Service Manual

TOYOTA ORDERPICKER

Model 6BPU15 Serial No. 70001-79999

00700-CL22 1 Issued: 9/10/98

 Service Manual Change History
Description Page # Date
1 Added Change History 2 8/31/13
2 Added Information Bulletin list 3-4 8/31/13
3 Added SIB CC13-006 482 8/31/13
 Service Information Bulletins
1 SIB BR 10-002 Master Cylinder Change
2 SIB BR09-002 Master Cylinder Installation
3 SIB CC00-001 Battery Charge And Lift Interupt Settings
4 SIB CC01-002 Compatability Of Firmware & Amplifier Versions
5 SIB CC02-002 Firmware Update
6 SIB CC04-001 Wire Guidance Problems After Display Card Replacement
7 SIB CC04-002 Steer Oscilation After Calibration
8 SIB CC05-001R Lift/lower Without Deadman Brake (LLWODM)
9 SIB CC05-004 Code 9E
10 SIB CC07-001 Password Reference Sheet
11 SIB CC13-006 Brake Pedal operation Change
12 SIB CE01-004 Improved Horn
13 SIB CE03-003R Solid State Control Handle
14 SIB CE05-003 New Line Driver Assembly
15 SIB CE06-006 Adding Lift Limit With Bypass
16 SIB CE09-003 Adding Lift Limit With Bypass
17 SIB DF00-001 Wider Pallet Clamp Jaw
18 SIB DU01-001 New Synthetic Gear Oil
19 SIB DU09-002 Drive Unit Leakage
20 SIB DU11-001 Drive Unit Overhaul

Technical News Brief

1 TNB-2003-02 Reach Truck Handles And Proximity Switch Adjustment
2 TNB-2008-01 Metal Battery Doors
3 TNB-2008-04 Brake Fluid Decal

Hotline Tech Tips

1 HTT-2005-04 Error Code 51
2 HTT-2005-11 Brake Bleeding
3 HTT-2006-02 Axle Seal SSTs
4 HTT-2006-03 Code 66 & Code 67
5 HTT-2006-06 Code 66 & 67
6 HTT-2007-12 Wire Guidance
7 HTT-2008-06 6BPU Mast Switch Issues
8 HTT-2009-05 Brake Release Pedal
9 HTT-2009-10 Wire Guidance; Losing Wire After A Few Feet Of Travel
10 HTT-2009-11 Drive Unit Leakage Repair
11 HTT-2010-02 RF Interference
12 HTT-2010-03 Master Cylinder Shimming
13 HTT-2010-06 Flashware Version 4.2
14 HTT-2010-10 New Brake Master Cylinder
Copyright O 1998 by Toyota lndustrial Equipment, a division of Toyota Motor Sales, U.S.A., Inc.

All Rights Reserved. No portion of this manual may be reproduced mechanically, electronically or by
any other means, including photocopying, electronic retrieval or transfer, or recording without the
written permission of the publisher.

Toyota lndustrial 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 lndustrial Equipment is
not responsible for any errors that may appear in this manual.
Toyota Orderpicker Service Manual How to Use This Manual

How to Use This Manual

00700-CL221 Issued: 9/10/98

How to Use This Manual Toyota Orderpicker Service Manual

Map of the Manual

Map of the Manual

HOW to Use 1
This Manual / Shooting

1 Manual Design ~
1 !
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1
Page Revision
Record 1 Component

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1 able of Contents 11
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Start Page ' Component
Location Photos

1 Scheduled
Maintenance
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Index
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Toyota Orderpicker Service Manual How to Use This Manual
Manual Design

Manual Design

The Toyota Orderpicker Service Manual is

designed with the following objectives in mind:
Provide technical coverage for expected
levels of user expertise.
Anticipate your needs and reduce your
decisions regarding maintenance.
Reduce page flipping through a "one-stop
shopping" approach.

The two-line running page header at the top of

each page tells you:
the name of the manual
(Toyota Orderpicker Service Manual)
the current Chapter Title
(e.g., this page How to Use This Manual)
the current topic
(e.g., this page Manual Design)

We suggest you get in the habit of turning to the

START page first when you use this manual.

00700-CL22 1 issued: 9/10/98

How to Use This Manual Toyota Orderpicker Service Manual

Manual Design

The START page asks a few simple questions to

guide you to the proper chapter.
How to Use This Manual explains the
manual format and design and contains the
Table of Contents and START page.
Safety explains warning and caution notes,
general safety rules and safety rules for
batteries, static, jacking, and welding.
Systems Overview includes truck
specifications and functional overview of
the major systems.
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 GENERAL TROUBLESHOOTING
chart (see List of Troubleshooting
Charts on page 5-25) will guide you to
the individual troubleshooting symptom
chart you need.

Once you're familiar with the symptoms

listed, you may instead simply find the
symptom chart from the List of
Troubleshooting Charts on page 5-27.
When you complete a troubleshooting
procedure, be sure to follow the steps in
End of Troubleshooting Chart END- 1.
Electrical Codes and Tests contains
information about electrical fault codes and
diagnostic tests under the control of the
system firmware.
Component Procedures gives step-by-step
procedures for testing, removal,
installation, and adjustment of individual
truck components. Components are listed
in an order which considers:
Frequency of attention
Physical attachment (e.g., brake must
be removed before drive motor)
Functional relation (e.g., carriage and
mast components are grouped together)

00700-CL22 1 Issued: 9/10/98

How to Use This manual Toyota Orderpicker Service Manual

To find a component procedure, you may

use one of three methods:
Look up the component name in the
Alphabetical List of Components.
Find the component in the Component
Locators.
Look up the component name in the
maintenance manual
Index.
Theory of Operation gives detailed theory
of operation information for all major
systems.
Appendix contains reference information
such as torque values and lubricants.
Index lists subjects alphabetically.

00700-CL22 1 Revised: 2/ 1 5/01)

Toyota Orderpicker Service Manual How to Use This manual

Page Revision Record

Page Revision Record

This page is a record of the latest revised pages in this manual. Whenever a page is revised, we
update this section and include it in the revision. This lets you keep track of the latest revised pages
for this manual.
If no date appears in the "revised" column, it means that the page has never been revised since the
manual was first issued.
Cover .................. 3-5 ...................... 4-5 ...................... 5-29 ....................
1-1 ...................... 3-6 ...................... 4-6 ...................... 5-30.. ..................
1-2 ...................... 3-7 ...................... 4-7 ...................... 5-31 ....................
1-3...................... 3-8 ...................... 4-8 ...................... 5-32.. ..................
1-4 ...................... 3-9 ...................... 4-9 ...................... 5-33. ...................
1-5 ...................... 3- 10 ..................... 4- 10 .................... 5-34.. ..................

00700-CL22 1 Revised: 2/ 1 5/00 1-6

How to Use This manual Toyota Orderpicker Service Manual

Page Revision Record

00700-CL22 1 Revised: 2/ 1 5/00

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Page Revision Record

00700-CL221 Revised: 2/ 15/00

Toyota Orderpicker Service Manual How to Use This manual

Page Revision Record

00700-CL22 1 Revised: 9/23/98

How to Use This manual Toyota Orderpicker Service Manual

Page Revision Record

00700-CL22 1 Issued: 9/ 1 0/98

Toyota Orderpicker Service Manual How To Use This Manual
Table of Contents

Table of Contents
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
MapoftheManual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
ManualDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Tableofcontents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Startpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Generalsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BatterySafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Staticsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
JackingSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
WeldingSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Systems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
SystemsOveniew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
m e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Electric Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator's Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Operator Compartment Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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Table of Contents

Steer Controller Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. 13

DriveandBrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Driveunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. 19
HydraulicComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 1
Electrical Components and Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Miscellaneous Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Sidegate Switches (S60. S61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Tie-Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Over-the-Mast Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 1

Planned Maintenance ................................ 4-1

PlannedMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
PlannedMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BatteryMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
BatterySafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Battery Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 15
Battery Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. 15
Charging Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 16

Troubleshooting .................................... 5-1

How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. 12

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Toyota Orderpicker Service Manual How To Use This Manual

Table of Contents

MotorTypes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Open Circuit Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Grounded Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Short Circuited Armature or Field Winding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Hydraulic Troubleshooting Guidelines ................................. 5-15
HydraulicLeakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
List of Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Electrical Codes and Tests ............................ 6-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Disable the Brush Wear Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Start the Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Entering the Secondary Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Self-diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maneuvering within
Self-diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Analyzer (AnL)Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Entering the Secondary Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Entering Analyzer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Maneuvering within Analyzer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Tuning (Tuning) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Entering the Secondary Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Maneuvering within Tuning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Exiting Tuning Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Calibrate (Calibrte) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Entering the Secondary Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Entering Calibrate Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Maneuvering within Calibrate Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Configure (Configur) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Entering the Secondary Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code Summary Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

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Table of Contents

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.25

Category 1 Class 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Steer Controller Guidance Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-99
CodesandTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Steer Controller Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Analog Input Tests: (Category 1. Class 2: 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
12-20: Steer Controller Power Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Steer Controller Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-173

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Maintenance Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Adjustment and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Powersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Theory of Operation ................................. 8-1

Electrical Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Operating Description Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
LiftILower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Unique System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Brakingsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Proportional Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Appendix ......................................... 9-1

Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2
Torque Chart . Standard (Ferrous). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Torque Chart . Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Torque Chart . Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7
StandardIMetric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.9

Issued: 9/10/98
Toyota Orderpicker Service Manual How To Use This Manual

Table of Contents

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Hydraulic Schematic .............................................. 9-17

