 2 82 CONTROL FUSE FOR CARRIAGE HEATERS, 10 AMPS (COLD STORAGE OPTION]
FUI2 2 84 CONTROL FUSE FOR TRACTOR HEATERS.10 AMPS (COLD STORAGE OPTION]
FU13 2 A2 CONTROL FUSE FOR CARRIAGE HEATERS, 10 AMPS (COLD STORAGE OPTION]
FU14 I B5 CONTROL FUSE FOR GUIDANCE MANAGER B+ESTOP, 2A (WIREGUIDANCE OPTION].
H I Cb ELECTRONIC HORN
HM I Cb HOUR METER
HTRl 2 83 HEATER FOR OPERATOR'SCONSOLE (COLD STORAGE OPTION]
HTR2 2 83 HEATER FOR DEADMAN (COLD STORAGE OPTION]
HTR3 2 84 HEATER FOR TRACTOR COMPARTMENT (COLD STORAGE OPTION]
HTR4 2 84 HEATER FOR TRACTOR COMPARTMENT (COLD STORAGE OPTION]
HTRb 2 82 HEATER FOR CONTROL HANDLE (COLD STORAGE OPTION]
L I (CM] I G6 CARRIAGE MANAGER HEARTBEAT LED, STEADY ON = +5V PRESENT,

BLINKING SLOW = PROGRAM RUNNING, BLINKING CODE = ERROR CONDITION
L I (SPH] I C3 STEER POWER HEAD STEER CURRENT LIMIT LED, O N = CURRENT LIMIT
L1 (STM] I 07 STEER/TRACTOR MANAGER +12 VOLT POWER SUPPLY LED; O N = 112V PRESENT
L2(STM] I D4 STEER/TRACTOR MANAGER DEADMAN 2 SWITCH (5231LED, ON =SWITCH DEPRESSED

ILZ(CM1 I G4 CARRIAGE MANAGER COMMUNICATIONSRECEIVE LED, BLINKING = RECEIVING COMMUNICATION
L3 (STM] I 03 STEER/TRACTOR MANAGER HEARTBEAT LED; BLINKING SLOW = PROGRAM RUNNING,
BLINKING CODE = ERROR CONDITION
L3 (CM] I G5 CARRIAGE MANAGER COMMUNICATIONS TRANSMIT LED, BLINKING = TRANSMITTING COMMUNICATION
L4(STM] I 07 STEER/TRACTOR MANAGER +5 VOLT POWER SUPPLY LED; O N = +5V PRESENT
L5(STM] I 03 STEERT
i RACTOR MANAGER PC DISABLED LED, ON = OEM TRACTION CONTROLLERHAS DEENERGIZEDTHE PC CONTACTOR
Lb 1 I D5 STEER/TRACTOR MANAGER WARNING LIGHT CONTROL LED, ON = CONTROL OUTPUT ACTIVATED
Lb 2 I D5 STEER/TRACTOR MANAGER SPARE CONTROL LED, ON = CONTROL OUTPUT ACTIVATED
L6-4 I D5 STEER/TRACTOR MANAGER BRAKE CONTROL LED; O N = CONTROL OUTPUT ACTIVATED
L6-5 I D4 STEER/TRACTOR MANAGER PUMP CONTACTOR CONTROL LED, ON = CONTROL OUTPUT ACTIVATED
L6-6 I 06 STEERnRACTOR MANAGER HORN CONTROL LED; ON = CONTROL OUTPUT ACTIVATED
Lb 7 I D5 STEER/TRACTOR MANAGER LFT/LOWER SOLENOID CONTROL LED, ON =CONTROL OUTPUT AVTIVATED
(BRIGHTNESSINDICATES % PWM]
L6-8 I D5 STEERnRACTOR MANAGER POWER CUTOFF CONTACTOR CONTROL LED, ON =CONTROL OUTPUT ACTIVATED
L6-9 I D5 STEERflRACTOR MANAGER LOAD HOLD SOLENOID CONTROL LED, ON = CONTROL OUTPUT ACTIVATED
L6-10 I 03 STEER/TRACTOR MANAGER DEADMAN 1 SWITCH (52) LED; O N = SWITCH DEPRESSED
I L7 I 03 STEER/TRACTOR MANAGER STEER CURRENT LIMIT LED, ON = CURRENT LIMIT
I L8 I D7 STEER/TRACTOR MANAGER BOOST POWER SUPPLY LED, ON = BOOST VOLTAGE PRESENT
IL9 I D5 STEER/TRACTOR MANAGER COMMUNICATIONSTRANSMIT LED, BLINKING = TRANMInNG COMMUNICATIONS
L10 I D5 STEER/TRACTOR MANAGER COMMUNICATIONSRECEIVE LED, BLINKING = RECEIVING COMMUNICATIONS
11 I C3 TRACTION POWER AMP CONNECTOR
JPCl I F2 CARRIAGE MANAGER CONNECTOR FOR DISPLAY CARD

JPC2 1.2 G2.82 CARRIAGE MANAGER CONNECTOR FOR STEER INPUT ENCODER
JPC3 I G3 CARRIAGE MANAGER CONNECTOR LOWER LIMIT & W/G AUTO MANUAL SWITCHES
JPC5 I G5 CARRIAGE MANAGER CONNECTOR FOR LFT/LOWER LIMIT BYPASS SWITCH
JPC6 I G2 CARRIAGE MANAGER CONNECTOR (SPARE]
JPC7 I G5 CARRIAGE MANAGER CONNECTOR FOR DEADMANILIMIT SWITCHES
JPC8 I F4 CARRIAGE MANAGER CONNECTOR FOR MAST CABLE 1 (SIGNALS]
JPC9 I F4 CARRIAGE MANAGER CONNECTOR FOR MAST CABLE 1 (POWER]
JPClO I F3 CARRIAGE MANAGER CONNECTOR FOR SPARE POWER
JPCl 1 I G3 CARRIAGE MANAGER CONNECTOR FOR KEY, EPO SWITCHES
JPCl2 I G6 CARRIAGE MANAGER CONNECTOR FOR SDEGATE SWITCHES, STEER INPUT ENCODER 2
JPCl3 I G4 CARRIAGE MANAGER CONNECTOR FOR CONTROL HANDLE
JPH3 I B5,C5 WARNING LIGHT CONNECTOR

JPH4 I B5,C5 WARNING LIGHT CONNECTOR
JPH5 I B5.U BRAKE CONNECTOR
JPH6 2 D4 TRAVEL SPEED ENCODER CONNECTOR
JPH7 I E5 STEER FEEDBACK ENCODER CONNECTOR
JPH8 2 B6,Cb BIN LIGHT CONNECTOR (OPTION]
JPH9 2 B6,C6 BIN LIGHT CONNECTOR (OPTION]
JPHl1 2 A2,A3 TRACTOR MANAGER CONNECTOR FOR COLD STORAGE HEATERS
JPH12 2 82.03 CARRIAGE MANAGER CONNECTOR FOR COLD STORAGE HEATERS
JPHl3 2 B3,C3 INTERFACE CABLE CONNECTOR FOR DEADMAN HEATER (OPTION]
JPH14 2 A2.82.83 INTERFACE CABLE CONNECTOR FOR CONTROL HANDLE HEATER (COLD STORAGE OPTION]
Figure 9- 1 . Electrical Schematic legend (Sheet 1 of 2)
9-2 00700-CL222-05, 1 5 March 2005

DENT SHEET ZONE DESCRIPTION

JPlL 2 03 LOAD ANTENNA CONNECTOR TO FILTER CARD
JPlT 2 D2 TRACTOR ANTENNA CONNECTOR TO FILTER CARD
JPSl 2 E4 TRAVEL SPEED ENCODER CONNECTION TO GUIDANCE MANAGER
JPS2 2 E6 POWER TO GUIDANCE MANAGER
JPS4 2 E5 GUIDANCE MANAGER CONNECTION TO CAN
JPT2 1 E7 STEERflRACTOR MANAGER CONNECTOR FOR CAN INTERFACE

JPT3 1 E6 STEERflRACTOR MANAGER CONNECTOR FOR HOME SENSOR STEER
JPT4 1 E5 STEERnRACTORMANAGER CONNECTOR (SPARE]
JPT5 1 E2 STEER/TRACTOR MANAGER CONNECTOR FOR MAST LIMIT SWITCHES, LIFT LIMIT SWITCH
JPT6 1 E5 STEERflRACTOR MANAGER CONNECTOR FOR STEER ENCODER FEEDBACK
JPT7 1 E3 STEERflRACTOR MANAGER CONNECTOR (SPARE]
JPT8 1 C2 STEERnRACTORMANAGER CONNECTOR FOR STEER POWER HEAD
JPTP 1 E4 STEERnRACTORMANAGER CONNECTOR FOR MAST CABLE 1 (SIGNALS]
JPTl 0 1 E4 STEERflRACTOR MANAGER CONNECTOR FOR MAST CABLE 1 (POWER]
JPTl 1 1 C3 STEERflRACTOR MANAGER CONNECTOR FOR TRACTION POWER AMP
JPTl2 1 C4 STEERnRACTORMANAGER CONNECTOR FOR POWER & DRIVERS
PS 1 1 C2 STEER/POWER HEAD CONNECTOR

JSI 2 E2 FILTER CARD AND GUIDANCE MANAGER INTERFACE
JTI 1 C7 STEER/TRACTOR MANAGER CONNECTOR FOR COMPUTER INTERFACE
JPWl 2 03 FILTER CARD CONNECTOR TO LOAD ANTENNA

JPW2 2 02 FILTER CARD CONNECTOR TO TRACTOR ANTENNA
K1 1 D4 STEERflRACTOR MANAGER B+ESTOP RELAY
L/H SOL 1 C5 LOAD HOLD SOLENOID
L/L SOL 1 C5 LIFT/LOWER PROPORTIONAL SOLENOID
MD 1 84 DRIVE MOTOR
MP 1 84 LIFT PUMP MOTOR
MS 1 83 STEER MOTOR
P 1 83 PUMP CONTACTOR CONTACTS

P 1 C4 PUMP CONTACTOR COIL
PC 1 A3 POWER CUTOFF CONTACTOR CONTACTS

PC 1 C5 POWER CUTOFF CONTACTOR COIL
PC~I 2 A2,A4 COLD STORAGE OPTIONS CONNECTION
S1 1 H3 KEY SWITCH
52 1 H5 DEADMAN 1 SWITCH
56 1 H5 2 4 LIMIT SWITCH (LOCATEDO N CARRIAGE]
S7 1 H6 6 0 LIMIT SWITCH 1 (LOCATEDON CARRIAGE)
S8 1 E6 HOME POSITION SWITCH
S19 1 H6 SDEGATE SWITCH 1 (OPTION]

520 1 H6 SDEGATE SWITCH 2 (OPTION]
52 1 1 H4 EPO (EMERGENCY POWER OFF] SWITCH
S23 1 H5 DEADMAN 2 SWITCH
524 1 E3 LIFT LIMIT SWITCH (OPTION]
525 1 E3 180' LIMIT SWITCH (LOCATEDO N MAST]
S26 2 C6 BIN LIGHT SWITCH (OPTION]
S27 2 E2 BIN LIGHT SWITCH (OPTION]
529 1 02 120/150" LIMIT SWITCH (LOCATEDON MAST]
S5 1 1 H5 LIFT/LOWER LIMIT BYPASS SWITCH (OPTION]
S6O 1 H3 LOWER LIMIT SWITCH
56 1 1 H3 W/G AUTO MANUAL SWITCH
SPLl 2 83 SPLICE FOR DEADMAN HEATER (COLD STORAGE OPTION]

SPL2 2 C3 SPLICE FOR DEADMAN HEATER (COLD STORAGE OPTION]
SPL3 1 C5 SPLICE FOR POWER TO GUIDANCE MANAGER
SPL5 2 C2 SPLICE FOR HEATER IN HANDLE (COLD STORAGE OPTION]
TA 1 C5 TRAVEL ALARM (OPTIONAL]
TH 1 2 82 THERMOSTAT FOR CARRIAGE HEATERS (COLD STORAGE OPTION]

TH2 2 B4 THERMOSTAT FOR TRACTOR HEATERS (COLD STORAGE OPTION]
TH3 2 B2 THERMOSTAT FOR CONTROL HANDLE HEATER (COLD STORAGE OPTION]
TPI 1 A3 TIE POINT FOR TRACTION POWER FUSE (FU3J

TP2 1 83 TIE POINT FOR STEER POWER FUSE (FU41
TP3 1 83 TIE POINT FOR LIFT PUMP POWER FUSE (FUS]
TP4 1 B4 TIE POINT FOR B-
TP4 2 A3,A5 TIE POINT FOR 8~
TS 1 2 B5 TERMINAL STRIP FOR OPTIONAL POWER (EE OPTION]
VRI 1 H4 CONTROL HANDLE TRAVEL REQUEST VARIABLE RESISTOR
VR2 1 H4 CONTROL HANDLE LIFT REQUEST VARIABLE RESISTOR
WL 1 C5 WARNING LIGHT
Figure 9-1 (Cont.). Electrical Schematic legend (Sheet 2 of 2 )
00700-CL222-05, 1 5 March 2005

Battery Plugged In
Battery Plugged In
Refer to the schematic in Figure 9-2 on
page 9-6.
When a properly charged battery is connected

to the truck battery positive is present with
reference to TP4 (B-) a t the following points:
1. B+ side (PC-1) of the open PC contactor tip
2. JPT12-11 and JPT12-120n the
steer/tractor manager (STM)
3. FU2 on the steer/tractor manager
4. JPT12-24 (horn) on the steer/tractor
Manager a s B+F
5. JPT10-2 on the steer/tractor manager to
JPC9-2 on the carriage manager (CM) a s
B+F
6. JPC 11-5 on the carriage manager to S1- 1
a s B+F
7. JPC10- 1 and JPC 10-2 on the carriage
manager a s B+F
00700-CL222-05, 1 5 March 2005

Battery Plugged In
00700-CL222-05, 1 5 March 2005

Battery Plugged In
A 1
STEER/TRACTOR
MANAGER
DGND
12VP
AGND
STEER OIRI
1
STEER DlR2
STEER DlRl PWM
STEER OR2 PWM
BOOST +
80057
STEERCURRENTLIMIT
F;;
@G
8
STEERCURRENT i B 17 @ 7
7
NC L3
NC
TF/FORWARD
FF/RtVERSt
T R M E L REP
MS1
MS2
DEADMAN
TWVtL REF
MDA? SENSE
BiESTOP RELAY
SPARE CTRL
NC
BiHORN HORN
HonNcmL o4
L64
B
B
B
PSENSE
PCSENSE
B+PC
B+
B+
12VP
HOUR METER ENABLE
DGND - 1
Tracing! Legend - Electrical
POWER SUPPLY
-WHHHHHHHHHHA
= B+ Circuit
= B- Circuit
= Signal
= 12V/ 5V
112"
Figure 9-2. Battery Plugged In (Sheet 1 of 4)
00700-CL222-05, 1 5 March 2005

Battery Plugged In
@ E 1 F 1 G 1 H
JPCI? STEER NPUT ENCODER 2

CARRIAGE
MANAGER
STEER NPUT ENCODER 1
IT$$~~
JPC6
113VF 3 1
DGND
N /C
LowERILzD N /C
12VP
S61
SPARE IN 3 W/G AUTO MANUAL
IOPW
DGND DGND
h, !?
CONTROL HANDLE
TRAVEL REOUEST
112 @0 DEADMAN2
DGND
8 TRAN SM IT
RECEIVE
DGND HORN k&b'd2s3 JPC2 I
DGND
1i]
LIFTlLOWtRLIMIT BYPASS
ENCODER
FEEDBACK
NC IOPW
CHB DGND
N/C
PTd
S P R t IN 4
SPARE
SPARE IN4
DGND
SPARE IN 5
DGND
POWER SUPPLY
HEARTBEAT
+12VP
N SIDEGATE 1
I I 3VP
SIDEGATE 2 520
IOPTI
Figure 9-2 (Cont.). Battery Plugged In (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005

Battery Plugged In

CONTROL HANDLE
I
I
JPC212 PC2 6
r - - - - - -WIRE
- -GUIDANCE
- - - -MANAGER
- - - - (OPTION)
----
JSl
AGRD
112v
AGRD
t12V -
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OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN I
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TS 1 I
(EE ONLY]
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(OPTION]
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Figure 9-2 (Cont.). Battery Plugged In (Sheet 3 of 4)
9-8 00700-CL222-05, 1 5 March 2005