Index ............................................ 10-1

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Table of Contents

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List of Figures

List of Figures
Figure 2-1: Anti-Static Kit with Wrist Strap and Mat . . . . . . . . . . . . 2-12
Figure 2-2: Correct Jacking Locations . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 3-1: Toyota Orderpicker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Figure 3-2: Component Identification . . . . . . . . . . . . . . . . . . . . . . . .3-8
Figure 3-3: Operator's Console . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Figure 3-4: Hydraulic Compartment Components (Sheet 1 of 2) . . . 3-26
Figure 3-5: Electrical Compartment Components . . . . . . . . . . . . . . 3-28
Figure 3-6: Platform Components (ElectricSteering. Cover Removed) 3-29
Figure 3-7: Caniage Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Figure 3-8: Tractor Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Figure 3-9: Steer Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Figure 3-10: Display Controller Card . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Figure 3-11: Filter Card (with wire guidance only) . . . . . . . . . . . . . . 3-39
Figure 4- 1: Lubrication/Inspection Points . . . . . . . . . . . . . . . . . . . . 4-12
Figure 5-1: Shorts to Frame Test . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Figure 5-2: Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Figure 5-3: GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . 5-26
Figure 5-4: END1: End of Troubleshooting Procedure . . . . . . . . . . . 5-27
Figure 5-5: W- 1: Truck Functions Partially . . . . . . . . . . . . . . . . . . .5-28
Figure 5-6: H- 1: Hydraulic Lift/Lower Problem . . . . . . . . . . . . . . . . 5-29
Figure 5-7: H-2: No Lift; Lift Motor/Pump Won't Turn . . . . . . . . . . . 5-30
Figure 5-8: H-3: No Lift; Lift Pump/Motor Rotate . . . . . . . . . . . . . . . 5-34
Figure 5-9: H-4: Load Drifts Down while Forks are Elevated . . . . . . . 5-36
Figure 5-10: H-5: Cannot Pick Up a Load . . . . . . . . . . . . . . . . . . . .5-38
Figure 5- 11: T- 1: Travel Problem . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41
Figure 5- 12: T-2: No Travel in Either Direction . . . . . . . . . . . . . . . . 5-42
Figure 5-13: T-3: Travel in One Direction Only . . . . . . . . . . . . . . . . 5-43
Figure 5- 14: T-4: Problem with Slow Travel . . . . . . . . . . . . . . . . . . . 5-44
Figure 5-15: T-5: Truck Does Not Accelerate Properly . . . . . . . . . . . 5-45
Figure 5-16: T-6: Truck Does Not Travel . . . . . . . . . . . . . . . . . . . . . 5-47
Figure 5-17: T-7: No Slow travel When Mast Elevated Above S11
Mast Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-52
Figure 5-18: T-8: Slow travel Speed Occurs All the Time . . . . . . . . . 5-54
Figure 6-1: Menu Structure for the Different Modes . . . . . . . . . . . . . 6-4
Figure 6-2: Steer Controller Card . Code 52 . . . . . . . . . . . . . . . . .6- 101
Figure 6-3: Steer Controller Card . Code 53 . . . . . . . . . . . . . . . . . 6-102
Figure 6-4: Location of Wire Guidance Coils and Related Tests . . . 6- 153
Figure 6-5: Location of Wire Guidance Coils and Related Tests . . . 6- 155
Figure 6-6: Location of Wire Guidance Coils and Related Tests . . . 6- 157
Figure 6-7: Location of Wire Guidance Coils and Related Tests . . . 6- 159
Figure 6-8: Location of Wire Guidance Coils and Related Tests' . . . 6-161

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How to Use This Manual Toyota Orderpicker Service Manual

List of Figures

Figure 6-9: Location of Wire Guidance Coils and Related Tests . . . 6. 163
Figure 7- 1: Component Locations (Sheet 1 of 5) . . . . . . . . . . . . . . . . . 7.2
Figure 7-2: Correct Jacking Locations . . . . . . . . . . . . . . . . . . . . . . . .7.9
Figure 7-3: Proper/Improper Method of Holding Circuit Card . . . . . . 7. 12
Figure 7-4: Integrated Circuit Tool . . . . . . . . . . . . . . . . . . . . . . . . . .7. 15
Figure 7-5: Preparing Integrated Circuit for Insertion . . . . . . . . . . . .7. 15
Figure 7-6: Installation of Integrated Circuit . . . . . . . . . . . . . . . . . .7. 16
Figure 7-7: Removing Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
Figure 7-8: Drive Unit Senice Tools . . . . . . . . . . . . . . . . . . . . . . . . .7.20
Figure 7-9: Drive Unit Cross Section . . . . . . . . . . . . . . . . . . . . . . . .7.20
Figure 7-10: Drive Unit Components. Lower End . . . . . . . . . . . . . .7.2 1
Figure 7-11: Removing Axle Bearing . . . . . . . . . . . . . . . . . . . . . . . .7.2 1
Figure 7-12: Pressing Bearing Cone onto Axle . . . . . . . . . . . . . . . . .7.22
Figure 7-13: Assembly of Axle into Housing . . . . . . . . . . . . . . . . . . .7.23
Figure 7-14: Preparing Axle Seal for Assembly into Housing . . . . . . . 7.23
Figure 7-15: Install/Torque Clamp Nut on Axle . . . . . . . . . . . . . . . .7.24
Figure 7- 16: Securing Clamp Nut by Tightening Retaining Screw . . . 7.25
Figure 7-17: Installing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
Figure 7-18: Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .7.28
Figure 7-19: Checking Skidpads . . . . ;. . . . . . . . . . . . . . . . . . . . . .7.29
Figure 7-20: Deadman Pedal/Master Cylinder . . . . . . . . . . . . . . . . .7.32
Figure 7-21: Brake Bleeding Set-Up . . . . . . . . . . . . . . . . . . . . . . . . .7.34
Figure 7-22: Exploded View of Brake Assembly . . . . . . . . . . . . . . . .7.35
Figure 7-23: Deadman Switch (S2)Adjustment (Not to Scale) . . . . . . 7.36
Figure 7-24: 2 Stage Lift Cylinder (Top End) . . . . . . . . . . . . . . . . . . .7.38
Figure 7-25: 2 Stage Lift Cylinder (Bottom End) . . . . . . . . . . . . . . . .7.39
Figure 7-26: Center Lift Cylinder, 3 Stage (Top End) . . . . . . . . . . . . 7.41
Figure 7-27: Center Lift Cylinder, 3 Stage (Bottom End) . . . . . . . . . .7.42
Figure 7-28: Lift/Lower Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . .7.44
Figure 7-29: Proper Installation of Proportional Valve . . . . . . . . . . .7.45
Figure 7-30: Access for Lift Cylinder Bleed Screws . . . . . . . . . . . . . .7.47
Figure 7-31: Directional/Speed Control . Exploded View . . . . . . . . .7.48
Figure 7-32: Lift/Lower Return Spring Replacement . . . . . . . . . . . .7.52
Figure 7-33: Lift/Lower Control Assembly, Potentiometer Wiring . . . 7.53
Figure 7-34: Elevating Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
Figure 7-35: Elevating Section (cont.) . . . . . . . . . . . . . . . . . . . . . . . .7.57
Figure 7-36: Elevating Section (cont.) . . . . . . . . . . . . . . . . . . . . . . . .7.58
Figure 7-37: Elevating Section (cont.) . . . . . . . . . . . . . . . . . . . . . . . . 7.59
Figure 7-38: Three Stage Elevating Section . . . . . . . . . . . . . . . . . . .7.60
Figure 7-39: End Cap Pulley Assembly (3Stage mast only) . . . . . . . 7.61
Figure 7-40: Staging of Mast Prior to Shimming Bearings . . . . . . . . . 7.62
Figure 7-41: End Cap Assembly, 3 Stage Mast . . . . . . . . . . . . . . . . . 7.63
Figure 7-42: Steering Control Assembly . . . . . . . . . . . . . . . . . . . . . . 7.66
Figure 8-1: Steering Encoder Output . Left Turn . . . . . . . . . . . . . . . 8. 12
Figure 8-2: Steering Encoder Output . Right Turn . . . . . . . . . . . . . . 8. 13

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Toyota Orderpicker Service Manual How to Use This Manual

List of Figures

Figure 8-3: Wire Guidance Functional Block Diagram . . . . . . . . . . . 8-18

Figure 8-4: Location of Wire Guidance Coils and Related Tests . . . . 8-19
Figure 8-5: Wire Guidance LEDs on the Operator's Display . . . . . . . 8-21
Figure 9-1: Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . .9-2
Figure 9-2: Torque Chart . Standard . . . . . . . . . . . . . . . . . . . . . . . . .9-4
Figure 9-3: Torque Chart . Standard Brass . . . . . . . . . . . . . . . . . . . . 9-5
Figure 9-4: Torque Chart . Ferrous Metric . . . . . . . . . . . . . . . . . . . . .9-6
Figure 9-5: Torque Chart . Brass Metric . . . . . . . . . . . . . . . . . . . . . .9-6
Figure 9-6: Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Figure 9-7: Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12
Figure 9-8: Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Figure 9-9: Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

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How to Use This Manual Toyota Orderpicker Service Manual

List of Figures

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Toyota Orderpicker Service Manual How To Use This Manual

Start Page

( START

Go to Chapter 2
"Safety"

A To examine Go to Chapter 3
- ~ - -- r. - . ---- ,!

/ \ 1 Go to Chapter 4
"Planned ~ainienance"
1
maintenance?

No

Go to Chapter 5
Yes b 'Troubleshooting"

b- Troubleshooting Guidelines
No

List of Troubleshooting
Go t o Chart Charts
START-2

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How To Use This Manual Toyota Orderpicker Service Manual

Start Page

( erform tests?
y e
Go to Chapter 6
"Electrical Codes and
Tests"

Go to Chapter 7
inspect. adjust.
"Component Procedures"

Go to Chapter 8

of operations? 'Theory of Operation"

Go to Chapter 9
"Appendix"
general reference
information?

t9
Return to

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Safety

Safety

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Safety Toyota Orderpicker 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.

A CAUTION
Caution means a potentially hazardous
situation exists which, if not avoided,
could result in minor or moderate iniury
or in damage to the lift truck or nearby
objects.

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Toyota Orderpicker Service Manual Safety
- -

General Safety

General Safety
Do not operate or work on this lift truck unless
you are trained, qualified, authorized to do so,
and have read the operator's manual.

Know the lift truck's controls and what they do.

Do NOT operate this lift truck if it needs repair

or if it is in any way unsafe.

Operate this lift truck only from the operator's

position.

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Safety Toyota Orderpicker Service Manual

General Safety

Before working on this lift truck, always turn

the key switch to OFF and disconnect the lift
truck's battery connector (unless this manual
tells you otherwise).

Do NOT wear watches, rings, or jewelry when

working on this lift truck.

Follow the scheduled lubrication, maintenance

and inspection steps.

Follow exactly the safety and repair instructions

in this manual. Don't take "shortcuts".

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Toyota Orderpicker Service Manual Safety

General Safety

Do NOT use gasoline or other flammable liquids

for cleaning parts.

Always park this lift truck indoors.

Do NOT wash this lift truck with a hose.

Do NOT add to or modify this lift truck until you

contact your local Dealer to receive written
manufacturer approval.

Do NOT park this lift truck in a cold storage

area overnight.

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Safety Toyota Orderpicker Service Manual

Battery Safety

Battery Safety

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
spark can ignite this gas, resulting in
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 immediately.

Wear personal protective equipment to protect

eyes, face and skin when checking, handling or
W g batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields) and a rubber apron.

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Toyota Orderpicker Service Manual Safety

Battery Safety

Make sure a shower and eyewash station are

nearby in case there is a n accident.

A battery gives off explosive gases. NEVER

smoke, use a n open flame, or use anything that
gives off sparks near a battery.

Keep the charging area well-ventilated to avoid

hydrogen gas concentration.

Turn the key switch off before disconnecting the

battery from the lift truck a t the battery
connector. Do not break live circuits a t the
battery terminals. A spark often occurs at the
point where a live circuit is broken.

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Safety Toyota Orderpicker Service Manual

Battery Safety

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.

Keep plugs, terminals, cables and receptacles in

I

good condition to avoid shorts and sparks.

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Toyota Orderpicker Service Manual Safety

Battery Safety

Keep m e r plugs firmly in place at all times

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.

Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck's
specification plate for more information.

Never plug a battery charger into the lift truck's

battery connector. Plug the battery charger only
into the battery connector from the battery.

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Safety Toyota Orderpicker Service Manual

Battery Safety

Follow the charging procedures in the Battery

Brtt---
Instruction Manual and in the Battery Cnarger
Charger
Instruction Manual.

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Toyota Orderpicker Service Manual Safety

Static Safety

Static Safety
Electronic circuit boards and devices used on
the Toyota lift truck can be damaged by the
discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal
operation of the lift truck a s well a s movement
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, Styrofoam coffee cups, etc.)
Accumulated static can be discharged through
human skin to a circuit board or component by
touching the parts. Static discharge is also
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 your seeing or feeling it.
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. Connect the ground clamp to an unpainted,
grounded surface on the lift truck frame.
3. If you will be removing or installing static-
sensitive components, place them on a
properly grounded static mat.
4. To transport static-sensitive components,
including failed components being
returned, place the components in an
antistatic bag or box (availablefrom your
dealer).
The wrist strap and associated accessories
should be tested monthly to verify they are
working properly. A defective static discharge
wrist band will not alert you that it is bad.

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Safety Toyota Orderpicker Service Manual

Static Safety

Figure 2- 1 : Anti-Static Kit with Wrist Strap and Mat

Figure 2-1 shows the components of the Toyota

antistatic field service kit, part number 00590-
04849-7 1. The kit includes a wrist strap,
ground cord and static-dissipative work surface
(mat). Follow the instructions packaged with
this kit.
Wrist straps are available in quantities of 25, a s
part number 00590-04848-71.
A wrist strap tester is available as part number
00590-04850-7 1.
Contact your local Dealer for further
information.

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Toyota Orderpicker Service Manual Safety

Jacking Safety

Jacking Safety
Sometimes you may need to jack up the lift
truck off the floor to perform maintenance
procedures. When doing so, observe the proper
safety precautions:
1. Lower the forks completely. Remove any
load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Disconnect battery connector.
5. Place the jack under the designated jacking
points. See Figure 2-2.

Use extreme care whenever the lift truck

is jacked up. Keep hands and feet clear
from vehicle while jacking the lift truck.
After the lift truck is jacked, place solid
blocks beneath it to support it. DO NOT
rely on the jack alone to support the lift
truck.

Tractor
1. Place the jack in the designated jacking
position. See Figure 2-2.
2. Jack the rear of the lift truck so that the
drive tire is off the floor no more than 2" (51

-
mm).
3 . Block the lift truck in place.

Mast
no more than 2" (51 Only jack in this area, no more than y2"
1. Place the jack in the designated jacking mm)off the noor. (13 mm) OK the floor.

position. See Figure 2-2.

2. Jack the side of the truck so that the load
wheel is off the floor no more than 1/2" ( 1 3 Figure 2-2: Correct Jacking Locations
mm).
3 . Block the lift truck in place.
NOTE: After working on a vehicle, test all
controls and functions to assure proper
operation.

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Safety Toyota Orderpicker Service Manual

Tie-down for Transport

Tie-down for Transport

To transport your Toyota lift truck in an over-
the-road vehicle or rail car, follow these steps:
1. Lower the forks and locate the lift truck in
the center of the transport vehicle.
2. Using suitable lifting device, remove the
battery. See "Battery Safety" on page 2-6.
3. Position the adjustable chain over and
through the battery compartment.
4. Position an additional adjustable chain over
and through the battery compartment.
5. Position the chain ends of one chain toward
the front of the vehicle bed and the chain
ends of the other chain to the back of the
vehicle bed and draw taut. This will secure
the lift truck to the vehicle bed and prevent
tip-over and forward or backward
movement.
6. Secure the battery according to the battery
\

manufacturer's instructions.

Towing
To safely tow a Toyota lift truck:
1. Lower the carriage and remove any load
from the forks.
2. Turn the key syitch OFF and disconnect
the battery connector.
3. Using a suitable towing vehicle, lift the
tractor end of the lift truck until the drive
tire is no more than 1" off the floor.
4. Tow the lift truck slowly in the tractor-first
direction.

A CAUTION
Use care to avoid damage to the wire
guidance sensor located beneath the
truck.

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Toyota Orderpicker Service Manual Safety
Welding Safety

Welding Safety

Flame cutting or welding on painted

surfaces may produce potentially
harmful fumes, smoke and vapors. Prior
to performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where
the operation(s) will be performed.

Coating removal may be by mechanical

methods, chemical methods or a
combination of methods. Flame cutting
and/or welding operations should be
carried out only in well ventilated areas
using local exhaust if necessary.

Before working on this lift truck, make sure

that:
Fire protection equipment is nearby.
You know where the nearest eyewash
station is.

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Safety Toyota Orderpicker Service Manual

Welding Safety

A CAUTION
Disconnect the battery before you
attempt to inspect, service or repair the
lift truck.

Check for shorts to frame as described in

"Shorts to Frame Test" on page 5-6.
If any shorts are detected, remove them
before you proceed with the welding
operation.
Clean the area to be welded.
Protect all lift truck components from heat,
weld spatter and debris.
Attach the ground cable as close to the weld
area a s possible.
Do not perform any welding operations
near the electrical components.
Disconnect the following connectors:
HD1 on Display Card
JPC 1 on Carriage Interface Card
JPR1,JPR3 on Tractor Interface Card
JP4, J P 5 on Steer Controller Card
JT1, JT2 on Traction Power Amplifier
JL1, JL2 on Lift Power Amplifier

A CAUTBON
If welding must be done near the battery
compartment, remove the battery from
the lift truck.

When you are finished welding, perform all

ground tests and electrical inspections
before the vehicle is operated.

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Toyota Orderpicker Service Manual Systems Overview

Systems Overview

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Systems Overview Toyota Orderpicker Service Manual
-
Systems Overview

Systems Overview

Figure 3-1 provides a n overview of the Toyota

Orderpicker. Detailed descriptions of major
components, supported by photographs and
drawings, are contained herein.

Figure 3- 1: Toyota Orderpicker

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Toyota Orderpicker Service Manual Systems Overview

Use

Use
The Orderpicker is designed for indoor
warehouse use only.

TYpe
Stand-up, rider type, designed for narrow aisle
installations where the operator must orderpick
items from storage racks. The lift truck is
operated with electric steering and may be wire
or rail guided.

Power
24-volt industrial battery.

Capacity
Refer to specification plate.

Mast
Two\three stage, hydraulic lift with a variety of
overall lowered heights (OALH) and elevated
heights (EH).

Controls
Lockable key switch, emergency power off
switch, emergency lower valve, steering wheel,
electric steering, wire/rail guidance, traction/
lift/lower amplifiers, brake, and horn button.
Selector switches are available for options such
a s working lights, fan, or other customer
selected options.

Indicators
Operator's display, wire/rail guidance
acquisition light, and an audible alarm which
sounds to alert the operator of certain system
conditions and when acquiring the guide wire/
rail. A strobe light helps to alert others of the
orderpicker's presence.

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Electronics

Electronics
The traction and lift control systems use
separate Pulse Width Modulated (PWM), solid
state, programmable power amplifiers to
monitor and control current flow through the
traction and lift motors. The amplifiers are
located on the right side of the power section.
Both amplifiers feature fail safe operation and
the traction power amplifier has regenerative
braking capability.

Electric Steering System

The electric steering system controls all the lift
truck steering and wire/rail guidance
functions. The system has stand-alone
programming and test capabilities. It
communicates with the Display Card through
the CAN bus.

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Toyota Orderpicker Service Manual Systems Overview

Specifications

Specifications

Category Description
MODEL Toyota Model Designation
SER. NO. Serial number assigned by the factory for
this particular lift truck during
manufacture.
VOLTS Nominal battery voltage.
TRUCK WEIGHT Approximate weight of the lift truck without
(Minimum) battery installed, minus operator and load.