Battery Plugged In
....................... 1
JSI I
bE~Tow
I COLD STORAGE LIGHTS AND FAN [OPTION)
I
------
I SUPPRESSOR I
I . -N E-
T W-
O R K- - -
FAN I
I
SUPPLY I T O FU9-2
I I (TSI-2, EE ONLY) I
I I I
I
LIG TS
I T O FU10-2 I
(TSI-3, EE ONLY)
I I-----J I
I I
LIGHT
I SWITCH I
I SUPPRESSOR
I NETWORK I
STEER I
CONTROLLER
I I
I
I LIGHTS
I I
I I
I I *I
I LIGHT
I I
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I STANDARD LIGHTS AND FAN [OPTION)
I
IPS1
- I I SUPPRESSOR I
<< SPEEDFBA
I I . -N E-
T W-
O R K- - -
FAN I
<< SPEEDFB B
I I TOFU92
19
,: 1 2 v
/ I (TSl 2, EE ONLY) I
I
12,
<, I I
13
GND I
I
I
I TOFU102
(TSl 3, EE ONLY)
I-----J
I
l9 <t I I LIGHT
<t I I SWITCH
I I SUPPRESSOR
20
<t JPS4
I I .------
NETWORK
FAN I
:: I
I
I
I
I
I
I I-----J
I LIGHT
I SWITCH
I
1
I -
Tracing Legend - Electrical
= B+ Circuit
= B- Circuit
= Signal
I
I
WHHHHHHHHHHA = 12V/ 5V
Figure 9-2 (C0nt.J. Battery Plugged In (Sheet 4 of 4)
00700-CL222-05, 1 5 March 2005

Section 9. Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual
Key Switch (S1 ) O n
Key Switch ( S l ) On JPT12-21 through the brake coil to

JPT12-17
5. The steer/tractor manager receives battery
When the key switch is first turned on, the
voltage and produces the following
microprocessor control system performs a
voltages:
self-diagnostics of certain inputs and outputs.
The self-diagnostics lasts approximately 1 +12volts (12VP)
second. Sensor leads are checked for the +5 volts
correct voltages during the self-diagnostics. If a Boost for steer power head
problem is detected, the steer/tractor manager
prevents truck operation and displays a fault 6. +12 volts (12VP) is present a t the following
code on the operator display. points on the steer/tractor manager:
JPT5-2 (height 120"/150" switch S29)
With the wire guidance option, the guidance JPT5-5 (height 180" switch S25)
manager receives battery voltage a t JP2- 1 1 a s
B+ESTOP. JFT5-8 (optional lift limit switch S24)
JPT7-2 (spare switch input)
Refer to the schematic in Figure 9-3 on JPT3-2 (steer home sensor S8)
page 9- 12. (The electrical schematic legend is
on page 9-2.) JFT12-6 (optional hour meter)
JPT9-6 (to carriage manager)
The following voltage points are measured with
JPT1-9 (MULTI connector)
respect to TP4 (B-):
JFT8-8 (steer power head)
1. Turning the key switch (S1) on supplies
battery voltage from S1-2 to JPC1 1 - 1 (B+ 7. +1 1.3 volts is supplied
by the carriage
KEY). manager to the following points on the
carriage manager (this is generated from
2. Battery voltage is a t the following points
on the carriage manager:
+12VP from the steer/tractor manager):
JPC3-6 (optional lower limit S60)
JPC 1 1-2 through S2 1 to JPC1 1-3 (B+
ESTOP) JPC12-6 (optional sidegate switch 1,
JPC9-4 (B+KEY)to JFT10-4 on the S19)
steer/tractor manager JPC7-2 (Deadman 1 S2)
JPC9-3 (B+ ESTOP) to JPT10-3 on the JPC7-5 (Deadman 2 S23)
steer/tractor manager (closing relay K1) JPC7-8 (24" limit switch S6)
3. Battery voltage is a t the following points JPC7-1 1 (60" height switch S7)
on the steer/tractor manager: JPC 12- 15 (optional sidegate switch 2,
JPT11-10 (B+ KEY) to the traction S20)
power amplifier J 1 -16 JPC1 -1 (operator display)
4. Battery voltage is a t the following points
8. +5 volts is present a t JPC2-3 (steer
on the steer/tractor manager a s B+
encoder) on the carriage manager.
ESTOP:
JPT12-2 1 through the load-holding 9. +5 volts is present a t PT6-3 steer feedback
encoder) on the steer/tractor manager.
solenoid coil to JPT12-9
JPT12-21 through the lift/lower With the wire guidance option, the guidance
solenoid coil to JPT12-8 manager receives:
JPT12-2 1 through the PC contactor coil 1. Battery positive a t JPS2-1 1 a s B+ESTOP.
to JPT12-20 This is also used by the power supply on
the guidance manager (GM) to generate
+12 volts which is used by the steer
00700-CL222-05, 1 5 March 2005

Key Switch (S1) O n
controller micro processor, internal If a problem is detected, the steer/tractor

circuitry, and the filter card. The +12 volts manager prevents truck operation and tells the
is also supplied to: CM to display a corresponding fault code on the
Tractor sensor a t JPW2- 15 operator display.
Load sensor a t JPW1 -15
Speed encoder a t J P S1-19
2. Battery negative a t JPS2-24.
3. Battery negative a t JPS4-3 a s DGND.
When the key switch is first turned on, the

Microprocessor's perform a self-diagnostics of
certain inputs and outputs.
The carriage manager checks:

1. The +12 volt supply from the steer/tractor
manager.
2. Checks to make sure the steer tiller
encoder is plugged in.
3. Checks the state of Deadman 1 and
informs the STM.
4. Checks the voltage from the travel and lift
pot and sends the voltages to the STM.
The steer tractor manager checks:

1. The +12 volt supply.
2. The voltages from the travel and lift pot
and compares them to the learned neutral
and out of range values.
3. The state of the P contactor a t JPT12-3.
4. The state of the mast switches.
5. The state of the EPO switch a t JPT10-3.
6. The state of the Deadman switches.
7. The state of the PC contactor a t JPT12-3.
8. Battery Voltage for proper range a t B+ key.
9. Calculates BDI using B+PC.
10. Requests feedback from the Guidance
Manager on the results of it's
self-diagnostics.
1 1. Inputs from the TPA to verify its operation.
The Guidance Manager checks:

1. To make sure the filter card is plugged in
based on a jumper on the filter card
between JS1-A10 and A1 1.
00700-CL222-05, 1 5 March 2005

Tracing Legend - Electrical
- = B+ Circuit
= B- Circuit
= Signal
VHHHHHHHHHH~ = 12V/ 5V
Figure 9-3. Key Switch O n (Sheet lof 4)
00700-CL222-05, 1 5 March 2005

Key Switch (S1) O n
@ E 1 F 1 G 1 H
4 E 1 F 1 G 1 H
Figure 9-3 (Cont.]. Key Switch On (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005


CONTROLHANDLE
r - - - - - -WIRE
- -GUIDANCE
- - - - MANAGER
- - - - -(OPTION]
---
I
I "
HTRl 1 9 "
73
I AGRD
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Tll I
( t E ONLY]
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Figure 9-3 (Cont.). Key Switch O n (Sheet 3 of 4)
9-1 4 00700-CL222-05, 1 5 March 2005

Key Switch (S1) O n
COLD STORAGE LIGHTS AND FAN [OPTION]

................................
I SUPPRESSOR I
I NETWORK
FAN I
I T O FU92
I ITS1 2. EE O N L Y )
I
I
I LIGHT
I
I SWITCH I
I SUPPRESSOR
STEER I . -N E-
T W-
O R K- - - I
CONTROLLER
LIGHTS I
I I
I w I
LIGHT
I
I I
L------------------------------J
STANDARD LIGHTS AND FAN [OPTION)

................................ SUPPRESSOR
-N E-
T W-
O R K- - - Chh
1-----A
I
I SWITCH
SUPPRESSOR
NETWORK
SWITCH
E I F
Figure 9-3 (Cant.). Key Switch O n (Sheet 4 of 4)
00700-CL222-05, 1 5 March 2005

Closing Deadman Switches
B+ side of the open pump (P)contactor
Closing Deadman tips, P-1
Switches MHA-1 on the steer power head
Drive motor (MD) armature terminal A1
Stepping on the deadman pedal closes B+ terminal of traction power amplifier
deadman switches S2 (Deadman 1) and S23
(Deadman 2). Both switches must be closed to M- terminal of traction power amplifier
travel, lift/lower and/or steer. If either switch Drive motor (MD) armature terminal A2
opens while traveling, the travel command to MDA2 sense a t JPT11-7
the traction power amplifier stops and the
brake is applied. JPT12-1 a s B+PC
1. With S2 closed, a circuit is completed FU 1 a s B+PC and B+PCF
between JPC7-3 and JPC7- 1 on the JPT12-2 a s PCSENSE
carriage manager. JPT12-13 to pump contactor coil (X)
2. With S23 closed, a circuit is completed terminal a s B+PCF
between JPC7-6 and JPC7-4 on the JFT12-13 to warning light a s B+PCF
carriage manager. (optional)
3. With the S2 (Deadman 1) circuit complete, 8. The steer/tractor manager also turns on
the micro processor on the CM detects the brake coil driver which is indicated by
that the switch is closed. The carriage a n LED (IL6-4).With this coil driver on, a
manager communicates to the current path is completed between
steer/tractor manager via the transmit JPT12-21 and JPT12-17 and the brake
line that switch S2 is closed. releases. If the Deadman switches are
4. The Deadman 2 input from S23 is wired opened during travel the brake will be
directly through the mast cable from the applied immediately.
carriage manager (JPC8-5) to the 9. After the truck has completed
steer/tractor manager (JPT9-5).The CM self-diagnostics and the deadman pedal is
does not look a t the input or use it for depressed, the STM looks a t the input
anything. from the Home Reference Proximity
5. The Deadman 1 message and Deadman 2 Sensor. If the prox is over metal, the STM
input are received by the steer/tractor will turn the drive unit to the left. As soon
manager and monitored continually to a s the prox switch transitions from metal
ensure they both agree. If only one of the to no metal the STM removes the steer
switches closes while the pedal is command. If it is not over metal, the drive
depressed the operator display indicates a unit turns to the right. Once the home
fault. LEDs on the steer/tractor manager prox transitions from off to on, the STM
for Deadman 1 (IL6-10) and Deadman 2 turns the drive unit back to the left until
(IL2) are lit when the switches are closed. the switch transitions to no metal and
6. After the steer/tractor manager removes the steer command. This position
determines both Deadman switches agree, is considered center and the position
it turns on the PC contactor coil driver register for the steer feedback encoder is
which is indicated by a n LED (IL6-8).With set to a zero reference point. During the
this coil driver on, a current path is auto steer center function, the STM
completed between JFT12-21 and monitors the steer feedback encoder and
JFT12-20 which energizes the PC the steer motor current to verify the drive
contactor coil. unit is actually powered and moving in the
proper direction. If the STM does not see
7. The PC contactor tips close and battery current or encoder pulses, a n error code
voltage is supplied to the following: displays. If the STM does not see a home
TPl,TP2 reference proximity sensor transition, it
00700-CL222-05, 1 5 March 2005

turns the drive unit to the physical stop.
Current limit is invoked and a n error code
is displayed.
10. The STM places the truck in a speed limit
condition waiting to see inputs from the
steer tiller.
00700-CL222-05, 1 5 March 2005

A I B
STEER/TRACTOR
MANAGER
DMANI
m."r
HOUR METER ENABLE
Tracine Legend - Electrical
= B+ Circuit
= B- Circuit
= Signal
WHHHHHHHHHHA = 1 2V/ 5V
Figure 9-4. Closing Deadman Switches (Sheet I of 4)
00700-CL222-05, 1 5 March 2005

6 E I F I G I H
STEERINPUT ENCODER 2
W/G AUTO MANUAL
LIFT/LOWER LIMIT BYPASS
Figure 9-4 (Cont.). Closing Deadman Switches (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005

A I B I C I D

--------
CONTROL HWDLE
r - - - - - -WIRE
- -GUIDANCE
- - - - MANAGER
- - - - -[OPTION]
---
JPHld 1
iU13
JPHll l
WIRES
AGRD
112"
TPd L - - - - - - -1
AGRD
I 15
I 112"
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A I B I C I D
00700-CL222-05, 1 5 March 2005

E I F I G I H
COLD STORAGE LIGHTS AND FAN (OPTION]

------
I SUPPRESSOR I
I . -N E-W O-R K- - -
I TO FU92
I
I as 1 3. E:OON"$
I
LIGHT
SWITCH
I
I SUPPRESSOR
I .------
NEWORK I
I
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I LIGHTS I
I
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STANDARD LIGHTS AND FAN (OPTION]

I SUPPRESSOR I
I NEWORK FAN
I TO FU92
I
I $: O;A
ITS1 3.
I
I SWITCH
SUPPRESSOR
NEWORK im I
1-----A3
SWITCH
-
Tracing! Legend - Electrical
- = B+ Circuit
= B- Circuit
= Signal
VHMBMHHM = 12V/5V
+b E I F I G I H
00700-CL222-05, 1 5 March 2005

Travel
Travel traction power amplifier which will

determine the drive motor field polarity to
enable travel in the forward direction.
General 3. The traction power amplifier will then drive
its internal field control transistors to turn
When the potentiometer voltage increases or the drive motor in the correct direction.
decreases from the neutral deadband, the 4. Simultaneously a n analog voltage, which
steer/tractor manager sends a travel request for represents and is proportional to the
direction (TF/FORWARD or FF/REVERSE) and throttle command, is outputted from the
speed (TRAVEL REQ) to the traction power steer tractor manager and sent to the
amplifier. The voltage from the steer/tractor traction power amplifier. This voltage
manager is directly related to the speed request. (TRAVEL REQ) ranges from 0 to about
As the input request changes, the travel request +4.25 VDC depending on throttle input
voltage to the traction power amplifier mirrors WRT TRAVEL REF. Based on this, the TPA
the change. will control the strength of the field and
armature to obtain the proper travel speed
When a change in direction is requested, the in the appropriate amount of time. The
steer/tractor manager changes the direction higher the voltage the faster the TPA will
request to the traction power amplifier and make the truck travel.
changes the speed request output (TRAVEL
REQ) to reflect the requested plugging strength. NOTE: Travel speed is limited until the operator
requests steering and the steer/tractor
manager detects the request.
Movin Directional/Speed
Contro 7 5. The TRAVEL REQ voltage is used by the
traction power amplifier to drive the
See the schematic in Figure 9-5 on page 9-24. armature and field transistors to meet the
(The electrical schematic legend is on page 9-2.) throttle request. The armature transistor
is, in effect, connecting terminal M- to B-
NOTE: The current flowing through the drive (in varying amounts) allowing current to
motor armature and field windings are flow through the drive motor armature.
controlled independently of each other The traction power amplifier will also drive
by the traction power amplifier. its internal field transistors which, in turn,
1. When the throttle is moved to the forward will control the amount and direction of
position (tractor-first), the wiper in the flow through the drive motor field winding.
variable resistor (VR-1) is moved so that When a plug is requested, the
the voltage output decreases. The carriage steer/tractor manager changes the
manager, sensing this decrease in voltage, direction request to the traction power
sends a communication message over the amplifier and changes the speed request
transmit line to the tractor manager. The output (TRAVEL REQ) to reflect the
tractor manager interprets this a s a requested plugging strength. Current now
request for travel in the forward direction flows from B+ through:
and causes the following to occur: FU3
NOTE: For clarity and simplification, only Drive motor armature
circuits directly related to vehicle travel M-
will be traced on the remaining B- (TP4)
operation of the travel system diagram.
All are with respect to (WRT)TP4 (B-). To battery negative
2. The TF/FORWARD line to the traction 6. During operation, the traction power
power amplifier is activated (driven to amplifier monitors for:
about 19VDC).This is the input to the Armature current*
9-2 2 00700-CL222-05, 1 5 March 2005

Travel
Field current*
M- shorted to B-*
Battery under/over voltage: Less than
+16 volts cuts down the output from
the TPA and limits travel speed. Greater
than +45 volts places the controller in a
s h u t down condition
Under/over temperature: Over
temperature of the traction power
amplifier is 85 C (185 F) and above.
Overheating is unusual, but can occur
if the traction power amplifier is
installed incorrectly or overloaded. At
over temperature, the drive current
limit is linearly decreased from full set
current limit down to zero. Plugging
current is not reduced by any thermal
conditions to allow full plugging
strength a t all times. When the traction
amplifier is operating a t less than -25 C
(- 13 F), the current limit is cut back
resulting in reduced travel speed and
acceleration.
"Disables PC contactor through PC DRniTE
line. When the PC DRniTE line goes to 5
volts the PC opens and the STM tells the
CM to display a code 2,2
00700-CL222-05, 1 5 March 2005

Travel
STEER/TRACTOR
MANAGER
DGND -
12VP
AGND
STEER DIRl
STEER DlR2
STEER DlR1 PWM
STEER DlR2 PWM
BOOST +
BOOST itkR 8
STEER CURRENT LIMIT
STEERCURRENTIB
04 /"%
17
HEARTBEAT
@7
7
NC 113
NC
NC OMAN I
-
m."r
NC PC 116 10
DISABLE
PC DRIVE @0
BiKEY 15
TIIFORWARD
FF/REVERSE
TRAVEL RE0
zP
MS1
MS2
DEADMAN
TRAVEL REF
MDAZSENSE 1
B t l l l :ill?!##
SRRE
I162
rn 0
WARN
~
[WIRE
PAGE GUIDANCE
2 BiESTOP RELAY
~
OPTION ONLY) L/H SOL CTRL 0
116 9
0
~
L/L B+
TOJPS?II t 1 1 SOL c 0
1167
-*
PAGE 2
(WIRE GUIDANCE
OPTION ONLY) K CTRL b
L6 8
+ ro B+PC
BRKE
BRAKE CTRL rn 0
I164 g
SPARE CTRL
NC
HORNCTRL rn 0
1166
B
B
PSENSE
PCSENSE
B+K
B+
B+
12VP
HOURMETER ENABLE
DGND
Tracing Leeend - Electrical
= B+ Circuit
= B- Circuit
= Signal
VHMBMHHM = 12V/5V
A 1 B 1 C
Figur.e 9-5. Moving Speed/Directional Control (Sheet I of 4)
00700-CL222-05, 1 5 March 2005