TRUCK WEIGHT Approximate weight of the lift truck with

(Maximum) maximum size battery installed, minus
operator and load.
BATTERY WEIGHT Maximum weight of battery designed for
(Maximum) this lift truck.

BAmERY WEIGHT Minimum weight of battery required for

(Minimum) this lift truck.
BATTERY MAX. RATED
(Maximum Ampere Hour Power rating of the battery.
Capacity)
CAPACITY CHART Maximum load capacity of the lift truck.
Exceeding maximum load weight may
damage the lift truck or affect stability.

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Systems Overview Toyota Orderpicker Service Manual

Description

Description

Chassis
The Chassis is constructed of the following
parts:

Power Section Frame

The Power Section Frame is constructed of
formed sheet and plate steel welded together to
form a strong integral unit.
The Power Section is bolted to the baselegs and
mast.

Battery Compartment
The Battery Compartment will accept a battery
with the following dimensions (all dimensions
are maximum):

24 Volt Battery

Width Width
14.50" (370 mm) 13.25" (335 mm)

Height Height
32.25" (820 mm) 32.25" (820 mm)

Length Length
36.75" (935 mm) 31.50" (800 mm)

Battery gates located on each side of the lift

truck lift out to allow the battery to be removed
or installed from either side. Steel rollers
support the battery and allow easy removal and
installation. The battery gates contain
adjustment screws to limit battery movement.

Baselegs
The Baseleg frame is constructed of square
structural tubing and steel plate. Each baseleg
has one or two load wheels, depending on lift
truck configuration.

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Chassis

Forks
The Forks are constructed of 2-inch (50 mrn) by
4-inch (100 mm) rectangular steel (the length of
the forks is an option specified by the
customer). The forks are attached to the bottom
of the operator's compartment. The overall
width of the forks is adjustable from 24 to 28
inches (610 to 710 mm).

Covers
Two Covers constructed of formed plastic
enclose components on the power section.
Button assemblies allow both covers to be
removed from the lift truck.

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Chassis

Chains and Pulleys

Overhead \
Guard

Mast Guard i Decals

Control
Panel
I
Key Switch
\ /.
Sidegate

Sidegate'
Steel.ing
\
Contr I
~andile

battery
Com par1tment
Cover

Battery
\ Gate

Fork!/ Pedal \
Pallet
Clamp

Figure 3-2: Component Identification

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Toyota Orderpicker Service Manual Systems Overview

Operator's Compartment

Operator's Compartment
The Operator's Compartment has been
designed for safety, efficiency, and operator
comfort.

Compartment Dimensions
The operator's compartment is 28 inches
(710 mm) long, 76 inches (1930 mm) high, and
39 inches (990 mm) wide. The compartment
floor width is expandable to 55 inches
(1400 mrn).

Compartment Floor
The center section of the floor is plate steel. It is
covered by a rubber cushion. The extensions
are constructed of non-slip steel.

Overhead guard
The Overhead Guard is constructed of steel
tubing and bar stock. The overhead guard
covers the floor area to protect the operator and
complies with ANSI/ASME specification B56.1.
A bar a t the rear of the guard provides a n
attachment point for the tether.

The Belt/Tether is a safety device which is worn

around the waist of the operator whenever the
lift truck is operated. The tether prevents the
operator from falling from the carriage.

Sidegates
The operator's compartment has one Sidegate
on each side of the operator. The retractable
sidegates are spring loaded to keep them in
either the raised or lowered position. See
"Sidegate Switches (S60, S61)" on page 3-40.

Operator's Console
The Operator's Console provides the operator
with complete control of the lift truck. The
controls have been designed for operator safety,
efficiency, and comfort.
The steering wheel and the key switch are
located on the left side of the operator's console.

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Operator's Console

The traction/lift/lower control, horn button,

wire guidance on/off switch, and emergency
power off are located on the right side of the
operator's console.
The lower portion of the operator's console has
an accessory bin for storing pencils, pens,
clipboards, picklist, etc.

Operator's Display
The Operator's Display is used to display:
TOYOTA (turn on and system messages/
fault codes)
Total hours the key has been turned on (Ks)
Total hours on deadman (Bp)
Total hours drive (Dm)
Total hours spent lifting (Lt)
Clock/Calendar
Status messages:. Informational;
Performance Lirnitmg; and Fault Codes.
The operator display shows information on an
eight character, alphanumeric digital display.
Information will be displayed in either static or
scrolling format. Scrolling messages move from
right to left.

Steering Indicator and Keypad

All lift trucks are equipped with electric
steering; five drive unit position lights are
located above the steering wheel to indicate the
approximate position of the drive unit.
Additionally, all trucks have Guidance Status
lights located next to the wheel position
indicator; the status lights are not functional
unless the lift truck has the rail/wire guidance
option installed.
The keypad is used to access, enter, and change
parameters on the information/status display.

Emergency Power Disconnect Button

The Emergency Power Disconnect Button is
located on the operator's control console, to the
left of the directional/speed control. The switch
has two positions, UP allows the truck to travel,
and DOWN which prevents travel and lift/lower

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Operator Compartment Options

functions from operating. The manual

emergency lower function is not affected.

Key Switch
The lockable key switch is located near the
steering wheel. The key switch has two (2)
positions: OFF or ON.

Battery Discharge Indicator (BDI)

The Battery Discharge Indicator (BDI)shows
the energy which remains in the battery, based
on actual voltage readings. The value displayed
is the percentage of usable energy. Voltage
fluctuations occur during operation. Dependent
upon the setting in Tuning mode, lift will be
prevented until the battery is recharged or
replaced.

Brush Wear, Over temperature, Service

Required, and Lift Limit
Individual icons illuminate to inform the
operator of the specific condition.

Operator Compartment Options

The following components are available per
customer request (partial list):
Fan
Dome Light
Work Lights

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Operator Compartment Options

Steering Indicator Lights Operator's

Display Emergency
(electric steering)
\ / Keypad
Power Disconnect
Button

Switc
awer
ntrol

Lockehd On,
Wire ILights tion/

rol

Steering Horn switch \

Auto/Manual
Wheel
On/Off Switch

Figure 3-3: Operator's Console

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Toyota Orderpicker Service Manual Systems Overview

Steering and Controls

Steering and Controls

Steer Controller Guidance System

The electric power steering system is a
microprocessor-based control system using
sophisticated software to manage the steering
operation of the lift truck. It provides the
electronic intelligence to govern lift truck steer
functions under direct operator control or
automated wire/rail guidance systems.

Steer Motor and Gear Reducer

A permanent magnet steer motor connected to a
gear reducer provides the mechanical force to
steer the drive unit. The gear reducer has a
drain plug for changing the oil, and a filler level
plug to determine the quantity of lubricant in
the unit. The output shaft turns a gear that
powers a gear on the drive unit.

DirectionaVSpeed Control Assembly

The main components of the Directional/Speed
Controller are the:
Control Handle
Housing
Throttle Potentiometer m 1 )
Lift Potentiometer (VR2)
Horn Switch (S3)
Auto/Manual Switch (S45)(mountedon
bezel)

Control Handle
The Control Handle is constructed of formed
plastic. It has provisions for a horn button (S3),
and lift/lower potentiometer (VR2).

Housing
The Housing provides support and protection
for the throttle potentiometer (VR1).The control
handle is also attached to the housing by a
rotating shaft. The housing is constructed of
molded black polycarbonate and is mounted

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Steer Controller Guidance System

under the right-hand side of the operator's

control console.

Throttle Potentiometer (VR1)

The Throttle Potentiometer is mounted within
the housing. The potentiometer is turned by
two nylon gears: one gear is mounted on the
potentiometer shaft and the other gear is on the
control handle shaft. Potentiometer
specifications include the following:
Mechanical Rotation - 312'
Resistance - 2,000 ohms (2K)
As the throttle potentiometer is rotated by the
operator, a voltage proportional to the position
of the control is sent to the Carriage Interface
Card. VR1 voltage is sensed by the carriage
interface and passed to the Display Card, which
determines the direction and magnitude of the
speed request.

Lift/Lower Potentiometer (VR2)

The lift/lower potentiometer is directly
connected to the thumb lever; potentiometer
specifications include the following:
Mechanical Rotation - 3 12'
Resistance - 2,000 ohms (2K)
As the lift/lower potentiometer is rotated by the
operator, a voltage proportional to the position
of the control is sent to the Carriage Interface
Card. When the lift/lower control is moved to
lift, voltage from VR2 increases; when moved to
lower, the voltage from VR2 decreases. VR2
voltage is sensed by the carriage interface card
and passed to the Display Card which
determines whether to lift or lower. This is
accomplished by comparing the actual voltage
to the learned voltage values. Neutral for VR2 is
learned and stored.

Horn ( H I )
During the self diagnosis (power up) mode, the
horn (Hl) can be sounded whenever the key
switch is ON. The horn assembly is mounted on
the front lower section of the power section.

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Steer Controller Guidance System

Horn Switch (S3)

The Horn Switch is located on the front-side of
the directional/speed control handle. .

Auto/Manual Switch (S45)

Switch position selects steering mode, i.e.,
direct operator control or auto steer. Wire
guidance (and rail guidance) allows the lift
truck to follow a predetermined path
automatically, without steering assistance of
the operator. The switch is located on the
operator's console, beneath the control handle.

Drive Unit Position Encoder (ENC2)

The Drive Unit Position Encoder is located near
the gear reducer assembly. This encoder is
turned as the drive unit is steered. The signal
from the encoder is sent to the steer controller.
The steer controller uses this signal, in addition
to the signal from the Home Switch Proximity
Sensor, to determine the position of the drive
unit.