Travel
BiESTOP
RELAY
+b E 1 F 1
Figure 9-5 (Cont.). Moving Speed/Directional Control (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005

Travel

CONTROLHANDLE
IPC2 12
r - - - - - -WIRE
- -GUIDANCE
- - - - MANAGER
- - - - -( O-P-T W
-
FU13
CONSOLE
IPH13 1 IPH132
WIRES
AGRD
112"

1 9
AGRD
I
I 112"
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
T ll I
ItE ONLY
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L--------------------
00700-CL222-05, 1 5 March 2005

Travel

SUPPRESSOR I
NEWORK
I TOFU92
IITS1 2. EE ONLIj
I
1 ?:Lo;
ITS, 3,
I
SWITCH
LIGHT
SUPPRESSOR
.------
NETWORK
LIGHT
SWITCH
- LIGHTS I
I
I
I
I
I

--------------------------------
I (IIPPRFCCOR I
I NETW O RK FAN
I TOFU92
IITS1 2. EE ONLIj
I
I as1 3. L00N":Yia2
I
I SWITCH
SUPPRESSOR
. -NEWORK
----- FAN I
SWITCH
+b E I F I
00700-CL222-05, 1 5 March 2005

Steering
Steering individual square waves are produced (CHA and

CHB). The relationship between these two
square waves tells the CM which way the
The Steering Encoder is located on the steering wheel is turning. The number of pulses
operator's carriage, behind the steering wheel. generated tells it of how far and how fast the
steering wheel has been turned. The degree of
When the battery is connected, the key switch rotation of the drive unit is not in direct
is ON and the deadman pedal is down, the correlation to the distance the steering wheel is
following events occur when the operator turns turned. Once the steering wheel stops turning,
the steering wheel in either direction: the drive unit stops turning. Determining which
way the steering wheel is turned is based on
The steering encoder sends a quadrature-phase which one of the two square waves is ahead of
output to the CM when the steering wheel is the other. The one that is ahead tells which way
turned. As the steering wheel is turned, two the wheel is turning. See Figure 9-6.
CHANNEL A leads
CHANNEL B by
LEFC TURN angle 0
CHANNEL B nnl
CHANNEL A lags
CHANNEL B by
angle 0
RIGHT TURN
CHANNEL A
CHANNEL B
Figure 9-6. Steer Position Encoder Output
These square waves are read by the CM. The The BOOST + and BOOST - inputs are
CM sends this information over the transmit required for both steering directions.
line to the STM. BOOST + is used to power on set of
The STM sends voltages to the steer power transistors for steering and Boost - is used
head to activate the steer motor. STEER for the reference by Boost +.
DIR 1 and STEER DIR 1 PWM turn on the While the steering is activated the Steer
transistors required to turn in one Power Head sends a voltage to the STM
direction. The STEER DIR 2 inputs will that indicates the current draw of the
turn it the other direction. motor over the STEER CURRENT FB.
There is also a voltage that is sent over the
STEER CURRENT LIMIT whenever the
motor is in current limit.
00700-CL2 22-05, 1 5 March 2 005

Steering
The position of the drive wheel is indicated

by the five LEDs on the operator display.
These are based on the input from the
steer feedback encoder.
See Table 9-1 on page 9-29
See Figure 9-7 on page 9-30
NOTE: After self-diagnostics is complete, the
operator must request steering before
the truck will travel in full speed.
Display Truck Condition

All LEDs scroll in Drive unit position is
side-to-side pattern unknown
Left LED on steady Drive unit in left,
t h a n 65"
counter-clockwise)
Mid-Left LED on Drive unit in left zone
steady (10-65"
counter-clockwise)
Center LED on steady Drive unit in center zone
(within 10" of center)
I Mid-Right LED on
steady
Drive unit in right zone
(10-65" clockwise)
l
Right LED on steady Drive unit in right
t h a n 65" clockwise)
l
All LEDs blink in In maintenance mode
unison a s the horn
clicks I
Table 9- 1 . Steering Indicator Display Messages
00700-CL222-05, 1 5 March 2005

Steering
STEER/TkACTOR
MANAGER
DGND -
12VP
AGND
STEER DlR1
STEER DIR2
STEERDIRI PWM
STEER DR2 PWM
BOOST +
STEER
LIMIT
BOOST
STEER CURRENTLIMIT @4
STEER CURRENT FB
NC
17 @+
HEARTBEAT
L3
NC
NC
NC
PC
K DRIVE
BiKEY
DISABLE
@
ILS
+
TF/FORWARD
TRAVEL REF
MDA2 SENSE 1
WARN
:EIlNbllbK"131CN m0
116 1
BiESTOP RELAY
L/H
L/H SOL CTRL m /n/l
1169
iU2
L/L B+ B+i
L/L SOLCTRL m0 li*
1167
Lb 8 iU1
B+K B+PCF
BRKE
BRAKE CTRL
1164
0 li*
SRRE CTRL
NC $2
BiHORN HORN
HORN CTRL m0
116 6
B
B
B
PSENSE
PCSENSE
B+PC
B+
B+
12VP
HOUR METER ENABLE
DGND
Tracing Lesend - Electrical

TXD
= B+ Circuit
= B- Circuit
= Signal DSR BOOST
WHHHHHHHHHHA = 12V/ 5V RTS/BOOT

NC
12VP
A 1 B
Fig ure 9-7. Steering (Sheet 1 of 4)
00700-CL2 22-05, 1 5 March 2 005

Steering
6 E 1 F 1 G 1 H
Figure 9-7 (Cont.). Steering (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005

Steering

-----
CONTROL HANDLE
,PC2 12
r - - - - - -WIRE
- -GUIDANCE
- - - - -MANAGER
- - - -(OPTION]
---
OTM
WIRES
AGRD
112"
-1 COLD STORAGE TRACTOR
AGRD
112"
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L--------------------
A I B I C I D +b
00700-CL2 22-05, 1 5 March 2 005

Steering

--------------------------------
I SUPPRESSOR I
I . -N E-
T W-
OR-
K --
FAN I /Ah
I TOFU92
I ITS1 2. E E O N L Y ;
I
1 !&!%A
ITS1 3,
I
LIGHT
SWITCH
I
I I
I . -N E-T W -O R K- - - FAN
I
I
I
I
I 1-----A3
I
..
I SWITCH
I I

.I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR I
I . -N E-
T W-
O R K- - -
FAN I
I TOFU92
I ITS1 2. E E O N L Y ; I
I I
1 ITS1 3. A%'N"&P I
I
I SWITCH
SUPPRESSOR
NETWORK FAN
------------------------J
00700-CL222-05, 1 5 March 2005

Lift/Lower proportional solenoid valve coil a t

JPT12-8, indicated by the solenoid control
LED
Lift (55) (IL6-7)on the steer/tractor manager. The
lift/lower proportional valve begins to
The lift button commands the carriage to lift. ramp closed (this valve is normally open).
When the lift button is pressed, the lift/lower See Figure 9-8 on page 9-35.
proportional solenoid valve (normally open) 6. The lift pump/motor assembly is now
stays open while the lift contactor closes. After running and supplying hydraulic pressure
the contactor closes and the lift pump motor and flow to the lift cylinders.
turns on, the proportional solenoid valve ramps See Figure 9- 10.
closed which forces hydraulic fluid into the
cylinders and increases lift speed. The
proportional solenoid valve provides a smooth
transition between zero speed lift and full speed
lift and back to zero speed lift. When the lift
button is released, the proportional solenoid
opens and the lift contactor opens turning off
the lift pump motor. During lift, the load
holding solenoid valve remains closed
(de-energized).
The microprocessor on the steer/tractor

manager verifies the lift contactor remains
closed when commanded closed, and open
when commanded open. If either condition is
not met, the steer/tractor manager generates a
fault code.
See Figure 9-9 on page 9-36. (The electrical

schematic legend is on page 9-2.)
1. As the control handle lift switch is closed,
a digital ground is applied to JPC13-6 on
the carriage manager.
2. The carriage manager sends a lift
command message to the steer/tractor
manager over the transmit/receive lines.
3. The steer/tractor manager provides the
negative potential for the lift pump
contactor coil (JPT12-18) and the pump
contactor coil is energized. The lift pump
contactor LED (IL6-5)on the steer/tractor
manager indicates the pump contactor coil
driver is energized. See Figure 9-8 on
page 9-35.
4. When the lift pump contactor coil is
energized, the lift pump contactor tips
close supplying B+ to the lift pump motor.
5. The steer/tractor manager provides the
negative potential for the lift/lower
00700-CL222-05, 1 5 March 2005

Lift/Lower
Figure 9-8. LEDs 11 1-116 on Steer/Tractor Controller
00700-CL222-05, 1 5 March 2005

rfid
STEERjTRACTOR
MANAGER
E ND
12VP
AGND
STEER DlR1
F
P
@+
HEARTBEAT
L3
WARN
m."r
T O J P S ~ ~ ~
PAGE 2
> Lb l
/WIREGUIDANCE
L/H
OPTION ONLY) m."r
Lb9
L/L
T O J P S1 1~ Z m+
L6 7
PAGE GUIDANCE
[WIRE 2
OPTION ONLY1
116 8
L6 4 0
zP
HORN
m+
L6 6
12VP
HOUR METER ENABLE
Tracins Lesend - Electrical

DGND
-
VHMBMHHL
= B+ Circuit
= B- Circuit
= Signal
= 12V/5V
,L8
m
$J
BOOST
Figure 9-9. Lift (Sheet I of 4)
00700-CL222-05, 1 5 March 2005

Figure 9-9 (Cont.). Lift (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005


CONTROL HANDLE
r - - - - - -WIRE
- -GUIDANCE
- - - - -MANAGER
- - - -(OPTION]
---
iU13 TH I
WIRES 73
AGRD
112"
I
TPd L - - - - - - -I I
I
FU12 TH2 HTR3 1 9
, 2 1 2 r-----I 1 9
AGRD
PC I 1 o*
I
I 112"
3
I
I
HTRd I
r-----I I
I
I
I
I
TPd
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L--------------------
00700-CL222-05, 1 5 March 2005


--------------------------------
I SUPPRESSOR I
I
I
. -NETWORK
-----
-
FAN I
-+ rnk
1
-
TOFU92
I ITS1 2, EE ONLY)
1-----A3 I
I
LIGHT !
1'
II c, ,PPDF<C,,D
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SWITCH
. -N E-W O-R K- - - FAN
..
SWITCH
I

................................ SUPPRESSOR I
NEWORK I
I TOFU92 I
I ITS1 2, EE ONLY)
I I
SWITCH
00700-CL222-05, 1 5 March 2005

LEGEND
Pressure L i n e s
Return L i n e s
1 1 GPM
FLOW
CTRL
RES
Figure 9- 10. Lift
00700-CL222-05, 1 5 March 2005

Lower (54) 3. The steer/tractor manager provides the

negative potential for the lift/lower
The lower button commands the carriage to proportional valve coil a t JPT12-8,
lower. When the lower button is pressed, the indicated by the load holding solenoid LED
lift/lower proportional solenoid valve closes and (IL6-7)on the steer/tractor manager. See
the load holding solenoid valve opens. The Figure 9- 11 on page 9-4 1. The lift/lower
proportional valve opens and allows hydraulic proportional valve ramps closed (this valve
fluid to return from the lift cylinders to the is normally open).
reservoir. 4. The steer/tractor manager provides the
negative potential for the load holding
When lower is no longer requested, the valve coil a t JPT12-9, indicated by the load
proportional valve opens and the load holding holding solenoid LED (IL6-9).See
valve closes. Figure 9- 11 on page 9-4 1. The coil
energizes and the load holding valve
See Figure 9- 13 on page 9-44. (The electrical opens.
schematic legend is on page 9-2.) 5. The steer/tractor manager varies the
1. As the control handle lower switch is negative potential for the lift/lower
closed, a digital ground is applied to proportional valve coil a t JPT12-8,
JPC13-7 on the carriage manager. indicated by the load holding solenoid
2. The carriage manager sends a lower LED. The lift/lower proportional valve
command message to the steer/tractor gradually opens allowing hydraulic fluid to
manager over the transmit/receive lines. return to the reservoir. See Figure 9-12.
Figure 9- 1 1. LEDs 11 1-116 on Steer/Tractor Controller
00700-CL222-05, 1 5 March 2005

Lift/Lower
00700-CL222-05, 1 5 March 2005

I STEER/TRACTOR
MANAGER
DGND -
12"P
AGND
STEER DlR1
STEER DlR2
STEER DIRl PWM
STEER DlR2 PWM
80057 + STEER '
80057
STEER CURRENT LIMIT
STEER CURRENT FB
LIMIT
@
17
+2 Q
HEARTBEAT
NC L3
NC
NC OMAN1
NC - PK.'
PC 116 10
DISABLE
PC DRIVE @0
BiKEY ILS
TIIFORWARD
FFlRtVtRSt
TRAVEL RE0
MSI
MS2
DEADMAN
TRAVEL REF
MDA2 SENSE
BiPCF
PUMP
PUMPCTRL rn 0
116 5
SPARE
IbI, 1, :AIEb,bEt.> m0
1162
WARN
,,A>N\CCH1:1l,:':\, m0
Lb l
B+tSTOPRELAY
116 9
FU2
L/L B+ -B+F
L/L SOL CTRL rn G 15A
Lbi
116 8 FU1
B+PC *B+PCF
a
BRKE
BRAKE CTRL m 02 15A
SPARE CTRL
I164
2
NC 5Q
BiHORN HORN
HORNCTRL rn G
Lbb
B
B
B
PSENSE
PCSENSE
B+PC
B+
B+
12VP
HOURMETER ENABLE
DGND
RXD/PENDANTI
DTR/PtNDANT2
DGND
DSR
RTS/BOOT
NC
12VP
Figure 9- 13. Lower (Sheet 1 of 4)
00700-CL222-05, 1 5 March 2005

JPC12 STEER NPUT ENCODER 2

HEG
I HT 120"illo''S'~'
CARRIAGE
DGND MANAGER
LED 5
0 12 LED 7
0 11 LED 8
HEIGHT l8O"SW
LED 9
g DGND
W
I
a
DGND LOWER LIMIT
SPARE IN 3
12". hi1
DGND
N/C
N/C KEYSWITCH
S1
BiESTOP JPTlO
RELAY
CONTROL HANDLE
VRI
+I?VP
DEADMAN 2
DGND VR2
TI ; : : : ; ;
DGND
;:8$
LIFT/LOWER LIMIT BYPASS
NC
DGND
1 1 3"P
SRRE IN n
SRRE IN n
DGND
SRRE IN 5
DGND
POWER SUPPLY
112"P
SIDEGATE I
11 3VP
SIDEGATE 2
4 E 1 F 1 G 1 H
Figure 9- 13 (Cont.). Lower (Sheet 2 of 4)
00700-CL222-05, 1 5 March 2005


CONTROL HANDLE
r - - - - - - -WIRE
--- GUIDANCE MANAGER ( O P T W
----------
FU13 TH I
WIRES
AGRD
112"
I
TPd L - - - - - - -I I
iU12
TH2 HTR?
I
1 9
Z
, 2 1 2 r-----I 1 9
AGRD
PC, 1 o*
I
I 112"
I
I
HTR4 I
r-----I I
I
I
I
I
TP4 I
I
I
I
I
I
I
I
I
-, I
JPClO
-
+-* I iU7 2
24
1
,OPTION,
I
I
I
RF TERMINAL
I
I I
I
I
I
I
I
I
I
I
I
L--------------------
Figure 9-13 (Cont.). Lower (Sheet 3 of 4)
00700-CL222-05, 1 5 March 2005


--------------------------------
I SUPPRESSOR I
I . -NE- -RK- - -
TWO
FAN
I TOFU92
I FSl 2. EE ONLY]
I
I TOFU102
I Fsl 3. EE ONLY]
I
I
I .. ...-
I . -NE-
TW- ---
ORK
I
I
I
I
I I----- J3
I
I LIGHT
SWrCH
I I

--------------------------------
I SUPPRESSOR I
I NETWORK FAN
I TOFU92
I FSl 2. EE ONLY)
I
I TOFU102
I Fsl 3. EE ONLY]
I
I
I SUPPRESSOR
I NETWORK
I
I
I
I
I
I
I SWITCH
I
L -----
Figure 9-13 (Cont.). Lower (Sheet 4 of 4)
00700-CL222-05, 1 5 March 2005

24" Limit Switch (56) 180" Limit Switch (525)

(Optional)
The 24" limit switch is mounted to the carriage,
and the switch rail is mounted on the truck The 180" limit switch is included with the High
frame 24" (60.96 mm) from the bottom. The Performance option.
switch is closed until the carriage lifts high
enough for the switch to r u n above the switch This switch is mounted on the carriage and
rail. When open, the switch limits travel speed limits travel speed to 1 rnph (1.6 kph) when
to 3 rnph (4.8 kph). Travel speed is further open, or disables travel if the steering angle is
limited to 1 rnph (1.6 kph) when steering is more than 5" from center.
more than 5" from center.
If the truck is equipped with the High Lift Limit Switch (524) (Optional)
Performance option, travel speed is limited to
2.5 rnph (4 kph) when this switch is open and The lift limit switch disables lift when open.
the steering angle is greater than 5" from This switch is mounted on the mast. It can be
center. There is no speed limit if the steering bypassed by pressing the optional lift limit
angle is less than 5". bypass switch on the carriage.
150" Limit Switch (S29) Lift Limit Bypass Switch (551)

(Optional)
The 150" limit switch is mounted to the mast
behind the battery connector. This switch opens When the lift limit switch is open, pressing the
when the outer mast raises above it and the lift limit bypass switch allows the truck to
forks are 150" off the floor. At this height, travel continue lifting.
speed is limited to 1 rnph (1.6 kph), or disabled
if the steering angle is more than 5" from center.
Lower Limit Switch (560)
(Optional)
60" Limit Switch (57) (Optional)
The lower limit switch disables lower when
The 60" limit switch is included with the High closed. It is mounted on the carriage and can be
Performance option. bypassed using the optional lower limit bypass
switch on the carriage.
This switch is mounted on the carriage and
limits travel speed to 4.3 rnph (6.9 kph) when
open, or 1 rnph (1.6 kph) if the steering angle is Pump Contactor
more than 5" from center.
The pump contactor provides power to the lift
motor and is closed during lift.
120" Limit Switch (S29)
(Optional) Load Holding Solenoid
The 120" limit switch is included with the High
The load holding solenoid is closed whenever
Performance option.
there is no request to lower. When lower is
requested, the solenoid opens. It closes when
This switch is mounted on the mast and limits
lower is no longer requested.
travel speed to 2.5 rnph (4 kph) when open, or
limits travel speed to 1 rnph (1.6 kph) if the
steering angle is more than 5" from center.
00700-CL222-05, 1 5 March 2005

Pump Sense
The pump sense line monitors the status of the
pump contactor a t all times. If the pump
contactor is closed when commanded open, a n
error code displays and the PC contactor opens.
If the pump contactor is open when
commanded closed, a n error code displays.
CV- 1 Valve
This 5 psi (34.5 kPa) check valve makes sure
that oil returning from the lift cylinders does
not drive the lift pump and motor backward.
CV-2 Valve
This is the 100 psi (689.4 kPa) fork hang-up
valve. If the pressure in the return line falls
below 100 psi (689.4 kPa), the valve will close
and not allow the carriage to lower.
Flow Control Valves

Each lift cylinder has a flow control valve a t the
bottom of the cylinder. If a lift hose fails, the
flow in the side cylinders will be limited to 9
gpm (34 lpm) while the flow in the center
cylinder will be limited to 1 1 gpm (41.6 lpm).
Oil Filter Check Valve

The oil filter is mounted to a n adapter that
incorporates a spring-loaded check valve. It
provides a bypass around the filter in case the
oil pressure in the return line is greater than
what the filter can handle. Additionally, if the
filter gets clogged, the oil will bypass the filter
and return to the hydraulic reservoir.
REL-1 is the high pressure relief valve. I t opens

when lift pressure exceeds the pressure
necessary to lift a full-rated load.
00700-CL222-05, 1 5 March 2005

Primary Memory
Primary Memory c. If the test fails, the STM is not

communicating and should be
replaced.
The primary memory location of the truck's
identification and options are stored in the Installing a card that has firmware installed for
Carriage Manager (CM).A back UP COPY of this a different model truck can lead to a n
information is stored in the Steer Tractor inoperable truck.
Manager (STM). Every time the truck is started
a comparison is performed between the two. If
they do not agree or one is "Blanked" the
hierarchy is:
1. When a pre programmed CM is installed in
a truck, the information programmed into
the card is downloaded to the STM when
the key is first turned on.
2. If a CM with the primary memory
"Blanked" is installed in the truck, the
information stored in the back-up memory
location on the STM is uploaded to the
CM.
These rules are always true except when

FlashWare has been connected to the STM and
software has been loaded or a n option has been
changed. When this has been done, there is a
bit in the STM that is activated and the STM
now becomes the primary memory location.
When the FlashWare program is s h u t down, the
bit in the STM is turned off and the information
is uploaded to the CM. The CM again has the
primary memory status.
1. A pre programmed CM is not required
unless one of the following codes is the
cause for replacement: 4,6, 5,4 or 5,5.
When troubleshooting a n inoperable truck do

not install firmware or change a n option with
FlashWare until the truck is functional again.
2. When trying to install new firmware or
change a n option and the attempt fails:
a. Run the test portion of the program. If
communication is found to be working
between the PC and the CM, they are
functioning correctly.
b. If there is no communication, r u n a
diagnostic test for a component on the
tractor side of the truck. If the test
passes, the STM is communicating and
the CM should be replaced.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
b. Identifies possible causes for lack of

Pinout Matrix proper signal.
5. Normal Level: the approximate voltage that
The pinout matrix chart lists functions and should be seen on that wire for the state
normal voltages of terminals and harness indicated. Unless otherwise indicated,
connector pins. The matrix columns have the voltages are measured with respect to (wrt)
following meanings: B- at TP4.
1. Item #: sequential number to aid in 6. Signal Source: the device or connection
reference. that supplies the signal directly to the
2. Connection: the actual wire numbers or wire.
component abbreviations on the electrical 7. Signal User: the device or connection to
schematic. which the wire directly delivers the signal.
3 . Function Description: brief definition of
the signal carried on the wire.
4. Theory of Operation:
a. A detailed description of the signal
carried on the wire. If the signal can be
variable, it indicates the state of a
related component that will cause the
signal to vary.
head will not function and code 3,2 is

displayed during self-diagnostics. Check
voltage at (+12VF) on the STM.
PS 1-9 AGND Battery negative for the control circuitry <O.SVdc wrt TP4 STM Steer
on the steer power head. It comes from (B-) Power
the STM. Head
PSI-1 STEER DlRl Input from the STM to turn on the circuitry 5V no steering STM Steer
in one half of the steer transistor circuit for OV steering right Power
steering right. Head
PSI-10 STEER DIR2 Input from the STM to turn on the circuitry 5V no steering. STM Steer
in one half of the steer transistor circuit for OV steering left Power
steering left. Head
PS 1 -6 STEER DlRl Input from the STM to PWM the circuitry in OV not steering. STM Steer
PWM one half of the steer transistor circuit for 4.6V steering Power
steering in the left. fast left Head
PSI-15 STEER DIR2 Input from the STM to PWM the circuitry in OV not steering. STM Steer
PWM one half of the steer transistor circuit for 4.6V steering Power
steering right. fast right Head
00700-CL222-05, 1 5 March 2005 9-5 1

Pinout Matrix
in the top side of the H bridge SRT PSI -2.
PS 1-5 STEER Input to the STM telling it the steer power 4.8V not Steer STM
CURRENT LIMIT head has detected the steering system in steering. OV in Power
current limit. current limit Head
PSI-4 STEER Input to the STM telling it the actual motor OV not steering Steer STM
CURRENT FB current the steer power head has 1.5V steering Power
measured in the steering system. fast Head
PSI-1 1 NC Not connected to any circuitry on the steer NA NA NA

power head or STM.
PSI-12 NC Not connected to any circuitry on the steer NA NA NA

power head or STM.

power head or STM.

power head or STM.
J1-4 PC DRIVE Input from the TPA to the STM to disable PC open = 5V TPA STM
the PC contactor if a fault is detected by closed = OV
the TPA.
J1-16 B+KEY Supplies working voltage to the TPA when B+ w/key switch TPA STM
B+ Key is present on the STM. closed
OV w/key switch
open
J1-12 FF FORWARD Input to the TPA from the STM to enable 19V when travel STM TPA
the fork first travel circuits. is requested, OV
w/no request
J1-11 TF REVERSE Input to the TPA from the STM to enable 19V when travel STM TPA
the tractor first travel circuits. is requested, OV
w/no request
J1-6 TRAVEL Travel velocity request from the STM to the No request = OV. STM TPA
REQUEST TPA. Travel request
voltage ramps up
to about 4.25V
at full speed
J1-13 JUMPER The iumper between J1-13 and J1-10 B- w/jumper TPA TPA
disables the emergency reverse option in connected
the TPA.
J1-10 JUMPER The iumper between J1-13 and J1-10 B- w/jumper TPA TPA
disables the emergency reverse option in connected
the Power Amp.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPT11-6 TRAVEL REF Same as J1 on traction amp.
JPT11 - 7 MDA2 SENSE Not used for anything. PC

Contactor
JPT8-3 DGND Same as PSI on the steer power head. <0.5Vdc wrt TP4
(B-1
JPT8-8 12VP Same as PSI on the steer power head. +10.8 - 13Vdc
w/key switch
closed
JPT8-9 AGND Same as PSI on the steer power head. <0.5Vdc wrt TP4
(B-1
JPT8-1 STEER DlRl Same as PSI on the steer power head.
JPT8-10 STEER DIR2 Same as PSI on the steer power head.
JPT8-6 STEER DlRl Same as PSI on the steer power head.

PWM
JPT8-15 STEER DIR2 Same as PSI on the steer power head.
PWM
JPT8-7 BOOST+ Same as PSI on the steer power head.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
CURRENT LIMIT
JPT8-12 NC Same as PSI on the steer power head.
JPT12-13 B+PCF B+ supplied to the warning light, P B+ w/PC STM Warning

contactor coil and the Travel Alarm. It contactor closed Light,
comes from the STM through FU1 and is OV w/PC P contactor
dependant on B+PC at JPT12-1. contactor open coil and
Travel
Alarm
JPT12-18 PUMP CTRL Path for the STM to supply B- to the P Not activated= STM P Contactor
contactor. There is also an LED (116-5)on 20.5V.
the STM that will light when B- is supplied Activated= less
to the coil. Voltages are measured with than 1 V.
meter leads on the coil X and Y.
JPT12-16 TRAVEL ALARM Path for the STM to supply B- to the Travel Not activated= STM Travel
Alarm. There is also an LED (116-2)on the 20.5V. Alarm
STM that will light when B- is supplied. Activated= less
Voltages are measured with meter leads than 1 V/
on terminals 1 and 2 of travel alarm.
JPT12-14 WARNING Path for the STM to supply B- to the Not activated= STM Warning
LIGHT warning light. There is also an LED (116-1) 20.5V. Light
on the STM that will light when B- is Activated= less
supplied. Voltages are measured with than 1 V.
meter leads on terminals 1 and 2 of the
light.
JPT12-21 B+ ESTOP B+ supplied to the load holding and lift B+ w/EPO STM LH, LL
RELAY lower solenoids, PC contactor coil and the closed solenoids,
brake coil. It comes from the STM through OV w/EPO open PC and
the K1 relay and is dependant on B+F Brake coils,
from FU2. Steer
Controller
Card
JPT12-9 L/H SOL CTRL Path for the STM to supply B- to the L/H Not activated= STM Load
solenoid. There is also an LED (116-9)on 20.5V. Holding
the STM that will light when B- is supplied Activated= less Solenoid
to the coil. Voltages are measured with than 1 V. Coil
meter leads on solenoid coil 1 and 2.
00700-CL222-05, 1 5 March 2005

Section 9 . Theory of Operation Toyota Orderpicker Model 7BPUE 15 Service Manual
Pinout Matrix
motor stops rotating. That information is
JPT12-4 DGND Battery negative for the control circuitry <0.5Vdc wrt TP4 STM Steer
on the steer power head. It comes from (B-) Power
the STM. Head
JT1-1 NC Not connected to any circuitry on the NA NA NA

STM.
JT1-2 TXD Connection for computer interface no N o useful

usable measurements available. voltages are
measurable
JT1-3 RXD/PENDANT Connection for computer interface no N o useful

1 usable measurements available. voltages are
measurable
9-5 6 00700-CL222-05, 1 5 March 2005

Pinout Matrix
usable measurements available.
measurable
JT1-7 RTS/BOOT Connection for computer interface no No useful

usable measurements available. voltages are
measurable
JT1-8 NC Not connected to any circuitry on the NA

STM.
JT1-9 12VP Supplies working voltage to the lift lower +10.8 - 13Vdc STM Lift Lower
pendant. If not present, check voltage at with key switch Pendant
STM JPT9-6and see if IL1 is lit. closed
JPT5-2 12VP Supplies working voltage to the 120/150 +10.8 - 13Vdc STM 120/150
in. switch. If not present, check voltage at with key switch inch switch
JPT5-1 HEIGHT Supplies B- to circuitry on the STM when Switch closed 120/150 STM
120/150 in. the switch is closed. When the switch is <1 Vdc in. switch
SW (S29) open the truck will have limited travel Switch open
speed. 5Vdc
JPT5-3 DGND B- for S29, supplied through the STM via <0.5Vdc wrt TP4 STM S29
B- cable at the TPA. (B-1
JPT5 -5 12VP Supplies working voltage to the1 80 in. +10.8 - 13Vdc STM 180 in.
switch. If not present, check voltage at with key switch switch
JPT5-4 HEIGHT 180 in. Supplies B- to circuitry on the STM when Switch closed 180 in. STM
SW the switch is closed. When the switch is < I Vdc switch
open the truck will have limited travel Switch open
speed. 5Vdc
JPT5-6 DGND B- for S25, supplied through the STM via <0.5Vdc wrt TP4 STM S25
B- cable at the TPA. (B-1
JPT5-8 12VP Supplies working voltage to the Lift Limit +10.8 - 13Vdc STM S24
Switch (S24). If not present, check voltage with key switch
at STM JPT9-6 and see if IL1 is lit. closed
JPT5-16 LIFT LIMIT SW Supplies B- to circuitry on the STM when Switch closed LIFT LIMIT STM
the switch is closed. When the switch is <lVdc SW
open the truck will have no lift unless the Switch open
bypass switch (S5 1) is closed. 5Vdc
JPT5-7 DGND B- for S24, supplied through the STM via <O.5Vdc wrt TP4 STM S24
B- cable at the TPA. (B-)
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPT10-4 B+KEY Supplies B+ Key to the circuitry on the B+ with key Carriage STM
STM via the over mast cable when the key switch closed. Manager
switch is closed. OV with key
switch open.
JPT10-3 B+ ESTOP Supplies B+ ESTOP to the K1 relay coil on B+ with the EPO Carriage K1 Relay
the STM via the over mast cable when the switch closed. Manager
EPO switch (S21) is closed. This closes the OV with the EPO
relay and supplies B+ ESTOP Relay to Open
circuits on the STM.
JPT10-1 B- Supplies B- to the carriage via the over <O.SVdc wrt TP4 STM Carriage
mast cable when the battery is plugged (B-) Manager
In.
JPT9-6 12VP Supplies 12V from the STM power supply +10.8 - 13Vdc STM Carriage
to the Carriage Manager via the over with key switch Manager
mast cable. The 12V is used to power the closed
C M power supply and supplies voltage to
all components using the 1 1.3VP. If not
present, check voltage at STM JPT9-6and
see if IL1 is lit.
JPT9-5 DEADMAN 2 Output from deadman switch S23 informs Switch Carriage STM
the microprocessor on the STM that the Closed: < 1 Vdc Manager
switch is closed and lights 112 on the STM. Open: 5Vdc
JPT9-2 DGND Supplies B- to the carriage via the over <O.SVdc wrt TP4 STM Carriage
mast cable when the battery is plugged (B-) Manager
In.
JPT9-4 TRANSMIT The wire that carries the communications N o useful STM Carriage
from the STM to the CM. N o usable voltages are Manager
information can be gained by measuring measurable
the voltage on this wire.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
In.
J PT6- 1 CHA This is a square wave generated Voltage should Steer STM
whenever there is movement of the Steer vary between Feedback
Feedback Encoder. Voltage varies >3Vdc to < 1 Vdc Encoder
between about 4Vdc and about OVdc as as encoder shaft
the encoder shaft rotates. The frequency is rotated slowly.
varies directly with the speed of the Drive
Motor. The STM uses the quadrature
phase relationship between CH A & B to
determine direction and speed.
JPT6-2 DGND B- to the steer feedback encoder. <0.5Vdc wrt TP4 STM Steer
(B-1 Feedback
Encoder
JPT6-3 5V Positive supply from the STM power 4.5 to 5.5V STM Steer
supply to the steer feedback encoder. Feedback
Encoder
JPT6-4 CHB This is a square wave generated Voltage should Steer STM
whenever there is movement of the Steer vary between Feedback
Feedback Encoder. Voltage varies >3Vdc to < 1Vdc Encoder
between approx 4Vdc and OVdc as the as encoder shaft
encoder shaft rotates. The frequency is rotated slowly.
varies directly with the speed of the Drive
Motor. The STM uses the quadrature
JPT6-5 NC Not connected to any circuitry on the NA NA NA