Home Switch Proximity Sensor (PROX)

The Home Switch Proximity Sensor is located
on the drive unit next to the Steering Position
Encoder. The switch opens or closes depending
upon its proximity to a metal surface. The
open/close signal is sent to the steer
controller.When the lift truck is initially turned
on, and deadman depressed, the steer
controller will steer the drive unit towards the
straight ahead position until the home switch
proximity sensor changes state. The switch
changes state when a metal surface passes
beneath it (when the drive unit is at the straight
ahead position).

Steering Encoder (ENC1)

The Steering Encoder is located on the
operator's carriage, behind the steering wheel.
A s the steering wheel is turned, the encoder
generates a quadrature phase signal and sends
it to the display card. The display card
processes the signal to determine the direction
and amount of steering request. The resulting
steering request is sent via the Bus+/Bus-
Controller Area Network (CAN) to the Steer

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Steer Controller Guidance System

Controller Card. The Steer Controller Card then

powers the steer motor to steer the drive unit.

Speed Feedback Proximity Sensors (SP1 and SP2)

The Speed Feedback Proximity Sensors
determine the speed and direction of rotation of
the drive motor. They are used in conjunction
with the holes in the brake drum to produce a
quadrature signal that is sent to the steer
controller. The characteristic pulses of the
quadrature signal are produced a s the
proximity sensors read either the metal or void
of the rotating brake drum.

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Drive and Brake

Drive and Brake

Drive Unit
The Drive Unit is a compact, self-contained
assembly. It consists of a pivot bearing, gear
housing, gear reduction assembly, drive motor,
brake, and drive wheel.

Pivot Bearing
The Pivot Bearing is the part of the drive unit
assembly that provides support for the drive
motor, wheel, and gear housing.

Gear Housing
The Gear Housing is a precision machined
casting into which the gear reduction system is
assembled.

Gear Reduction Assembly

The Gear Reduction Assembly is comprised of a
motor pinion, drive gear, drive pinion,
compound gear, and splined shaft. The gears
are continuously bathed in gear oil. The splined
axle shaft turns on two ball bearings.

Drive Wheel
The Drive Wheel consists of a polyurethane tire
mounted on an inner hub. The design of the
wheel permits replacement of the tire matkrial.

Brake
The Brake Assembly is mounted on top of the
drive motor. The brake is hydraulically-applied
and electrically released under control of the
deadman pedal.

Deadman Pedal
A Deadman Pedal is located on the
compartment floor. The deadman pedal is
spring loaded to the power off/brake engaged
position. The deadman pedal disables the travel
and lift/lower circuits and applies the brake
whenever the pedal is released.

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Systems Overview Toyota Orderpicker Service Manual

Brake

Deadman Switch (S2)

Switch S2 is located on the brake assembly,
near the drive motor, in the power section.
When the deadman pedal is up, switch S2 is
activated causing the circuit to open,
preventing travel and lift/lower functions.

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Toyota Orderpicker Service Manual Systems Overview

Mast

Mast

Mast Assembly
The Mast Assembly is constructed of the
following parts:

Mast Main Frame

The Mast Main Frame has a ladder type
construction. The mast uprights are made of
structural I-sections. The uprights are tied
together using structural steel crossties. The
mast uprights are welded to the baseleg kame,
forming a strong integral unit.

Telescopic Frame(s)
The Telescopic Frame is also of ladder type
construction. It is constructed of structural I-
sections and crossties.

Mast Bearings
The Mast Bearings are roller type construction
and lubricated for life.

24" Mast Switch (S11)

The 24" switch is physically located on the
carriage, and is mounted so that it is activated
whenever the carriage is below 24", and not
activated whenever the carriage is above 24".

60" Mast Switch (S12)

The 60" Switch is mounted on the 'right-hand
side of the mast, and is mounted so that it is
activated whenever the carriage is below 60",
and not activated whenever the carriage is
above 60".

120" Mast Switch (S10) (with enhanced

speed option)
The 120" Switch is mounted on the right- hand
side of the mast and is located about 3 feet
high. It is mounted so that it is activated
whenever the carriage is below 120". and not
activated whenever the carriage is above 120".

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Systems Overview Toyota Orderpicker Service Manual

Mast Assembly

150" Mast Switch (S26) (without

Enhanced Speed option)
The 150" Switch is mounted on the right-hand
side of the mast and is located about 5 feet
high. It is mounted so that it is activated
whenever the carriage is below 150", and not
activated whenever the carriage is above 150".

180" Mast Switch (S100) (with Enhanced

Speed option)
The 180" Switch is mounted on the right-hand
side of the mast and is located about 15 feet
high. I t is mounted so that it is activated
whenever the carriage is below 180", and not
activated whenever the carriage is above 180".

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Toyota Orderpicker Service Manual Systems Overview

Hydraulic Components

Hydraulic Components

Lift/Lower System
The orderpicker variable speed Lift/Lower
System is controlled manually by the operator
using a thumb lever located on the directional/
speed controller in the operator's compartment.
The lift/lower system consists of:
Lift Pump/Motor Assembly
Lift Cylinders
Lift Chains
Reservoir
Return Line Filter
Flow Controls
Relief Valves
Hydraulic Manifold Assembly

Lift Pump
A splined, fixed displacement gear pump is
used on all models.

Lift Cylinder Assembly

-
The Lift Cylinder is composed of the following:
Cylinder Housing
Piston
Flow Controls

Cylinder Housing
The Cylinder Housing is constructed of welded
steel tubing. The cylinder housing is attached to
the mast main frame.

Piston
The Piston is encased within the cylinder
housing and lifts the telescopic section of the
mast assembly. The piston is constructed from
chrome plated tubing.

Flow Controls
The Flow Control limits the rate fluid leaves the
cylinder in the event of a broken hose.

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Lift/Lower System

Lift Chain
The heavy duty Lift Chain is constructed of 3 / 4
inch pitch, 4x4 laced leaf chain. The lift chains
comply with ANSI/ASME 829.8 requirements.

Reservoir
The welded steel Reservoir has a capacity of
approximately 5.5 gallons (20.8 L).The
reservoir is located above the battery in the
power section and is vented to the atmosphere
through the filler cap.

Return Line Filter

The Return Line Filter consists of a 10 micron
filter element and bypass valve set a t 15 psi
(103.4 kPa) cracking pressure. The unit has a
replaceable spin-on type canister.

Lift/Lower Hydraulic Manifold Assembly

The Lift/Lower Hydraulic Manifold Assembly
controls hydraulic flow rate and direction in the
lift/lower system. The manifold assembly is
controlled electrically by the lift truck Tractor
Interface Card. The assembly is located in the
lower, forward, left-hand side of the power
section.
The Lift/Lower Hydraulic Manifold Assembly
consists of:
Manifold Housing
Check Valves
High Pressure Relief Valve
Fixed Low Pressure Relief Valve
Manual Emergency Lowering Valve
Proportional Lower Solenoid (SOL1)
Load Holding Solenoid (SOL2)
Pressure Test Ports
Pressure Transducer (optional weight
measurement)

Manifold Housing
The Manifold Housing is machined from
aluminum and contains the components
identified in Figure 3-4 on page 3-26.

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Lift/Lower System

Lift Pump Check Valve (5 PSI) (34 kPa)

The Lift Pump Check Valve prevents hydraulic
oil from flowing back through the lift pump.

High Pressure Relief Valve

The High Pressure Relief Valve is set to prevent
lifting a load which exceeds the maximum load
capacity of the lift truck.

Output Check Valve (100 PSI) (689 kPa)

The Output Check Valve provides for smooth
stopping during lift. It is also used as the fixed
low pressure relief valve.

Manual Emergency Lowering Valve

A Manual Emergency Lowering Valve provides
ground level control allowing the operator's
compartment to be lowered in the event the
operator is unable to bring the carriage down.
This is a knurled knob located on the lift/lower
hydraulic manifold assembly.

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Electrical Components and Systems

Electrical Components and Systems

General
This section is an overview; for actual
operation, see Theory of Operation or the
Operating Instructions in this manual.
The 24-volt electrical systems description
includes:
Traction/Lift System Components
Traction/Lift Power Amplifiers
Electric Steering
Miscellaneous Circuits

Traction/Lift Power Amplifiers

The Traction and Lift Power Amplifiers (Figure
3-5 on page 3-28) monitor and control current
flow through the traction and lift motors,
respectively, The traction amplifier is separately
excited and controls traction motor speed and
.torque. The lift motor amplifier controls the
series-wound lift motor. The ampmers are
located on the right side of the power section.
The amplifiers feature:
Smooth, step-less operation
Current limiting
Under/over voltage and thermal protection
Fault protection
Plug braking (traction only)
The amplifiers are low-maintenance sealed
units, with no user-serviceable parts.

Battery Connector
The Battery Connector is located on the left side
of the truck and is mounted on the power
section frame.

Solenoid 1 (SOL1) (Variable Lower)

SOL1 is the variable lower solenoid. Solenoid 1
proportionally controls hydraulic flow from the
lift cylinders.

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General

Solenoid 2 (SOL2)
SOL2 is the load holding solenoid. It prevents
hydraulic fluid from leaving the lift cylinder
when the camage is elevated and the lift/lower
control is in neutral.

Solenoid 12 (SOL1 2)
SOL1 2 is the brake dump solenoid. When
activated, it releases the brake; when
deactivated, the solenoid allows hydraulic
pressure to apply the brake.

Power Disconnect Contactor (MM)

The Power Disconnect Contactor is a single unit
with one contact actuated by a single coil.
N O T E: Contactors used are magnetic type,
designed for maximum
interchangeability of parts. Contactor
tips are silver alloy and are replaceable.

Drive Motor
The Drive Motor is a shunt-wound direct
current motor and uses sealed bearings for long
service life. The drive motor transmits power to
the reduction unit by a pinion gear on the
motor armature shaft. A brake drum mounts on
the other end of the armature shaft.

Drive Motor Temperature Sensor (DT)

A thermister provides a traction motor
temperature input to the tractor interface card.

Lift Motor
Power to drive the lift pump is a series wound,
fan cooled, intermittent duty motor.

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General

Reservoir ESD Jack Return Line Filter

Brake Assembly

Lift Pump
Motor (Dh

Lift Pump

LiWLower Steer Motor ~ r i v ; Motor

Manifold (DMS) (DMD)

Figure 3-4: Hydraulic Comportment Components (Sheet 1 of 2)

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Toyota Orderpicker Service Manual Systems Overview

General

.
Lift Pump
Output Check Valve

\ Proportional Valve
SOL,

Emergency
Lower
Valve

\
~ i ~ t pressure
-, ~oab Holding LiwLower Pressure Test
Relief valve Solenoid SOL2 Manifold C~nne~ti~tl

Pressure Transducer
(optional)

Figure 3-4: Hydraulic Compartment Components (Sheet 2 of 2)

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Systems Overview Toyota Orderpicker Service Manual

General

F4-F8

'ontactor

I n Amplifier

npliiier

Figure 3-5: Electrical Compartment Components

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Toyota Orderpicker Service Manual Systems Overview

General

Key Switch Operator's Display

Emergency Power
Disconnect Button

Steering b l

Travel, Lift/
Lower
Control

AutoIManu
OnIOif
Switch

Carriage
lnteriace
Card

Brake
Dump
Deadman
Solenoid
Cylinder
(SOL12 )

~ e a d ; n a nPedal
'
Pallet Clamp
Release

Figure 3-6: Platform Components (Electric Steering, Cover Removed)

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Systems Overview Toyota Orderpicker Service Manual

General

Carriagenractor lnterface Cards

Virtually all lift truck inputs and outputs pass
through and are monitored by the Carriage and
Tractor Interface Cards. The Display Card and
Steer Controller also have 1 / 0 functions. The
tractor interface card controls the traction and
lift/lower systems and "talks" to the Display
card over the CAN bus. The carriage interface
card accepts inputs from the control handle,
and transfers data to the Display Card. The
Carriage Card interfaces with the Display Card:
of the two, only the Display Card has
intelligence.

Carriage lnterface Card

The Carriage Interface Card (Figure 3-7) is a n
Input/Output (I/O) card that reads and passes
the readings to the Display Card. Readings
involve input/output from switches, the control
handle, and the brake dump solenoid,
including:
Control Handle Switches and Controls
EPO Switch
24" Limit Switch
60" Limit Switch
Key Switch
Auto/Manual Switch (optional)
Left Sidegate Switch (optional)
Right Sidegate Switch (optional)
Control Handle

Figure 3-7: Carriage Interface Card

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General

Tractor Interface Card

The Tractor Interface Card (Figure 3-8) is an
Input/Output (I/O) card that receives input/
output from switches, sensors, and solenoids. It
is controlled by the Display Card.
Switch Inputs:
Lift Brush Wear Switch
Traction Brush Wear Switch
Brake Switch
150"/180" Switch
120"Switch
Lift Inhibit Switch (optional)
Sensor Inputs:
Lift Sense
MM Contactor Sense
Outputs are:
Proportional Solenoid
Load Holding Solenoid
MM Contactor
Horn

Figure 3-8: Tractor Interface Card

Regulated Power Supply

A Regulated Power Supply is located on the
Steer Controller Card. The power supply
delivers clean, stabilized power throughout the

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General

network. Voltages generated by the power

supply are:
+12 volts (for all cards)
+5 volts used by the Steer Controller Card
NOTE: This power supply should not be used to
operate add-on accessories.

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Toyota Orderpicker Service Manual Systems Overview

Steer Controller Guidance System

Steer Controller Guidance System

The electric steering control system interfaces
with the Tractor Interface Card and the Display
Card, and determines the truck steer direction.
The steering system is comprised of the
following components:
Steer Controller
Steer Motor (DMS)
Display Card (see Note)
Filter Card (optional wire guidance)
Steering Encoder
Home Switch Proximity Sensor
Antennas (Load and Tractor - wire
guidance)
Cables
NOTE: The Display Card is integrated with all
systems.

Steer Controller
The Steer Controller Card (Figure 3-9 on page
3-34) contains status LED's and a maintenance
display. This section describes how the display
works and what the LED's mean.
The individual items discussed are the:
Heartbeat LED
CAN LED
+12 Volt LED
+5Volt LED
Seven Segment Display

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Steer Controller Guidance System

+5 Volt LED , ,+12 Volt LED

Heartbeat LED -3.L 4tyij-!7,,
CAN LED .----)1
2
.
-JS1
1

~
I

Firmware Socket
/ -
I

Seven -
Segment
Display

I
-
-

, JS2 (ref)

Figure 3-9: Steer Controller Card

Heartbeat LED
The Heartbeat LED will turn On/Off at a rate of
approximately 60 times per minute.
A s long a s the heartbeat LED is blinking, the
processor on the card is working.

CAN
CAN stands for Controller Area Network. A CAN
is a communication protocol developed for
"noisy" environments. A CAN uses two digital
signal lines referred to a s Bus+ and Bus-.

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Steer Controller Guidance System

CAN LED
The CAN LED indicates the status of
communications on the CAN Bus between the
Steer Controller Card and the Display Card.
When the CAN LED is Off, communications
across the CAN Bus are being processed
without error.
When the CAN LED is On, an error in
communications across the CAN Bus has
been detected.

+ 12 Volt LED
The +12 Volt LED is lit a s long a s +12 volts is
being generated by the power supply on the
Steer Controller Card. The LED only indicates
that +12 volts is being generated, not that the
voltage is within specification.

+ 5 Volt LED
The +5 Volt LED is lit a s long a s +5 volts is
being generated by the power supply on the
Steer Controller Card. The LED only indicates
that +5 volts is being generated, not that the
voltage is within specifications.

Seven Segment Display

The Seven Segment Display is used to
communicate the status of the steer controller
guidance system to the technician. When the
system is operating normally at idle, each
segment of the seven segment display will light
one at a time. This process will repeat
continuously until the steering/guidance
system is activated.
Since this is a single segment display, a code
having two digits must be displayed one digit at
a time. Also, the display is not able to show all
characters. An example of how some of the ,
codes are displayed follows:

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Systems Overview Toyota Orderpicker Service Manual

Steer Controller Guidance System

-1 1 Code VK is displayed.

Code 53 is displayed.

Code F2 is displayed.

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Toyota Orderpicker Service Manual Systems Overview
Display Controller Card

Display Controller Card

The Display Controller Card is located on the
operator's console. The display controller serves
a s a communication device and a s a feed
through for signals from the steering encoder to
the Steer Controller Card. It displays, in text,
various messages about all the truck systems.
It also has a keypad and additional LED'S to
interface with the operator and technician.
Figure 3- 10 on page 3-38 identifies the various
parts of the display card. Individual items
include:
IL1
LED Display

IL1 is the red LED located on the upper left

comer of the card assembly. IL1 will blink at a
rate of approximately 60 times per minute and
will start to blink when:
Successful communications with the steer
controller is established.

Alpha-numeric Display
The Alpha-numeric Display is the portion of the
card assembly that the operator/technician
sees. This display shows operation and fault
messages.

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Systems Overview Toyota Orderpicker Service Manual

Display Controller Card

I L l (red)
Heartbeat LED LED Display

bocket -* 1-

HD5
\i___. - -
-

f i (
HD2 (backside)

JS 1 (backside) HD4

Figure 3- 10: Display Controller Card

Filter Card
The Filter Card (Figure 3-11 on page 3-39) is
used only when wire guidance is installed. The
filter card mounts on top of the Steer Controller
Card. Individual items on the filter card
include:
JS1
JW1
JW2
IL1 (+12volts)
IL2 (+5volts)

This connector is located on the underside of

the filter card. This connector mates with the
Steer Controller Card.

JWl /JW2
The JW1 connector connects the tractor-end
sensors to the filter card. The JW2 connector
connects the load-end antenna to the filter
card.

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Toyota Orderpicker Service Manual Systems Overview

Display Controller Card

IL1 (+ 12 volts)
The +12 Volt LED is lit as long as +12 volts are
being generated by the power supply on the
Steer Controller Card. The LED only indicates
that +12 volts are being generated, not that the
voltage is within specification.

+5 Volt LED
The +5 Volt LED is lit as long as +5 volts are
being generated by the power supply on the
Steer Controller Card. The LED only indicates
that +5 volts are being generated, not that the
voltage is within specification.

Figure 3- 7 1: Filter Cord (with wire guidance only)

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Systems Overview Toyota Orderpicker Service Manual

Miscellaneous Circuits

Miscellaneous Circuits

Fuses
Fuses on the Orderpicker include the following:

Sidegate Switches (S60, S61)

The Sidegate Switches prevent all travel and
lift/lower functions when the sidegates are in
the vertical position. The sidegate switches
supply an input signal to the Carriage Interface
Card which monitors their status.

Tie-Points
Four (4)Tie-Points (TP) are located on the lift
truck: TP1 (F1 - B+);TP2 (I72 - Traction Motor);
TP3 (F3 - Lift Motor) and TP4 (B-).

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Toyota Orderpicker Service Manual Systems Overview
Cables

Cables

Over-the-Mast Cables
The Over-the-Mast Cables required for truck
operation are a s follows:
One 8-conductor cable
One 4-conductor cable

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Over-the-Mast Cables

This page intentionally left blank

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Toyota Orderpicker Service Manual Planned Maintenance

Planned Maintenance

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Planned Maintenance Toyota Orderpicker Service Manual

Planned Maintenance

Planned Maintenance

General Maintenance Instructions

Industrial lift trucks may become hazardous if
adequate maintenance is neglected. Only
trained technicians, using approved
procedures, in adequate maintenance facilities
should work on this or any other lift truck.