STM.
PT4- 1 SPARE I N 4 Input from optional switch connection. Switch Switch STM
Closed: <1 Vdc
Open: 5Vdc
PT4-3 DGND B- for optional switch <O.5Vdc wrt TP4 STM Switch
(B-1
PT4-5 SPARE IN 5 Input from optional switch connection Switch Switch STM
Closed: < 1 Vdc
Open: 5Vdc
PT4-7 DGND B- for optional switch <0.5Vdc wrt TP4 STM Switch
(B-1
PT4-2 SPARE I N 4 Input from optional switch connection Switch Switch STM
Closed: <1 Vdc
Open: 5Vdc
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPT3-2 12VP Supplies working voltage to the Steer +10.8 - 13Vdc STM Steer
Position Prox when B+Key is present on with key switch Position
the STM. If not present, check voltage at closed Prox
STM JPT9-6and see if IL1 is lit.
JPT3-1 STEER Output of Home Sensor Prox used by the Over metal= less Steer Steer
POSITION A ESM to determine if the drive unit is C W than 1V. Position Controller
or CCW of center. When over metal Not over metal= Prox Card
(CW), the switch is closed and the output 8V.
is low. When not over metal (CCW), the
switch is open and the output is hi.
JPT3-3 DGND DGND is the B- for the Steer Position Prox <O.SVdc wrt TP4 Steer STM
switch. It is connected through the STM. (B-) Position
Prox
JPT2-1 NC Not connected to any circuitry on the NA NA NA

STM.
JPT2-3 DGND The B- for the Steer Controller. It is <0.5Vdc wrt TP4 STM Steer
connected through the STM. (B-1 Controller
Card
JPT2-4 BUS+ The wire that carries the positive No useful STM/ STM/
component of the digital communications voltages are WGM WGM
between the STM and the Wire Guidance measurable
manager. N o usable information can be
gained by measuring the voltage on this
wire.
JPT2-2 BUS- The wire that carries the negative N o useful STM/ STM/
wire.
JPC1-11 LED 1 Takes LED 1 to B- when the C M wants it LED Off=13V Carriage Display
turned on. LED On=16.5V Manager Card
WRT B+
WRT B+
JPC 1-9 LED 3 Takes LED 3 to B- when the C M wants it LED Off=13V Carriage Display
turned on. LED On= 16.5V Manager Card
WRT B+
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPCld LED 6 Takes LED 6 to B- when the C M wants it LED Off=13V Carriage Display
WRT B+
WRT B+
JPC1 4 LED 8 Takes LED 8 to B- when the C M wants it LED Off=13V Carriage Display
WRT B+
WRT B+
WRT B+
JPC1-1 1 1.3 VP Supplies voltage to the lights on the +10.8 - 13Vdc Carriage Display
Display card when B+Key is present on with key switch Manager Card
the STM. closed
JPClO-1 B+F Supplies B+ for optional devices on the B+ with battery Carriage Optional
carriage like Bin Lights and RF terminals. plugged in. OV Manager Device
unplugged
JPC10-3 B- Supplies B- for optional devices on the <.5Vdc wrt TP4 Carriage Optional
carriage like Bin Lights and RF terminals. (B-) Manager Device
JPC1 0-2 B+F Supplies B+ for optional devices on the B+ with battery Carriage Optional
carriage like Bin Lights and RF terminals. plugged in. OV Manager Device
unplugged
JPC10-4 B- Supplies B- for optional devices on the <.5Vdc wrt TP4 Carriage Optional
carriage like Bin Lights and RF terminals. (B-) Manager Device
JPC9-2 B+F Same as JPTlO on the STM.
JPC9-4 B+KEY Same as JPTlO on the STM.
JPC9-3 B+ESTOP Same as JPTlO on the STM.
JPC9-1 B- Same as JPTlO on the STM.
JPC8-6 12VP Same as JPT9 on the STM.
JPC8-5 DEADMAN 2 Same as JPT9 on the STM.
JPC8-2 DGND Same as JPT9 on the STM.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
the steer wheel is spun by the operator.

The C M uses the quadrature phase
relationship between CH A & B to
determine direction and speed of steering
requested.
JPC2-2 DGND B- to the steer request encoder. <.5Vdc wrt TP4 Carriage Steer
(B-) Manager Request
Encoder
JPC2-3 SE 5V Positive supply from the C M power supply 4.5V to 5.5V Steer Carriage
to the steer request encoder. Request Manager
Encoder
JPC2-4 CHB This is a square wave generated Not turning= 5V Steer Carriage
whenever there is movement of the Steer or OV. Request Manager
Request Encoder. Voltage varies as the Turning= 2.2V Encoder
encoder shaft rotates. The frequency
varies directly with the speed the steer
wheel is spun by the operator. The C M
uses the quadrature phase relationship
between CH A & B to determine direction
and speed of steering requested.
JPC2-5 NC Not connected to any circuitry on the CM. NA NA NA

JPC6-3 11.3 VP Positive supply from the C M power supply +10.8 - 13Vdc Carriage Optional
for optional devices. with key switch Manager Device
closed
JPC6-1 SPARE Input from the S10 switch (optional). Switch closed S10 Carriage
<lVdc Switch Manager
Switch open
5Vdc
JPC6-2 DGND B- to the optional S10 switch. <0.5Vdc wrt TP4 Carriage S10 Switch
(B-1 Manager
JPC3-6 1 1.3 VP Positive supply from the STM power +10.8 - 13Vdc Carriage S60 Switch
supply for the optional S60 switch. with key switch Manager
closed
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPC3-2 NC Not Connected NA NA NA

JPC3-3 W/G AUTO Input from the S61 switch (optional wire Switch closed Carriage S61 Switch
MANUAL guidance auto manual switch). <lVdc Manager
Switch open
5Vdc
JPC3-1 DGND B- to the S61 switch (optional wire e0.5Vdc wrt TP4 Carriage S61 Switch
guidance auto manual switch). (B-1 Manager
JPC3-8 NC Not connected to any circuitry on the CM.
JPC3-4 NC Not connected to any circuitry on the CM.
JPC1 1-5 B+F Supplies B+ to the key switch on the B+ with the Carriage Key Switch
carriage via the over mast cable. B+ is battery plugged Manager
supplied from FU2 on the STM. in. 0 with battery
disconnected
JPC11-1 B+KEY Supplies B+ Key to the circuitry on the B+ with key Key Carriage
Carriage Manager and STM via the over switch closed. Switch Manager
mast cable when the key switch is closed. OV with key
switch open.
JPC1 1-2 B+KEY Supplies B+ Key to the EPO switch. B+ with key Carriage EPO Switch
switch closed. Manager
OV with key
switch open.
JPC1 1-3 B+ESTOP Supplies B+ ESTOP to the circuitry on the B+ with the EPO EPO Carriage
Carriage Manager and through the over switch closed. Switch Manager
mast cable to the STM when the EPO OV with the EPO
switch (S21 ) is closed. Open
JPC1 1 4 NC Not connected to any circuitry on the CM.
JPC1 3-7 POT 5V Supply voltage from the C M power supply 4.5 To 5.5V Carriage VR1
for the Travel potentiometer VR1. Manager
JPCl3-1 TRAVEL Variable voltage from VR1 wiper. The Neutral= 1.2V VR1 Carriage
REQUEST Carriage Manager monitors this voltage Full Tractor First= Manager
and translates it into a communication 0.5V
input to the STM. The STM determines the Full Forks First=
requested travel direction and speed 2.2V
based on the learn values stored in the
STM.
JPC 1 3-5 DGND B- for VR1, Travel potentiometer. e.5Vdc wrt TP4 Carriage VR1
(B-1 Manager
JPC1 3-8 POT 5V Supply voltage from the C M power supply 4.5V to 5.5V Carriage VR2
for the Travel potentiometer VR2. Manager
00700-CL222-05, 1 5 March 2005 9-6 3

Pinout Matrix
input to the STM. The STM determines the

request for lift or lower and speed based
on the learn values stored in the STM.
Second speed shift or lower is activated at
about 50% of the stroke on the pot.
JPC1 3-3 HORN Input from the S3 horn switch. Switch closed S3 Carriage
<lVdc Manager
Switch open
5Vdc
JPC1 3-2 DGND B- for the horn switch. <0.5Vdc wrt TP4 Carriage S3
(B-1 Manager
JPC5-3 LIFT/LOWER Input from the optional lift lower limit Switch closed S5 1 Carriage
LIMIT BYPASS bypass switch, S5 1 . <lVdc Manager
Switch open
5Vdc

JPC5-1 DGND B- for the optional lift/lower limit bypass <O.SVdc wrt TP4 Carriage S5 1
switch. (B-1 Manager
JPC7-2 1 1.3 VP Positive supply from the STM power + 10.8 - 1 3Vdc Carriage S2
supply for S2 Deadman 1 switch. with key switch Manager
closed
JPC7-1 DEADMAN 1 Input from the S2 Deadman 1 switch. Switch closed S2 Carriage
<lVdc Manager
Switch open
5Vdc
JPC7-3 DGND 6- to the S2 Deadman 1 switch. <O.SVdc wrt TP4 Carriage S2

(B-1 Manager
JPC7-5 1 1.3 VP Positive supply from the STM power +10.8 - 13Vdc Carriage S23
supply for the S23 Deadman 2 switch. with key switch Manager
closed
JPC7-6 DEADMAN 2 Input from the S23 Deadman 2 switch. Switch closed S23 Carriage
<lVdc Manager
Switch open
5Vdc
JPC7-4 DGND B- to the S23 Deadman 2 switch. <0.5Vdc wrt TP4 Carriage S23
(B-1 Manager
supply for the S6, 2 4 inch switch. with key switch Manager
closed
00700-CL222-05, 1 5 March 2005

Pinout Matrix
supply for the S7 switch, 6 0 in. switch. with key switch Manager
closed
JPC7-12 HEIGHT 6 0 in. Input from the 6 0 inch switch, S7. Switch closed S7 Carriage
SW e1Vdc Manager
Switch open
5Vdc
JPC7-10 DGND B- to the 60 in. switch, S7. cO.5Vdc wrt TP4 Carriage S7
(B-1 Manager
JPC1 2-6 1 1.3 VP Positive supply from the STM power +10.8 - 13Vdc Carriage S19
supply for the optional S19 Sidegate 1 with key switch Manager
switch. closed
JPC12-7 SIDEGATE 1 Input from the S19 Sidegate 1 switch Switch closed S19 Carriage
(optional). c1Vdc Manager
Switch open
5Vdc
JPC1 2-8 DGND B- to the optional S19 switch. e0.5Vdc wrt TP4 Carriage S19
(B-1 Manager
JPC12-15 11.3 VP Positive supply from the STM power +10.8 - 13Vdc Carriage S20
supply for the optional S20 Sidegate 2 with key switch Manager
switch. closed
JPCl2-16 SIDEGATE 2 Input from the S20 Sidegate 2 switch Switch closed S20 Carriage
(optional). c1Vdc Manager
Switch open
5Vdc
JPCl2-14 DGND B- to the optional S20, Sidegate 2 switch. e0.5Vdc wrt TP4 Carriage S20
(B-) Manager
JPCl2-17 N/C Not connected to any circuitry on the CM.
JPC12-10 SPARE Not used for anything.
JPC1 2-9 B+ESTOP B+ supply for the optional lift/lower B+ with the EPO Carriage Lift Lower
alarm. switch closed. Manager Alarm
OV with the EPO
Open
JPCl2-18 LIFT/LOWER Path for the Carriage Manager to supply Alarm O N - B+ Carriage Lift Lower
ALARM B- to the lift lower alarm. There will be B+ Alarm OFF - OV Manager Alarm
measured here with no command to wrt B+
activate the alarm and it will drop to OV
when the C M takes it to B-.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
her side you should see around
1.5 in. to the right you should see around

15mVAC. 1.5 in. left you should see
around 75mVAC.
JPW2-5 TO Communication lines used by the steer No useful Steer Antenna

controller card to tell the antenna card voltages are Controller Card
which frequency it should be looking for. measurable Card
JPW2-6 T1 Communication lines used by the steer N o useful Steer Antenna



JPW2-14 AGRD B- to the antenna card. <O.SVdc wrt TP4 Steer Antenna
(B-1 Controller Card
Card
JPW2-15 12 V Positive supply from the steer controller +10.8 - 13Vdc Steer Antenna
card power supply for the antenna card. with key switch Controller Card
closed Card
JPW2-13 SHIELD Shield that helps reduces noise <O.SVdc wrt TP4 Steer Antenna
interference in the AC voltage from the (B-) Controller Card
antenna card. It must be connected to B- Card
on the at the filter card connection only.
JPW1-1 RIGHT This is the input from the left tractor sensor Antenna Filter Card
coil to the filter card. Centered over the Card
wire you should see around 32mVAC.
1.5 in. to the right you should see around
15mVAC. 1.5 in. left you should see
around 75mVAC.
00700-CL222-05, 1 5 March 2005

Pinout Matrix
JPW1-15 12 V Positive supply for the antenna card from +10.8 - 13Vdc Steer Antenna
the wire guidance manager power supply. w/key switch Controller Card
closed Card
JPW1-13 SHIELD Shield that helps reduces noise <0.5Vdc wrt TP4 Steer Antenna
interference in the AC voltage from the (B-) Controller Card
antenna card. It must be connected to B- Card
on the at the filter card connection only.
JPS1-8 SPEEDFB A This is a square wave generated Sitting still either Steer Steer
whenever the drive motor is spinning. less than lVdc or Feedback Controller
Voltage varies between OVdc and 6.5Vdc approx. 6.5Vdc. Encoder Card
as the armature shaft rotates. The Full throttle
frequency varies directly with the speed. approx. 3.0Vdc
The steer controller uses the quadrature
00700-CL222-05, 1 5 March 2005

Pinout Matrix
relationship between CH A & B to

JPS1-19 12 V Positive supply for the steer motor encoder +10.8 - 13Vdc Steer Steer
from the wire guidance manager power w/key switch Controller Feedback
supply. closed Card Encoder
JPS1-12 GND B- for the steer feedback encoder. <O.SVdc wrt TP4 Steer Steer
(B-1 Controller Feedback
Card Encoder
JPS1-13 NC Not connected to any circuitry.
JPS4-1 TERM Terminating resistor for the communication Steer Steer

system. Controller Controller
Card Card
JPS4-4 RES Terminating resistor for the communication Steer Steer

system. Controller Controller
Card Card
JPS4-3 DGND B- supplied to the steer controller from the <O.SVdc wrt TP4 STM Steer
STM. (B-1 Controller
Card
JPS4-6 BUS+ The wire that carries the positive N o useful STM/ STM/
wire.
JPS4-5 BUS- The wire that carries the negative N o useful STM/ STM/
wire.
JPS2-24 B- B- supplied to the steer controller from the <O.SVdc wrt TP4 STM Steer
STM. (B-1 Controller
Card
JPS2-11 B+ESTOP B+ supply for the power supply on the B+ EPO closed STM Steer
steer controller card. OV EPO Open Controller
Card
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Section 10. Firmware Configuration
Section 10. Firmware Configuration
00700-CL222-05, 1 5 March 2005

Section 10. Firmware Configuration Toyota Orderpicker Model 7BPUE15 Service Manual
FlashWare Program
FlashWare Program
ACAUTION
We recommend using a surge protector
Overview (P/N 00590-43592-71) to protect your
PC from possible electrostatic discharge
The FlashWare program allows you to update or voltage surge.
software, configure options and troubleshoot
electrical components on your Orderpicker 3. Connect a standard 9-pin serial cable to
truck through the following features: the surge protector.
Flash memory program 4. Connect the cable to PT1 a t the top,
Clear primary memory outside edge of the steer/tractor manager.
There is a cutout in the card cover for the
Setup configurable items cable.
Options and serial number
Learn throttle
Diagnostics
Requirements
FlashWare can be installed on an
IBM-compatible PC. The PC communicates with
the truck software through a 9-pin serial cable.
We recommend using a surge protector

(P/N 00590-43592-71) to protect your
PC from possible electrostatic discharge
or voltage surge. Figure 10- 1 . Steer/Tractor Manager (Cover Removed]
Install Flashware on PC 5. Turn the key switch ON.
If you are a customer service technician, obtain Starting Flashware

FlashWare from your Toyota Dealer.
To start MashWare, click the desktop icon or
To install MashWare on the PC, double-click the via Start > Programs > Flashware.
installation file and follow the instructions on
the screen. The software package is a
self-extracting executable file. Read the FlashWare Functions
"Readme" file in the software package for the
latest detailed installation instructions. Follow the instructions in the Online Help.
PC Connection to Truck
1. Turn the truck key switch OFF.
2. Connect the surge protector to the COM I
or COM 2 port of your computer.
00700-C L2 2 2-05, 1 5 March 2 005

Toyota Orderpicker Model 7BPUE15 Service Manual Section A. Appendix
Section A. Appendix
00700-CL222-05, 1 5 March 2005

Section A. Appendix Toyota Orderpicker Model 7BPUE 15 Service Manual
Lubrication Specification Chart
Lubrication Specification
Chart
Drive Unit Gear Case Synthetic 75W-90 Gear oil 00590-04835-71

(below 30" F/- l oC) Gear Oil API Service CE,CD,CC,SG,SF (1 qt./0.9 liter)
(above 30" F/- 1" C) 00590-04837-71
(5 gal./ 18.9 liters)
Lift Chains Oil 10W-30 Motor Oil 00590-04835-71
API Service CE,CD,CC,SG,SF (1 qt./0.9 liter)
00590-04837-71
(5 ga1./18.9 liters)
Hydraulic Reservoir Hydraulic IS046 00590-04934-71
(non-cold storage trucks) Fluid (1 qt./0.9 liter)
(+50°F to + 120"F) 00590-04840-71
(+10°C to +4g0C (5 ga1./18.9 liters)
Hydraulic Reservoir (Class I1 Hydraulic MIL-H-5606A 00590-04841-71
cold storage trucks) Fluid (1 gal. /3.8 liters)
(-20"F to 0" F)
(-29"C to - 18"C)
(confined to freezer)
Hydraulic Reservoir (Class I11 Hydraulic IS0 32 00590-04842-71
cold storage trucks) Fluid (1 gal. /3.8 liters)
(-20"F to +70°F) 00590-04843-71
(-29"C to +21°C) (5 ga1./18.9 liters)
(in and out of freezer)
Hydraulic Reservoir Hydraulic 1OW-30 Motor Oil 00590-04842-71
(for extreme heating Fluid API Service CE,CD,CC,SG,SF (1 gal. /3.8 liters)
conditions) 00590-04843-71
00590-04844-71
(10 cartridges per case)
00590-04845-71
00700-C L2 2 2-05, 1 5 March 2 005

Torque Chart - Standard (Ferrous)
Torque Chart - Standard

(Ferrous)
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
5/16-18 11 8 17 13 25 18
1 1/2-6 740 560 1940 1460 3160 2360

1 1/2-12 840 620 2200 1640 3560 2660
Figure A- 1 . Torque Chart - Standard
Figure A- 1 (Conk).* NOTE: Use " o i l e d values for bolts with thread locking compound
00700-CL222-05, 1 5 March 2005

Section A. Appendix Toyota Orderpicker Model 7BPUE15 Service Manual
Torque Chart - Standard (Brass)
Torque Chart - Standard

(Brass)
Figure A-2. Torque Chart - Standard Brass
Figure A-2 (Cont.). * NOTE: Use "oiled" values for bolts with thread locking compound
00700-C L2 2 2-05, 1 5 March 2 005

Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix
Torque Chart - Metric
Torque Chart Metric -
Figure A-3. Torque Chart - Ferrous Metric
Figure A-3 (Conk).* NOTE: Use " oiled values for bolts with thread locking compound
Figure A-4. Torque Chart - Brass Metric
Figure A-4 (Conk).* NOTE: Use " oiled values for bolts with thread locking compound
00700-CL222-05, 1 5 March 2005

Decimal Equivalent Chart
4ths Sths 16ths 32nds

1 64ths 1 To 3
places 1 Places
1 MM Equivalent 1)
Figure A-5. Decimal Equivalent Chart
00700-CL2 22-05, 1 5 March 2 005

Figure A-5. Decimal Equivalent Chart
00700-CL222-05, 1 5 March 2005

Standard/Metric Conversions
Standard/Metric
Conversions
.
To Convert.. .
Multiply..
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094

Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155

Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
1 Quarts to Liters 1 Quarts x 0.946 I

Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26
Ounces to grams Ounces x 28.35

Grams to ounces Ounces x 0.035
Ounces to kilograms Ounces x 0.028
Table A- 1
00700-C L2 2 2-05, 1 5 March 2 005

Toyota Orderpicker Model 7BPUE 15 Service Manual Section A. Appendix
To Convert... Multiply...
Kilograms to ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to pounds Kilograms x 2.2
Pounds per Square Inch (PSI) to Kilopascals (kPa) Pounds per Square Inch x 6.894
Kilopascals to Pounds per Square Inch Kilopascals x 0.145
Pounds per Square Inch (PSI) to Kilograms per square Pounds per Square Inch (PSI) x 0.0704
centimeter (kg/cm2)
Kilograms per square centimeter (kg/cm2) to Pounds Kilograms per square centimeter (kg/cm2)x 14.2
per Square Inch (PSI)
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.1 13
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lbs.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Miles per hour to kilometers per hour Miles per hour x 1.609
Kilometers per hour to miles per hour Kilometers per hour x 0.6214
Fahrenheit to Celsius (OF - 32) x 0.555
Celsius to Fahrenheit ("Cx 1.8) + 32
Table A- l
00700-CL222-05, 1 5 March 2005

00700-C L2 2 2-05, 1 5 March 2 005

Electrical Schematics
Electrical Schematics
00700-CL222-05, 1 5 March 2005

STEERnRACTOR
MANAGER
DGND
12VP
AGND
STEER DIRI
STEER DIR2
STEER DIRl P W M
STEER DR2 P W M
BOOST +
BOOST
STEER CURRENT LIMIT HEARTBEAT
STEERCURRENT FB
NC
@0
113
NC
NC
NC PC L6lO
DISABLE
K DRIVE
BiKEY
@
IL5 1
FFVREVERSE
TRAVEL REQ
TRAVEL REF
MDA2SENSE 1
WARN
ni\lN: I:HI:IU~IIO\ rn 0
116 1
B+ESTOP RELAY
L/H
L/H SOL CTRL rn 0
1169
PC CTRL
116 8 FU1
BRAKECTRL rn '?
1164
1
SPARE CTRL
NC 2g
B*HoRN HORN
HORN C P l rn 0
Lb 6
B
B
B
PSENSE
PCSENSE
B+PC
B+
B+
12VP
HOUR METER ENABLE
DGND 1
POWER SUPPLY
NC
TXD
DSR
RTSIBOOT
NC 118
1
jBoosTl
BOOST
12VP
Figure A-6. Elec. Schematic, Sheet I , Part I of 2
A-1 2 00700-CL222-05, 1 5 March 2005

Figure A-6 (Cont.). Elec. Schematic, Sheet I , Part 2 of 2
00700-CL222-05, 1 5 March 2005

--------
CONTROL HANDLE
SPL5 I
JPC2 12
r - - - - - -WIRE
- -GUIDANCE
- - - - MANAGER
----- (OPTION)
---
IS1
-
NEAR WIRE
LEFT
OTM
WIRES
AGRD
+12v
I
TP4
COLD STORAGE TRACTOR 11

12
FU12 lH2 HTR3
r-----i 13
AGRD
PC-I -
I
I
I
I
I
I
I
I
TPd
I
I
I
I
I
I
I
I
TS 1 I
IEE ONLY1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L--------------------
Figure A-7. Elec. Schematic, Sheet 2, Part I of 2
A-14 00700-CL222-05, 1 5 March 2005

COLD STORAGE LIGHTS AND FAN (OPTION)
................................
I SUPPRESSOR I
I . -NETWORK
----- FAN I
I TOFU92
I ITS1 2, EE ONLY)
I
I ITS l 3 &%'N"$p' [-----A
I
I
I SUPPRESSOR I
I . -NETWORK
----- I
I
I I
I LIGHTS I
I I
I I
I I
I
I I
L------------------------------J
STANDARD LIGHTS AND FAN (OPTION)

................................
I SUPPRESSOR I
I NETWORK FAN I
I TOFU92
I ITS1 2, EE ONLY)
I I
I TOFUlO2
ITS1 3, EE ONLY)
I
I SWITCH
I SUPPRESSOR
I NETWORK FAN I
I
I
I
I
I
I UGHT
I SWITCH
I
L------------------------------J
Figure A-7 (Cont.). Elec. Schematic, Sheet 2, Part 2 of 2
00700-CL222-05, 1 5 March 2005

IDENT. SHEET ZONE DESCRIPTION
JPIL 2 D3 LOAD ANTENNA CONNECTOR TO FILTER CARD
JPIT 2 D2 TRACTOR ANTENNA CONNECTOR TO FILTER CARD
JPSl 2 E4 TRAVEL SPEED ENCODER CONNECTION TO GUIDANCE MANAGER
JPS2 2 E6 POWER TO GUIDANCE MANAGER
JPS4 2 E5 GUIDANCE MANAGER CONNECTION TO CAN
JPT2 1 E7 STEER/TRACTOR MANAGER CONNECTOR FOR CAN INTERFACE

JPT3 1 E6 STEER/TRACTOR MANAGER CONNECTOR FOR HOME SENSOR STEER
JPT4 1 E5 STEERnRACTORMANAGER CONNECTOR [SPARE]
JPT5 I E2 STEER/TRACTOR MANAGER CONNECTOR FOR MAST LIMIT SWITCHES, LIFT LIMIT SWITCH
JPT6 1 E5 STEER/TRACTOR MANAGER CONNECTOR FOR STEER ENCODER FEEDBACK
JPT7 1 E3 STEERnRACTORMANAGER CONNECTOR [SPARE]
JPTB 1 C2 STEERnRACTORMANAGER CONNECTOR FOR STEER POWER HEAD
JPT9 1 E4 STEER/TRACTOR MANAGER CONNECTOR FOR MAST CABLE 1 (SIGNALS]
JPTIO 1 E4 STEER/TRACTOR MANAGER CONNECTOR FOR MAST CABLE 1 (POWER]
JPTl 1 1 C3 STEERnRACTORMANAGER CONNECTOR FOR TRACTION POWER AMP
JPT12 1 C4 STEERnRACTORMANAGER CONNECTOR FOR POWER & DRIVERS
PS 1 1 C2 STEER/POWER HEAD CONNECTOR

JS1 2 E2 FILTER CARD AND GUIDANCE MANAGER INTERFACE
JT 1 1 C7 STEER/TRACTOR MANAGER CONNECTOR FOR COMPUTER INTERFACE
JPWl 2 D3 FILTER CARD CONNECTOR TO LOAD ANTENNA

JPW2 2 02 FILTER CARD CONNECTOR TO TRACTOR ANTENNA
KI 1 D4 STEERnRACTORMANAGER BtESTOPRELAY
L/H SOL 1 C5 LOAD HOLD SOLENOID
L/L SOL 1 C5 LFT/LOWER PROPORTIONAL SOLENOID
MD 1 Bd DRIVE MOTOR
MP 1 64 LIFT PUMP MOTOR
MS 1 63 STEER MOTOR
P 1 63 PUMP CONTACTOR CONTACTS

P 1 C4 PUMP CONTACTOR COR
PC 1 A3 POWER CUTOFF CONTACTOR CONTACTS

PC 1 C5 POWER CUTOFF CONTACTOR COIL
PC~1 2 A2,A4 COLD STORAGE OPTIONS CONNECTION
S1 1 H3 KEY SWITCH
S2 1 H5 DEADMAN l SWITCH
S6 1 H5 24'' LIMIT SWITCH (LOCATEDON CARRIAGE)
S7 1 H6 60'' LIMIT SWITCH 1 [LOCATED ON CARRIAGE)
58 1 E6 HOME POSITION SWITCH
S19 1 H6 SIDEGATESWITCH 1 [OPTION]

S20 1 H6 SIDEGATESWITCH 2 [OPTION]
52 1 1 H4 EPO [EMERGENCY POWER OFF] SWITCH
523 1 H5 DEADMAN 2 SWITCH
S24 1 E3 LIFT LIMIT SWITCH [OPTION]
S25 1 E3 180' LIMIT SWITCH (LOCATEDON MASTj
526 2 C6 BIN LIGHT SWITCH [OPTION]
527 2 E2 BIN LIGHT SWITCH [OPTION]
S29 1 02 120"/150' LIMIT SWITCH (LOCATEDON MAST]
S5 1 1 H5 LIFT/LOWER LIMIT BYPASS SWITCH (OPTION]
560 1 H3 LOWER LIMIT SWITCH
56 1 1 H3 W/G AUTO MANUAL SWITCH
SPLl 2 63 SPLICE FOR DEADMAN HEATER (COLD STORAGE OPTION]

SPL2 2 C3 SPLICE FOR DEADMAN HEATER [COLD STORAGE OPTION]
SPL3 1 C5 SPLICE FOR POWER TO GUIDANCE MANAGER
SPL5 2 C2 SPLICE FOR HEATER IN HANDLE (COLD STORAGE OPTION)
TA 1 C5 TRAVEL ALARM [OPTIONAL]
THI 2 62 THERMOSTAT FOR CARRIAGE HEATERS [COLD STORAGE OPTION]

TH2 2 64 THERMOSTAT FOR TRACTOR HEATERS (COLD STORAGE OPTION]
TH3 2 62 THERMOSTAT FOR CONTROL HANDLE HEATER (COLD STORAGE OPTION]
TP 1 1 A3 TIE POINT FOR TRACTION POWER FUSE (FUB]

TP2 1 63 TIE POINT FOR STEER POWER FUSE [FU4]
TP3 1 63 TIE POINT FOR LIFT PUMP POWER FUSE [FU5]
TP4 1 64 TIE POINT FOR B-
TP4 2 A3,AS TIE POINT FOR B-
TS 1 2 65 TERMINAL STRIP FOR OPTIONAL POWER (EE OPTION]
VRI 1 H4 CONTROL HANDLE TRAVEL REQUEST VARIABLE RESISTOR
VR2 1 H4 CONTROL HANDLE LIFT REQUEST VARIABLE RESISTOR
WL 1 C5 WARNING LIGHT
Figure A-8 (Cont.). Elec. Schematic, Legend, Part 2 of 2
00700-CL222-05, 1 5 March 2005

Hydraulic Schematic
RES
Figure A-9. Hydraulic Schematic
00700-CL222-05, 1 5 March 2005