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Toyota Orderpicker Service Manual Planned Maintenance

Planned Maintenance

Planned Maintenance

Introduction
A planned maintenance program will ensure:
Maximum truck performance
Maximum truck life
Reduction of costly downtime
Avoidance of expensive repairs
Planned maintenance includes:
Cleaning
Inspection
Lubrication
Creating a list of repairs required.

Maintenance Manual
Use this manual as required to perform all
repair procedures listed in the Planned
Maintenance Schedule.

Planned Maintenance Schedule

Perform all inspections and lubrication in
accordance with the Planned Maintenance
Schedule. See "Lubrication Equivalency Chart"
on page 9-2.

NOTE: Daily (8 hour) inspections should be

performed by the operator.
All listed repairs should be scheduled for
a convenient time between,a n
authorized Customer Representative
and a Qualified Service Technician. All
repairs should be carried out AFTER the
planned maintenance tasks are
completed. Labor and parts for repairs
should be calculated as part of the
standard truck maintenance costs,
separate from the planned maintenance
charges.

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Planned Maintenance Toyota Orderpicker Service Manual

Maintenance Manual

Time Requirements
Performing Planned Maintenance will require
approximately 1.25 hours.

General Truck Operation

Talk to the driver to see if any problems
were noticed.
Operate all functions of the truck and
check for any abnormal operation.
Check to see if all the safety and
operational decals are in place and legible.
List repairs required.

Gearbox Oil Level

Check oil level.
Check breather.
Check for leaks a t seals, and the condition
of the oil to see if it requires changing.
Listen to the drive unit gears for harsh or
unusuai sounds which could indicate wear.
List repairs required.

Reservoir Oil Level

Check the oil level in the reservoir for the
proper amount. The correct level is a t the
bottom of the screen.
Check the time interval between hydraulic
filter replacements.
List repairs required.

Truck Lubrication Points (Figure 4-1 on page

4-1 2)
Grease/lubrication all identified lubrication
points.
Replace any broken grease fittings.
Look for any excessive wear in these areas.
Check for presence of wet or cold storage
dielectric grease a t control wire
connections.
List repairs required.

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Toyota Orderpicker Service Manual Planned Maintenance

Maintenance Manual

Electrical Connections

NOTE: Refer to "Electrical Connector Locator

Chart" on page 5-4.

Wiring Harness Check

Check to make sure the harnesses are not oil
soaked and that they are in good condition.
Switches and Contactors
Make sure that the contactor tips are not
burned or pitted.
Make sure that all switches are operating
and providing their designated function.
List repairs required.

Motor Brush Wear

Check every brush in every motor for the
proper length. For drive and lift motors, the
minimum brush length is 0.63"(1600 mm).
Check the spring tension on the brushes.
For drive and lift motors, a spring tension of
30-36 oz. (852-1022 g) for new brushes is
acceptable.
Check the commutator in the armature for
wear. For drive and lift motors, the
minimum commutator diameter is 2.75"
(69.80mm).
Check all electrical connections for
tightness, damage, or wear.
List repairs required.

Hydraulic Cylinder
Check all cylinders for leaks.
Loose fittings.
Loose mountings.
Rod wear or damage.
List repairs required.

Hydraulic Llnes
Check to see if there are leaks or any improper
wear of hoses and that hoses and lines are not
crimped, or in danger of being damaged.
List repairs required.

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Planned Maintenance Toyota Orderpicker Service Manual

Maintenance Manual

Brake & Linkage

Check the brake for proper wear and
adjustment.
Check the linkage to make sure it is free
and adjusted correctly.
List repairs required.

Wheels
Inspect the condition of the drive and load
wheels.
Check and remove all foreign matter
between wheels and housings.
Remove any steel chips to prevent damage
to the wheels.
Check for gouging and chunking of tire
surface.
Check to make sure the bearings are still
good and shimmed properly.
Check caster wheel adjustment if
applicable.
List repairs required.

Accessories
Check all accessories for their proper functions.
List repairs required.

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Toyota Orderpicker Service Manual Planned Maintenance

Maintenance Manual

Battery

NOTE: The following steps constitute an

abbreviated version of battery
maintenance. Refer to Battery
Maintenance in this section for
comprehensive procedures.
Check for correct battery electrolyte level.
Check the battery leads for excessive wear
and corrosion.
Check for corrosion on the battery case.
Check the charger connector for damage.
Check the connections on the battery and
charger connectors.
Make sure the charger is operating
correctly.
Check truck battery rollers and surface
condition.
Check battery stand rollers and surface
condition.
List repairs required.

NOTE: Cleaning and adding water to batteries

requires labor over and above the
standard planned maintenance time
allocation.

Chain Condition
Check for excessive wear and/or stiff spots
in chain.
Check for proper adjustments and
alignment.
Check for cleanliness.
Check for excessive grease.
List repairs required.

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Planned Maintenance Toyota Orderpicker Service Manual

Maintenance Manual

Steering Assembly
Check for proper operation.
Check for oil leaks.
Check steer stop function and condition.
Check wire guidance system, including
brake dump operation (if installed).
Check rail guidance system/steer centering
switch (if installed).
List repairs required.

Lift Pump Spline

At 1000 hours of operation, disassemble lift
pump from lift motor and apply grease to the
coupling. Reassemble lift pump and motor.

NOTE: Greasing the lift pump spline requires

labor over and above the standard
planned maintenance time allocation.

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Toyota Orderpicker Service Manual Planned Maintenance

Planned Maintenance Schedule

Planned Maintenance Schedule

Time Interval
Refer to Figure 4-1 for Item Number Locations (Hours on Deadman)
1 30 180 360
Day Days Days Days
8 200 1000 2000
Hrs. Hrs. Hrs. Hrs.
Item Component Check
1 Check Charge, Volts, and Specific Gravity. (every X X X
Battery 40 X X X
Cleanliness
Water Level hrs,) X X X
2 Battery No damage, solid electrical connections, X X X X
Connector battery disconnect works properly.
3 Battery Properly installed, locked securely,
Gates horizontal motion of battery limited to 1 /2" X X X X
(13 rnrn)- add spacers as required.
4 Proper action, stops truck within 10 feet
Brake (3 meters), releases completely when X
X X X
deadman pedal is depressed. Check fluid
level in brake reservoir.
5 Contactor
No pitting, burning. Sufficient contact
Tips X X X
material remaining.
6 Cable/
Hoses/ Hoses and cables in good condition. Spring X
Tension tension adjusted properly?
Springs
Chassis/ Grease. Guards/covers installed. Sidegates
Mast X X X
work properly.
8 Deadman Smooth action, no binding, releases when
X X X
Pedal foot is lifted off pedal.
9 Deadman Disables travel/lift functions and stops
X X X X
Switches truck when pedal is released.
X X
10 Drive Unit Check fluid level. X X
Change Fluid X X
Grease the ring gear. X X X
Grease the pivot bearing. X

11 Forks Not bent, no modifications X X X X

12 Function Travel and lift/lower should control their
Controls respective function. Steers smoothly from X X X X
stop-to-stop.
13 Horn Sounds when activated. X X X X

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Planned Maintenance Toyota Orderpicker Service Manual

Planned Maintenance Schedule

Time Interval
Refer to Figure 4-1 for Item Number Locations (Hours on Deadman)
1 30 180 360
Day Days Days Days
8 200 1000 2000
Hrs. Hrs. Hrs. Hrs.
Item Component Check
* All Hydraulic
Connections
No leaks. X X X X

Hydraulic Check fluid level (1" [2.54cm] above top of

Reservoir strainer with carriage lowered a t room X X x
15 temperature.)
Change filter.
Change fluid. X
Lift Chains Inspect, check for wear/lubrication X X X
16
17 Lights All lights should function. X X X X
Motor Condition of brushes, springs, and holders. X X X
l8 Does length exceed minimum length?
Brushes
19 Switches Control assigned function X X X X
Wheels / Cracks, wearable surface in good
20 Tires condition, flat spots, bond failure, foreign X X X X
material.

Inspect. Replace any components that X X X X

Tether/ show damage or excessive wear. Replace a s
21
Safety Belt
necessary.

Overhead Inspect for cracks or damage. X X X X

22
Guard -
Windscreen X X X X
23 Inspect for damage.
(optional)
Fire
24 Extinguisher Check charge. Replace if charge is low. X X X X
(optional)

Static Straps Check all straps for wear. Keep straps X X X X

25 (beneath
clean. Replace as necessary.
truck)

Decals,
25 Warning In place and legible. X X X X
Labels
Operator
Clean. Remove any ice accumulations (cold X X X X
26 Floor/
storage vehicles).
Operator
Controls

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Toyota Orderpicker Service Manual Planned Maintenance

Planned Maintenance Schedule

Time Interval
Refer to Figure 4-1 for Item Number Locations
(Hours on Deadman)
1 30 180 360
Day Days Days Days
8 200 1000 2000
Hrs. Hrs. Hrs. Hrs.
Item Component Check
Decals,
27 Warning In place and legible. X X X X
Labels
Visually inspect all cables for damage and
poor connections.
X X X
Electrical Check for battery leakage to truck frame.
28 X X X
system Check for shorts to truck frame.
X X X
Check for dielectric grease when cold
X X X
storage.

29 Lift Pump Disassemble and lubricate. X X X

spline
All Hardware Check for tightness or damage. Tighten or
30 X
repair as necessary.

NOTE: List repairs and report any damage to

the supervisor or maintenance
personnel.

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Planned Maintenance Toyota Orderpicker Service Manual

Planned Maintenance Schedule

Figure 4- 1: Lubrication/lnspection Points

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Toyota Orderpicker Service Manual Planned Maintenance

Battery Maintenance

Battery Maintenance

The following information does not supersede or

replace information supplied by the battery and
battery charger manufacturer. Read the manual
supplied with the battery and charger.
Notify your supervisor if you have any concerns
or questions regarding battery safety or
procedures.

Battery Safety

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. An open
flame or spark can 'ignite this gas,
resulting in serious damage or injury.

A CAUTION
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 immediately.