Toyota Orderpicker Model 7BPUE15 Service Manual Index
Index
Chains
2-Stage . . . . . . . . . . . . . . . . . . . . 7-93
.
Air Gap Adjustment. Brake . . . . . . . . 7-27 Center Cylinder. 3-Stage . . . . . . . .7-91
Anti-Static Kit . . . . . . . . . . . . . . . 2.9. 2-10 Side Cylinders. 3-Stage . . . . . . . . .7-91
Armature . . . . . . . . . . . . . . . . . . . . . 5-12 Circuit Cards . . . . . . . . . . . . . . . . . . 7 . .52
Auto/Manual Switch . . . . . . 8.2.8.7.8-40 Carriage Manager . . . . . . . . . . . . .6-40
Filter Card . . . . . . . . . .8-3. 8.28. 8-40
Steer Controller . . . . . . . . . . 8.3. 8-41
Steer/Tractor Manager . . . . 6.40. 6-43
Cleaning. Motor . . . . . . . . . . . . . . . . .7-35
Battery . . . . . . . . . . . . . . . . . 7-32 to 7-34 Code 1.1 TPA . . . . . . . . . . . . . . . . . . . 6 ..8
Charging . . . . . . . . . . . . . . . . . . . 7-34 Code 1.2 TPA . . . . . . . . . . . . . . . . . . . 6 ..8
Cleaning . . . . . . . . . . . . . . . . . . . 7-33 Code 1.3 . . . . . . . . . . . . . . . . . . . . . . .6.16
Indicator Messages . . . . . . . . . . . . 6-2 Code 1.3 TPA . . . . . . . . . . . . . . . . . . . 6 ..9
Fault Code . . . . . . . . . . . . . . . . 6-3 Code 1.4 . . . . . . . . . . . . . . . . . . . . . . 6
..17
Info Display . . . . . . . . . . . . . . . 6-3 Code 1.5 . . . . . . . . . . . . . . . . . . . . . . 6
..18
Install . . . . . . . . . . . . . . . . . . . . . 7-33 Code 1.6 . . . . . . . . . . . . . . . . . . . . . . 6
..19
Remove . . . . . . . . . . . . . . . . . . . . 7-32 Code 1.8 . . . . . . . . . . . . . . . . . . . . . . 6
..20
Rollers Code l.P . . . . . . . . . . . . . . . . . . . . . . 8
..15
Inspect . . . . . . . . . . . . . . . . . . 7-33 Code 2.1 . . . . . . . . . . . . . . . . . . . . . . 6
..2 1
Replace . . . . . . . . . . . . . . . . . 7-33 Code 2.1 TPA . . . . . . . . . . . . . . . . . . . 6 ..9
Safety . . . . . . . . . . . . . . . . . 2-6 to 2-8 Code 2.2 . . . . . . . . . . . . . . . . . . . . . . 6
..22
Theory . . . . . . . . . . . . . . . . . 9-4 to 9-9 Code 2.3 . . . . . . . . . . . . . . . . . . . . . . 6
..23
Bearings Code 2.4 . . . . . . . . . . . . . . . . . . . . . . 6
..24
Mast. Shimming . . . . . . . 7-85 to 7-90 Code 2.5 . . . . . . . . . . . . . . . . . . . . . . 6
..25
Bearings. Mast . . . . . . . . . . . . . . . . . 7-85 Code 2. 6 . . . . . . . . . . . . . . . . . . . . . .6
..26
Bleeding the Hydraulic System . . . . . 7-64 Code 2. 6 TPA . . . . . . . . . . . . . . . . . . .6.10
Blocking . . . . . . . . . . . . . . . . 2- 1 1 to 2-12 Code 3.1 . . . . . . . . . . . . . . . . . . . . . . 6
..27
Brake . . . . . . . . . . . . . . . . . . 7-27 to 7-29 Code 3.2 . . . . . . . . . . . . . . . . . . . . . . 6
..28
Air Gap Adjustment . . . . . . . . . . . 7-27 Code 3.3 . . . . . . . . . . . . . . . . . . . . . . 6
..30
Assembly . . . . . . . . . . . . . . . . . . . 7-29 Code 3.3 TPA . . . . . . . . . . . . . . . . . . .6.11
Disassembly . . . . . . . . . . . . . . . . 7-28 Code 3.4 . . . . . . . . . . . . . . . . . . . . . . 6
..32
Friction Plate . . . . . . . . . . 7-28 to 7-29 Code 3.5 . . . . . . . . . . . . . . . . . . . . . . 6
..33
Inspection. Disassembled . . . . . . 7-28 Code 3. 6 . . . . . . . . . . . . . . . . . . . . . .6
..34
Brake Switches Code 3.7 . . . . . . . . . . . . . . . . . . . . . . 6
..35
Theory . . . . . . . . . . . . . . . 9-16 to 9-21 Code 4.1 . . . . . . . . . . . . . . . . . . . . . . 6
..36
.
Brushes Motor . . . . . . . . . . . 7-35 to 7-37 Code 4.1 TPA . . . . . . . . . . . . . . . . . . .6.12
Code 4.2 . . . . . . . . . . . . . . . . . . . . . . 6
..38
Code 4.2 TPA . . . . . . . . . . . . . . . . . . .6.12
Code 4.3 . . . . . . . . . . . . . . . . . . . . . . 6
..39
Carriage Code 4.3 TPA . . . . . . . . . . . . . . . . . . .6.13
2-Stage . . . . . . . . . . . . . . 7-82 to 7-83 Code 4. 6 . . . . . . . . . . . . . . . . . . . . . .6
..40
3-Stage . . . . . . . . . . . . . . 7-74 to 7-76 Code 4.8 . . . . . . . . . . . . . . . . . . . . . . 6
..41
Carriage Manager . . . . . . . . . . . . . . . 6-46 Code 5.1 . . . . . . . . . . . . . . . . . . . . . . 6
..42
Communication . . . . . . . . . . . . . . 6-40 Code 5.2 . . . . . . . . . . . . . . . . . . . . . . 6
..43
Caution. Definition . . . . . . . . . . . . . . . 2-2 Code 5.3 . . . . . . . . . . . . . . . . . . . . . . 6
..44
Center Cylinder . . . . . . . . . . . 7-69 to 7-70 Code 5.4 . . . . . . . . . . . . . . . . . . . . . . 6
..45
Code 5.5 . . . . . . . . . . . . . . . . . . . . . . 6
..46
Code 6.1 . . . . . . . . . . . . . . . . . . . . . . 6
..47
00700.CL222.05, 1 5 March 2005

Index Toyota Orderpicker Model 7BPUE15 Service Manual
Code 6. 2 . . . . . . . . . . . . . . . . . . . . . . . 6.49 Definitions . . . . . . . . . . . . . . . . . . . . .5-17

Code 6.3 . . . . . . . . . . . . . . . . . . . . . . 6.50. Design. Manual . . . . . . . . . . . . . . . . . .1-4
Code9.1 . . . . . . . . . . . . . . . . . . . . . . 8-16 . Diagnostic History . . . . . . . . . . . . . . . 5-20
Code 9. 2 . . . . . . . . . . . . . . . . . . . . . . 8.17
. Directional/Speed Control. Theory 9-22 to 9-27
Code 9.3 . . . . . . . . . . . . . . . . . . . . . . .8. 19 Drive Tire . . . . . . . . . . . . . . . .7-25 to 7-26
Code9.4 . . . . . . . . . . . . . . . . . . . . . . 8-20 . Drive Unit . . . . . . . . . . . . . . . . . . . . .7-24
Code9.6 . . . . . . . . . . . . . . . . . . . . . . 8-21 . Troubleshooting . . . . . . . . . . . . . . 5-25
Code 9.8 . . . . . . . . . . . . . . . . . . . . . . 8.23. Drive Wheel . . . . . . . . . . . . . . 7-25 to 7-26
Code9.C . . . . . . . . . . . . . . . . . . . . . . 8-24 . Duty Cycle . . . . . . . . . . . . . . . . . . . . . .4-2
Code9.E . . . . . . . . . . . . . . . . . . . . . . 8-26 .
Code9.F . . . . . . . . . . . . . . . . . . . . . . 8-28 .
Code9.H . . . . . . . . . . . . . . . . . . . . . . 8-29 .
Code 9.J . . . . . . . . . . . . . . . . . . . . . . 8.3 . 1 EE Label. UL . . . . . . . . . . . . . . . . . . . . 4-2
Code9.K . . . . . . . . . . . . . . . . . . . . . . 8-33 . Electric Motor Tests . . . . . . . . . . . . . . 5-11
Code LED Heartbeat TPA . . . . . . . . . . .6.7 Electrical Connector Locator . 5-18 to 5-19
Code LED Off TPA . . . . . . . . . . . . . . . . 6.6 . Electrical Troubleshooting
Code LED Solid On TPA . . . . . . . . . . . .6.7 Symptoms . . . . . . . . . . . . . . . . . .5-34
Cold Storage . . . . . . .3.9 to 3- 10. 4.2. 5- 18 Electrostatic Discharge . . . . . . . . . . . . 2-9
Communication . . . . . . . . . . . . . . . . .6.40 Emergency Lowering m o b . . . . . . . . . 7-61
Commutator. Motor . . . . . . . . . . . . . .7.38 Emergency Power Off Switch . . . . . . . 6-19
Component Locator Photos . . . . . . . . . .7.5
Encoder
Configuration. Software . . . . . . . . . . .6.45 Speed Feedback . . . . . . . . . . . . . .8-42
Contactors . . . . . . . . . . . . . . .7.46 to 7-49 Test . . . . . . . . . . . . . . . . . . . .8-35
Inspecting . . . . . . . . . . . . . . . . . . .7.46
Steer
Lift . . . . . . . . . . . . . . . . . . .6.16. 6-17 Test. Maintenance Mode . . . . . . 6-5
PC . . . . . . . . . . . . . . . .6.22. 6.38. 6-39 Steer Feedback . . . . . . . . . . . . . . .8-41
Testing . . . . . . . . . . . . . . . . . . . . 5-15 . Test . . . . . . . . . . . . . . . . . . . .8-35
Tip Replacement . . . . . . . .7.48 to 7-49
Steer Handle . . . . . . . . . . . . . . . .6-27
Continuity. Definition . . . . . . . . . . . . .5. 17 ESD. See Electrostatic Discharge
Control Handle
Cleaning . . . . . . . . . . . . . . . . . . . 7.2 . 1
Inspection . . . . . . . . . . . . . . . . . . 7.2 . 1
Installation . . . . . . . . . . . . . . . . . 7.22 .
Lift/Lower b o b . . . . . . . . . . . . . .7.2 1
Removal . . . . . . . . . . . . . . . . . . . 7. . 17
Repair/Replacement Procedures
. . . . . . . . . . . . . . . . . . 7. 17 to 7-22
Soldering Procedures . . . . . . . . . . .7.22
Travel Pot Repair/Replace . . . . . . .7. 19
Conversions. Standard/Metric . . . . . . .A.8
COP. Steer/Tractor Manager . . . . . . . .6.43
Covers
Operator Console . . . . . . . . . . . . .7. 12
Tractor . . . . . . . . . . . . . . . . . . . . 7. . 11
Cylinders
Center . . . . . . . . . . . . . . . .7.69 to 7-70
Side . . . . . . . . . . . . . . . . 7.65 . to 7-68
Decals . . . . . . . . . . . . . . . . . . . . . . . 7.
. 14
Decimal to Fraction Conversion . . . . . .A.6
00700.CL222.05, 1 5 March 2005

Code 1.3 . . . . . . . . . . . . . . . . . 6 ..9

Code 1.4 . . . . . . . . . . . . . . . . . 6 ..9
Fault Codes Code 2. 6 . . . . . . . . . . . . . . . . .6.10
Guidance Manager Code 3.3 . . . . . . . . . . . . . . . . .6.11
Code 1.P . . . . . . . . . . . . . . . .8-15 Code 4.1 . . . . . . . . . . . . . . . . .6.12
Code9.1 . . . . . . . . . . . . . . . .8-16 Code 4.2 . . . . . . . . . . . . . . . . .6.12
Code9.2 . . . . . . . . . . . . . . . .8-17 Code 4.3 . . . . . . . . . . . . . . . . .6.13
Code9.3 . . . . . . . . . . . . . . . .8-19 Code Heartbeat . . . . . . . . . . . . .6.7
Code 9.4 . . . . . . . . . . . . . . . .8-20 Code LED Off . . . . . . . . . . . . . .6.6
Code 9.6 . . . . . . . . . . . . . . . .8-21 Code Solid On . . . . . . . . . . . . . .6.7
Code 9.8 . . . . . . . . . . . . . . . .8-23 Traction Power Amplifier . . . . . . . . .6.6
Code 9.C . . . . . . . . . . . . . . . .8-24 Field Winding . . . . . . . . . . . . . . . . . . .5 .12
Code 9.E . . . . . . . . . . . . . . . . 8-26 Filter Card . . . . . . . . . 8.2. 8.3. 8.28. 8-40
Code 9.F . . . . . . . . . . . . . . . .8-28 Install . . . . . . . . . . . . . . . . . . . . . . 8
..3
Code 9.H . . . . . . . . . . . . . . . .8-29 Firmware (Flashware) . . . . . . . . . . . . .10-2
Code 9.J . . . . . . . . . . . . . . . .8-31 FlashWare
Code 9.K . . . . . . . . . . . . . . . .8-33 Installation . . . . . . . . . . . . . . . . . .10-2
Operator Display . . . .6-3.8-12 to 8-36 Flashware Program . . . . . . . . . . . . . .10-2
Code 1.3 . . . . . . . . . . . . . . . .6-16 Flashware. Troubleshooting Wire Guidance
Code 1.4 . . . . . . . . . . . . . . . .6-17 . . . . . . . . . . . . . . . . . . . . . . . . . .8-38
.
Code 1.5 . . . . . . . . . . . . . . . .6-18 Flow Control Valve . . . . . . . . . . . . . . .7.7 1
Code 1.6 . . . . . . . . . . . . . . . .6-19 Flowcharts. Troubleshooting . . . . . . . 5-27
Code 1.8 . . . . . . . . . . . . . . . .6-20 Forks . . . . . . . . . . . . . . . . . . . . . . . . .7.94
Code 2.1 . . . . . . . . . . . . . . . .6-21 Fraction to Decimal Conversion . . . . . .A.6
Code 2.2 . . . . . . . . . . . . . . . .6-22 Fuses . . . . . . . . . . . . . . . . . . . .5.15 . 7-50
Code 2.3 . . . . . . . . . . . . . . . .6-23
Code 2.4 . . . . . . . . . . . . . . . .6-24
Code 2.5 . . . . . . . . . . . . . . . .6-25
Code 2.6 . . . . . . . . . . . . . . . .6-26 Guidance Manager . . . . . . . . . . . . . . . . 8.3
Code 3.1 . . . . . . . . . . . . . . . .6-27 Guide
Code 3.2 . . . . . . . . . . . . . . . .6-28 Drive Unit Troubleshooting . . . . . . 5-25
Code 3.3 . . . . . . . . . . . . . . . .6-30 Guidelines
Code 3.4 . . . . . . . . . . . . . . . .6-32 Electrical Troubleshooting . . . . . . .5-3
Code 3.5 . . . . . . . . . . . . . . . .6-33 Hydraulic Troubleshooting . . . . . .5-16
Code 3.6 . . . . . . . . . . . . . . . .6-34 Safety, General . . . . . . . . . . .2.3 to 2-5
Code 3.7 . . . . . . . . . . . . . . . .6-35
Code 4.1 . . . . . . . . . . . . . . . .6-36
Code 4.2 . . . . . . . . . . . . . . . .6-38
Code 4.3 . . . . . . . . . . . . . . . .6-39
Code 4.6 . . . . . . . . . . . . . . . .6-40 High Performance Option . . . . . . . . . .9.48
Code 4.8 . . . . . . . . . . . . . . . .6-41 Horn Codes . . . . . . . . . . . . . . . . . . . . 8.36
Code 5.1 . . . . . . . . . . . . . . . .6-42 Horn Switch
Code 5.2 . . . . . . . . . . . . . . . .6-43 Replacement . . . . . . . . . . . . . . . . .7 .17
Code 5.3 . . . . . . . . . . . . . . . .6-44 Hydraulic Components
Code 5.4 . . . . . . . . . . . . . . . .6-45 Center Cylinder . . . . . . . . . . . . . . .7-69
Code 5.5 . . . . . . . . . . . . . . . .6-46 Hydraulic Fluid . . . . . . . . . . . . . . . . .7-60
Code 6.1 . . . . . . . . . . . . . . . .6-47 Cold Storage . . . . . . . . . . . . . . . . .7-60
Code 6.2 . . . . . . . . . . . . . . . .6-49 Hydraulic Manifold . . . . . . . . . . . . . . .7-58
Code 6.3 . . . . . . . . . . . . . . . .6-50 Hydraulic Reservoir . . . . . . . . . . . . . .7-59
TPA Hydraulic Schematic . . . . . . . . . . . . .A-18
Code 1.1 . . . . . . . . . . . . . . . . .6-8
Code 1.2 . . . . . . . . . . . . . . . . .6-8
00700.CL222.05, 1 5 March 2005

Hydraulic System Load Holding Solenoid. Theory . . . . . . 9-48

Troubleshooting Load Sensor Assembly . . . . . . . . . . . . . 8-4
Symptoms . . . . . . . . . .5.3 1 to 5-33 Load Sensor. Wire Guidance . . . . . . . . 8-40
Hydraulic Troubleshooting Guidelines 5- 16 Load Wheels . . . . . . . . . . . . . . . . . . . .7-96
Locator Photos. Components . . . . . . . . 7-5
Lower Function
Troubleshooting . . . . . . . . . .5-31. 5-32
Lower Limit Switch. Theory . . . . . . . . 9-48
Info Display . . . . . . . . . . . . . . . . . . . . . 6.3 Lower. Theory . . . . . . . . . . . . . 9-41 to 9-47
Inner Mast . . . . . . . . . . . . . . .7.78 to 7-80 Lubrication Specification Chart . . . . . . A-2
Installation Instructions . . . . . . . . . . . .3.7
Maintenance Intervals. Defined . . . . . . 4-2

Jacking Maintenance Mode . . . . . . 6-4 to 6.5. 8-35
Baseleg . . . . . . . . . . . . . . . . . . . . .2. 12 Enter . . . . . . . . . . . . . . . . . . . . . . .6-4
Operator Platform . . . . . . . . . . . . .2. 1 1 General Testing . . . . . . . . . . . . . . .6-4
Safety . . . . . . . . . . . . . . . .2. 11 to 2-12 Learning Throttle Potentiometer . . . 6-5
Tractor . . . . . . . . . . . . . . . . . . . . .2. 1 1 Tests
Steer Encoder . . . . . . . . . . . . . .6-5
Throttle Potentiometer . . . . . . . 6-5
Manifold. Hydraulic . . . . . . . . . . . . . . 7-58
Key Switch. Theory . . . . . . . . . 9. 10 to 9- 15 Manual Design . . . . . . . . . . . . . . . . . . .1-4
Kits Map. Navigating the Manual . . . . . . . . . 1-2
Wire Guidance . . . . . . . . . . .8.3 to 8-8 Mast
2-Stage . . . . . . . . . . . . . . . . . . . . .7-84
Bearing
Shimming . . . . . . . . . .7-85 to 7-90
Inner Mast to Carriage . . . 7-89
Lift Chains Main Frame to Outer Mast 7-87
2-Stage . . . . . . . . . . . . . . . . . . . . .7.93 Outer Mast to Inner Mast . 7-88
3-Stage . . . . . . . . . . . . . . .7.9 1 to 7-92 Bearing Replacement
Lift Contactor . . . . . . . . . . . . . . 6- 16, 6- 17 Upper . . . . . . . . . . . . . . . . . . .7-86
Lift Cylinder Disassembly . . . . . . . . . . . . . . . . .7-87
Three-Stage Center Inner . . . . . . . . . . . . . . . . 7-78 to 7-80
Installation . . . . . . . . . . . . . . .7.70 Outer . . . . . . . . . . . . . . . . . . . . . .7-81
Three-Stage Center w/Cushions Switches . . . . . . . . . . . . . . . . . . . .6-18
Service . . . . . . . . . . . . . . . . . .7.69 Mast Bearings . . . . . . . . . . . . . . . . . .7-85
Cushion Replacement . . . . 7.69
Mast Guard . . . . . . . . . . . . . . . . . . . .7-13
Seal Replacement . . . . . . . .7.70
Metric to Standard Conversion . . . . . . . A-8
Lift Function
Troubleshooting . . . . . . . . . . . . . .5.3 1
Lift Limit Bypass Switch, Theory . . . . .9.48
Lift Limit Switch, Theory . . . . . . . . . . .9.48
Lift Pressure Adjustment . . . . . . . . . . .7.63
Lift Pump . . . . . . . . . . . . . . . . . . . . . .7.62
Lift, Theory . . . . . . . . . . . . . . .9.34 to 9-40
Lift/ Lower
m o b Installation/Adjustment . . . . 7.2 1
Pot (VR2) Replacement . . . . . . . . .7. 17
Lift/Lower Troubleshooting . . . . . . . . .5.3 1
Lift/Lower, Theory . . . . . . . . .9.34 to 9-49
00700.CL222.05, 1 5 March 2005

Motors . . . . . . . . . . . . . . . . . 7-35 to 7-44 Power Amplifier . . . . . . . . . . . . . . . . .5-17

Brush Spring Tension . . . . . . . . . 7-37 Diagnostic History . . . . . . . . . . . .5.20
Brushes . . . . . . . . . . . . . . 7-35 to 7-37 Fault Codes . . . . . . . . . . . . . . . . . .6.6
Cleaning . . . . . . . . . . . . . . . . . . . 7-35 Parameters . . . . . . . . . . . . . . . . . .5.24
Commutator . . . . . . . . . . . . . . . . 7-38 Programmable Maintenance Tool . 3. 12
Field Winding . . . . . . . . . . . . . . . 5- 12 Test Mode . . . . . . . . . . . . . . . . . . .5.2 1
Overheating Power Cables . . . . . . . . . . . . . . . . . . . .5.8
Troubleshooting . . . . . . . . . . . 5-34 Power Supply . . . . . . . . . . . . . . . . . . .6.42
Short Circuited Armature . . . . . . 5-12 Programmable Maintenance Tool . . . . 3. 12
Terminal Nuts . . . . . . . . . . . . . . . 7-38 Procedures . . . . . . . . . . . .5-20 to 5-24
Tests . . . . . . . . . . . . . . . . . . . . . . 5-1 1 Test Mode . . . . . . . . . . . . . . . . . . .5.2 1
Grounded Motor . . . . . . . . . . 5- 12 Pulse Width Modulation, Definition . . . 5-17
Open Circuit . . . . . . . . . . . . . 5- 1 1 Pump . . . . . . . . . . . . . . . . . . . . . . . . 7.62
.
Short Circuit . . . . . . . . . . . . . 5- 12 Pump Contactor Coil Driver, Theory . . 9-48
Troubleshooting . . . . . . . . . . . . . 5-34 Pump Sense, Theory . . . . . . . . . . . . . .9.49
Moving Directional/Speed Control. Theory .
PWM Definition . . . . . . . . . . . . . . . . .5. 17
. . . . . . . . . . . . . . . . . . . . 9-22 to 9-27
Reservoir. Hydraulic . . . . . . . . . . . . . . 7-59

Neutral Braking . . . . . . . . . . . . . . . . 5-17 Rotor. Brake . . . . . . . . . . . . . .7-28 to 7-29
Open Circuit. Definition . . . . . . . . . . 5-17 Safety

Operator Display . . . . . . . . . . . . . . . . 7- 16 Battery . . . . . . . . . . . . . . . . .2.6 to 2-8
Operator Display Messages . . . . 6-2 to 6-3 Definitions . . . . . . . . . . . . . . . . . . .2.2
Battery Indicator . . . . . . . . . 6-2 to 6-3 General Rules . . . . . . . . . . . .2.3 to 2-5
Battery State-of-Charge . . . . . . 6-3 Jacking . . . . . . . . . . . . . . .2. 1 1 to 2-12
Fault Code . . . . . . . . . . . . . . . . 6-3 Static . . . . . . . . . . . . . . . . .2.9 to 2-10
Info Display . . . . . . . . . . . . . . . 6-3 Tie-Down for Transport . . . . . . . . .2. 13
Steering Indicator . . . . . . . . . . . . . 6-2 Towing . . . . . . . . . . . . . . . . . . . . .2. 14
Option K t s Welding . . . . . . . . . . . . . . . . . . . . .2. 15
Wire Guidance . . . . . . . . . . . 8-3 to 8-8 Safety Belt . . . . . . . . . . . . . . . . . . . . . .2.3
Options Scheduled Maintenance . . . . . . .4.2 to 4-8
Cold Storage . . . . . . . . . . . 3-9 to 3- 10 Guidelines . . . . . . . . . . . . . . . . . . .4.2
Wire Guidance . . . . . . . . . . . . . . . . 3-8 Moderate Usage, Definition . . . . . . .4.2
Outer Mast . . . . . . . . . . . . . . . . . . . . 7-81 Severe Usage, Definition . . . . . . . . . 4.2
Overheating See Overtemperature Sensor Test, Wire Guidance . . . . . . . . 8-35
Overtemperature. Definition . . . . . . . 5- 17 Sensor, Load . . . . . . . . . . . . . . . . . . . .8.40
Sensor, Tractor . . . . . . . . . . . . . . . . . .8.40
Shimming Mast Bearings . . . . 7-85 to 7-90
Inner Mast to Carriage . . . . . . . . . 7-89
Main Frame to Outer Mast . . . . . . 7-87
Pallet Clamp . . . . . . . . . . . . . . . . . . . 7-95
Outer Mast to Inner Tele . . . . . . . .7-88
Parameters. Traction Power Amplifier 5-24
Short Circuit. Definition . . . . . . . . . . . 5-17
PC Contactor . . . . . . . . . . 6.22. 6.38. 6-39
Short Circuited Armature . . . . . . . . . . 5-12
Pin Extractor . . . . . . . . . . . . . . . . . . . 3- 12
Shorts to Frame . . . . . . . . . . . . .5.4 to 5-6
Pinout Matrix . . . . . . . . . . . . 9-51 to 9-68
Side Cylinder . . . . . . . . . . . . .7-65 to 7-68
Plugging . . . . . . . . . . . . . . . . . . . . . .5-24
Skid Pads . . . . . . . . . . . . . . . . . . . . . .7.97
00700.CL222.05, 1 5 March 2005

Software Tests
Configuration . . . . . . . . . . . . . . . .6.45 Electric Motor . . . . . . . . . . . . . . . . 5-11
Solenoid Valves . . . . . . . . . . . . . . . . . 7.6 . 1 Motor
Special Tools . . . . . . . . . . . . . . . . . . . 3. . 12 Grounded . . . . . . . . . . . . . . . .5-12
Specifications . . . . . . . . . . . . . . . . . . . 3.2 . Open Circuit . . . . . . . . . . . . . .5-11
Speed Feedback Encoder . . .8.2, 8.5, 8-42 Power Amplifier . . . . . . . . . . . . . .5-21
Test . . . . . . . . . . . . . . . . . . . . . . . 8-35
. Speed Feedback Encoder . . . . . . . 8-35
Stacked Fault Codes . . . . . . . . . . . . . . .6.3 Steer Encoder. Maintenance Mode . 6-5
Standard to Metric Conversion . . . . . . .A.8 Steer Feedback Encoder . . . . . . . . 8-35
Static Discharge . . . . . . . . . . . . . . . . . 2.9 . Throttle Potentiometer. Maintenance Mode
Static Wrist Strap . . . . . . . . . . . . . . . .2.10 . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Static-Sensitive Components . . . . . . . . .2.9 Wire Guidance Sensor . . . . . . . . .8-35
Steer Controller . . . . . . . . . . . . .8.2, 8-41 Tether . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Steer Controller Card . . . . . . . . .8.3, 8-28 Theory of Operation
Install . . . . . . . . . . . . . . . . . . . . . . 8-3
. 120" Limit Switch . . . . . . . . . . . . .9-48
Steer Encoder 150" Limit Switch . . . . . . . . . . . . .9-48
Test, Maintenance Mode . . . . . . . . .6.5 180" Limit Switch . . . . . . . . . . . . .9-48
Steer Feedback Encoder . . . .8.2, 8.6, 8-41 24" Limit Switch . . . . . . . . . . . . . .9-48
Test . . . . . . . . . . . . . . . . . . . . . . . 8-35
. 60" Limit Switch . . . . . . . . . . . . . .9-48
Steer Handle Encoder . . . . . . . . . . . . .6.27 Battery . . . . . . . . . . . . . . . . .9-4 to 9-9
Steer/Tractor Manager Brake Switches . . . . . . . . .9-16 to 9-21
Communication . . . . . . . . . . . . . . .6.40 Directional/Speed Control 9-22 to 9-27
COP . . . . . . . . . . . . . . . . . . . . . . 6-43
. Key Switch . . . . . . . . . . . .9-10 to 9- 15
Steering . . . . . . . . . . . . ..6.30, 6.32, 6-33 Lift . . . . . . . . . . . . . . . . . .9-34 to 9-40
Steering Indicator Messages . . . . . . . . .6.2 Lift Limit Bypass Switch . . . . . . . .9-48
Strap, Static . . . . . . . . . . . . . . . . . . . 2. . 10 Lift Limit Switch . . . . . . . . . . . . . .9-48
Switches Lift/Lower . . . . . . . . . . . .9-34 to 9-49
120" Limit (S29) . . . . . . . . . . . . . .9.48 Load Holding Solenoid . . . . . . . . .9-48
150" Limit (S29) . . . . . . . . . . . . . .9.48 Lower . . . . . . . . . . . . . . . .9-41 to 9-47
180" Limit (S25) . . . . . . . . . . . . . .9.48 Lower Limit Switch . . . . . . . . . . . .9-48
24" Limit (S6) . . . . . . . . . . . . . . . 9.48 . Pinout Matrix . . . . . . . . . .9-51 to 9-68
60" Limit (S7) . . . . . . . . . . . . . . . 9.48 . Pump Contactor Coil Driver . . . . . 9-48
Deadman . . . . . . . . . . . . . . . . . . 7.53 . Pump Sense . . . . . . . . . . . . . . . . .9-49
Emergency Power Off . . . . . 6.19, 7-53 Travel . . . . . . . . . . . . . . . . . . . . . .9-22
General . . . . . . . . . . . . . . . .5.10, 7-53 Wire Guidance . . . . . . . . .8-40 to 8-42
Hall Effect . . . . . . . . . . . . . . . . . . .5. 10 Throttle Potentiometer . . . . . . . .6.2 1. 6-23
Key . . . . . . . . . . . . . . . . . . .5.10, 7-54 Learning . . . . . . . . . . . . . . . . . . . . .6-5
Lift Limit Bypass (S51) . . . . . . . . .9.48 Test. Maintenance Mode . . . . . . . . .6-5
Lift Limit (S24) . . . . . . . . . . . . . . .9.48 Tie-Down for Transport . . . . . . . . . . .2-13
Lower Limit (S6O) . . . . . . . . . . . . .9.48 Tire. Drive . . . . . . . . . . . . . . .7-25 to 7-26
Mast . . . . . . . . . . . . . . . . . . . . . . 6.. 18 Tools. Special . . . . . . . . . . . . . . . . . . .3-12
Test/Inspection . . . . . . . . . . . . . . .5. 10 Torque Chart . . . . . . . . . . . . . . . . . . . .A-3
Symptom Tables Metric . . . . . . . . . . . . . . . . . . . . . . A-5
.
Electrical Symptoms . . . . . . . . . . .5.34 Standard . . . . . . . . . . . . . . . . . . . .A-3
Hydraulic Functions . . . . .5.31 to 5-33 Standard (Brass) . . . . . . . . . . . . . .A-4
Travel Functions . . . . . . . . . . . . . .5.33 Towing . . . . . . . . . . . . . . . . . . . . . . . .2-14
Traction Power Amplifier . . . . . . . . . .5-17
Parameters . . . . . . . . . . . . . . . . . .5-24
Programmable Maintenance Tool . 3- 12
Tractor Sensor Assembly . . . . . . . . . . . 8-4
Terminal Nuts. Motors . . . . . . . . . . . .7.38 Tractor Sensor. Wire Guidance . . . . . . 8-40
00700.CL222.05, 1 5 March 2005

Transport Wire Guidance . . . . . . . . . . . . . . . . . . .8. 1

Horizontal . . . . . . . . . . . . . . . . . . 2-13 Enable. Flashware . . . . . . . . . . . . .8.9
Vertical . . . . . . . . . . . . . . . . . . . . 2-13 Guidance Parameter Setup . . . . . . .8.9
Travel Functions Install Kit . . . . . . . . . . . . . . .8.3 to 8-8
Troubleshooting . . . . . . . . . . . . . 5-33 Set-Up Procedure . . . . . . . .8.9 to 8-11
Travel Pot (VR1) Wiring Harness . . . . . . . . . . . . . .5.8 to 5-9
Disassembly . . . . . . . . . . . . . . . . 7-19 Wiring Problems, Troubleshooting . . . .5.8
Travel. Theory of Operation . . . . . . . . 9-22 Wrist Strap . . . . . . . . . . . . . . . . . . . . . 2.9
.
Troubleshooting
Dead Lift Truck . . . . . . . . . . . . . . 5-34
Definitions . . . . . . . . . . . . . . . . . . 5-17
Drive Unit . . . . . . . . . . . . . . . . . . 5-25
Electrical
Symptoms . . . . . . . . . . . . . . . 5-34
. . . . . . . . . . . . . . . . . . 5-18 to 5-19
Electrical Guidelines . . . . . . . . . . . 5-3
Fault Codes. Traction Power Amplifier
. . . . . . . . . . . . . . . . . . . . . . . . .6-6
Flowcharts . . . . . . . . . . . . . . . . . . 5-27
How to Use this Chapter . . . . . . . . 5-2
Hydraulic Guidelines . . . . . . . . . . 5-16
Lift/Lower Functions . . . . . . . . . . 5-31
Motors . . . . . . . . . . . . . . . . . . . . .5-34
Pinout Matrix . . . . . . . . . 9-51 to 9-68
Programmable Maintenance Tool.
Procedures . . . . . . . . . 5-20 to 5-24
Shorts to Frame . . . . . . . . . . 5-4 to 5-6
Symptom Tables . . . . . . . 5-31 to 5-34
Travel Functions . . . . . . . . . . . . . 5-33
Wire Guidance . . . . . . . . . . .8-37. 8-38
Wiring Problems . . . . . . . . . . . . . . 5-8
UL "EE" Label . . . . . . . . . . . . . . . . . . . 4-2

Undertemperature. Definition . . . . . . 5-17
Valves . . . . . . . . . . . . . . . . . . . . . . . .7-61
Flow Control . . . . . . . . . . . . . . . . 7-71
Warning. Definition . . . . . . . . . . . . . . . 2-2

Welding . . . . . . . . . . . . . . . . . . . . . . . 2-15
Wheels
Drive . . . . . . . . . . . . . . . . 7-25 to 7-26
Load . . . . . . . . . . . . . . . . . . . . . . 7-96
00700.CL222.05, 1 5 March 2005

00700-CL222-05, 1 5 March 2005

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7bpue15 SN 80001 - Repair Manual cl222-05

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7bpue15 SN 80001 - Repair Manual cl222-05

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Service

Traction Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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Pallet Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95

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Section 1. How to Use This Manual

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Map of the Manual

How To Use This

rn Safety Map of the Manual

Page Revision Record

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Component Alphabetical List of

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Page Revision Page

Page Revision Page

Original Issue - No Changes

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Warning means a potentially hazardous

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Operate this truck only from the operator's

Before working on this truck, always turn the

battery connector (unless this manual tells you

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Follow the scheduled lubrication, maintenance

Follow exactly the safety and repair instructions

Do NOT park a truck in a cold storage area

Do NOT use a n open flame near the truck.

Do NOT wash this truck with a hose.

00700-CL222-05, 1 5 March 2005

Do NOT add to or modify this truck until you

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As a battery is being charged, an

Battery electrolyte is a solution of

Wear personal protective equipment to protect

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Turn the key switch OFF before disconnecting

Make sure the vent holes in the filler plugs are

Do not allow cleaning solution, dirt or any

Do not lay tools or metal objects on top of the

Keep batteries clean. Corrosion causes shorts

Make sure you install the correct size battery. A

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Follow the charging procedures in the Battery

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Static Safety Whenever working on or near static-sensitive

Figure 2-2. ESD Plug on Operator Console

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Wrist Strap Static-Dissipative

Figure 2-3. Anti-Static Kit W i t h Wrist Strap a n d M a /

Wrist straps are available in quantities of 25, as

A wrist strap tester is available as part number

Contact your authorized Toyota Dealer for

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Jacking Safety Tractor