For your safety, observe the following

precautions when working with or around lift
truck batteries:
1. Read, understand, and follow procedures,
recommendations and specifications in the

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Battery Safety

battery and battery charger manufacturer's

manuals.
2. Wear protective clothing for eyes, face, and
skin. This equipment includes goggles or
face shield, rubber gloves (with or without
arm shields), and a rubber apron. Make
sure a shower and eye wash station are
nearby.
3. Do not smoke, use open flames or spark
producing devices near batteries.
4. Charge batteries in a well-ventilated area to
avoid hydrogen gas concentration.
5. Do not break live circuits at the battery
terminals because a spark usually occurs
at the point where a live circuit is broken.
6. Never lay tools or metal objects on top of
the battery, to avoid a short circuit or
explosion.
7. Keep batteries clean. Corrosion can cause
shorts to the frame and sparks.
8. Keep plugs, terminals, cables and
receptacles in good condition to avoid
shorts and sparks.
9. Keep Mer plugs firmly in place at all times
except when the electrolyte level is checked,
when water is added to the cells or when
the specific gravity is checked.
10. Make sure the venting holes in the filler
plugs are open so gas can escape from the
cells.
11. Do not allow cleaning solution, dirt or any
foreign matter to enter the cells.
12. Charge batteries a t the indicated rates and
do not overcharge.

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Battery lnspection and Care

Battery Inspection and

Care
N O TE: Read, understand, and follow
procedures, recommendations and
specifications in the battery and battery
charger manufacturer's manuals.
Batteries in industrial lift trucks pick up
various kinds of dirt and dust depending on
their surroundings and the types of material
handled. If cells are overfilled and electrolyte
collects on the covers, the following occurs:
1. The top of the battery becomes wet and
stays wet, since the acid in the electrolyte
does not evaporate.
2. This moist surface, in combination with
certain kinds of dirt, becomes electrically
conductive and permits stray currents to
flow externally over the top of the battery.
This degrades battery performance and lift
truck operation.
3. The acid also causes corrosion of cell posts,
nuts, connectors and the steel battery case.
When inspecting batteries, check the following:
1. Wet covers can indicate overfilling, l e w
seals at posts, or excessive gassing during
charge. If covers are wet, determine the
cause and correct the problem.
2. Make sure batteries cannot move more
than 0.5 inches ( 1 3 mm) in any horizontal
direction. Shim or block to restrain them.

Battery Cleaning Procedure

Refer to the recommended battery
manufacturer's guidelines for details.

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Planned Maintenance Toyota Orderpicker Service Manual

Charging Process

Charging Process
OSHA regulations require that battery charging
installations be located in areas designated for
that specific purpose. Such areas must provide
for flushing and neutralizing spilled electrolyte,
for fire protection, for protecting charging
equipment from damage by lift trucks and for
adequate ventilation of fumes from gassing
batteries.
To charge a battery, direct current is passed
through the battery cells in the direction
opposite that of discharge. Charging time is 5%
to 20% longer than discharge time.
Read, understand, and follow procedures,
recommendations and specifications in the
battery and battery charger manufacturer's
manuals.

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Toyota Orderpicker Service Manual Troubleshooting

Troubleshooting

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Troubleshooting Toyota Orderpicker Service Manual
How to Use This Chapter

How to Use This Chapter

This chapter uses 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.
Use the GENERAL TROUBLESHOOTING
Chart GEN1 to guide you to the individual
symptom chart you need. See "List of
Troubleshooting Charts" on page 5-25.
Once you're familiar with the symptoms
listed, you may instead simply look up the
symptom chart from the List of
Troubleshooting Charts.
As you work with a troubleshooting symptom
chart, you may be instructed to test various
electrical connector pins. Use the Electrical
Connector Locator Chart to find a particular
electrical connector.
Every time you complete a troubleshooting
procedure, be sure to follow the steps in End of
Troubleshooting Chart END1.
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 GEN1. This chart will
help you approach the problem in a systematic
and logical manner.
Each chart begins with a lozenge-shaped
symbol containing the title and symptom.
Charts are identified as H for Hydraulic, T for
Travel, and W for Wiring. The logic generally
flows top to bottom and left to right. A symbol
shaped like a baseball home plate means the
chart is continued on another page, either a
continuation of the current chart, or a different
chart. Continuation charts have a suffix
number added. A continuation chart begins
with a circle-shaped symbol containing the
chart number, including suffix.

Electrical Troubleshooting
Guidelines
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check
the electrolyte level and state of charge.

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Toyota Orderpicker Service Manual Troubleshooting

Electrical Troubleshooting Guidelines

Be sure to block the lift truck

whenever a troubleshooting
procedure requires turning key
switch S1 ON. This will avoid
accidents caused by unexpected lift
truck travel.

A CAUTION
Unless otherwise directed,
disconnect the battery connector
when you check electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Save time and trouble by looking for simple
causes first.
Visually inspect all wiring and electrical
components for:
Loose connections or connectors
Loose or broken terminals
Damaged terminals, blocks, or strips
Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring
continuity.
For information on connectors, refer to the
Electrical Connector Locator Chart. -

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Troubleshooting Toyota Orderpicker Service Manual

Electrical Connector Locator Chart

Electrical Connector Locator Chart

Connector Location Function or Routing
HD1 Display Card Can Bus +/- to Steer Controller a t J P 5
HD2 Display Card Overlay Up/Down/Hourglass Switches, BSOC 1
& 7- 10 LED's, Brush Wear, and Steer LEDs
HD3 Display Card Sonalert
HD5 Display Card Display card to JPP1: Steering Encoder
HD6 Display Card Overlay (BSOC LED'S 2-6, Input Ramp Switch,
Steer LED's)
JL1 Lift Power Amplifier Lift Power Amplifier to Tractor Interface Card a t
JPRlO
JL2 Lift Power Amplifier Lift Power Amplifier Can Bus to Tractor Interface
Card a t JPRlO
J P1 Steer Controller Card Steer Controller to Drive Unit position Encoder
and deadman signal from Tractor I/F Card
JP2 Steer Controller Card Steer Controller to Lift Pressure Transducer
(optional) and signals from/to Tractor I/F Card
JP4 Steer Controller Card Steer Controller CAN Bus to Tractor I/F Card
JPRl
JP5 Steer Controller Card CAN Bus and 12V over-the-mast cable connector
TP5 to Display Card HD1
JP6 Drive Unit Position Encoder Encoder ECN2 steering feedback to Steer
Controller Card
JP7 Steer Controller Rail Switch Rail Switch S15 connector JP7 to Steer
(optional) Controller Card
JP8 Steer Controller Home Switch PROX Switch on/off to JP2 on Steer Controller
Proximity Card
JP9 Steer Controller SP1 Speed Proximity 1 to JP2 on Steer Controller
Card
JPlO Steer Controller SP2 Speed Proximity 2 to JP2 on Steer Controller
Card
JPC 1 Carriage I/F Card Carriage I/F Card to Display Card: Travel, Lift/
Lower, and Data
JPC2 Carriage I/F Card Control Handle to Carriage I/F Card
JPC3 Carriage I/F Card Brake Dump Solenoid (SOL12) control
JPC4 Carriage I/F Card Over-the-mast cables for B+, B-, Key switch, and
E-stop functions
JPC5 Carriage I/F Card Battery Power Connector
JPC7 Carriage I/F Card S45 Auto/Manual Switch (optional), 24"/6OW
Limit Switch
JPC8 Carriage I/F Card Left Sidegate Switch S61
JPC9 Carriage I/F Card Right Sidegate Switch S60

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Toyota Orderpicker Service Manual Troubleshooting

Shorts to Frame Test

Connector Location Function or Routing

JPRl Tractor I/F Card Tractor I/F Card to Solenoid Coils SOL1 and
SOL2 (Proportional and Load Holding) and
Bus+,Bus- to Steer Controller
JPR3 Tractor I/F Card Tractor I/F card to Back Up Alarm and MM
Contactor
JPR4 Tractor I/F card Tractor I/F Card over-the-mast connector
JPR5 Tractor I/F Card Spare Switch (optional)
JPR6 Tractor I/F Card S26 - 150" Switch and SlOO - 180" Switch
JPR7 Tractor I /F card S 10 - 120" Switch (optional)
JPR8 Tractor I/F card S24 - Lift Inhibit Switch (optional)
JPR9 Tractor I/F card S27 - Travel Cutout Switch (optional)
JPRlO Tractor I/F card Tractor I/F card to:
Traction Power Amplifier at JT1
Lift Power Amplifier at JL1
Lift Motor Sensor (LM- on Lift power
Amplifier)
JPRl 1 Tractor I/F card Lift Motor Temperature Sensor (optional)
JPS2 Display Card Display Card Serial Communication to Carriage
I/F card at JPC1
JPS3 Display Card Display Card Analog Input to Camage I/F card
a t JPC 1
J S1 Filter Card Steer Controller to Filter Card
JT1 Traction Power Amplifier Traction Power Amplifier to Tractor I/F card at
JPRlO
JT2 Traction Power Amplifier Traction Power Amplifier CAN Bus to Tractor I/F
card at JPRlO
JPM Near Traction Motor Traction Motor Temperature Sensor (DT)to
Tractor Interface Card a t JPRl1
JPZ Near Lift Motor Lift Motor Temperature Sensor (LT) to Tractor
Interface Card at JPRl1
JP9/JP10 On top of Brake/Traction Speed Feedback Proximity Sensor to Steer
Motor Assembly Controller a t JP2
LB Near Lift Motor Lift Brush Wear
PT Pressure Transducer Steer Controller at JP2
TB Near Traction Motor Traction Brush Wear

Shorts to Frame Test

"Shorts to frame" is an industry term for
unintentional current leakage paths between
normally isolated electrical circuits and their
metal enclosures.

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Troubleshooting Toyota Orderpicker Service Manual

Shorts to Frame Test

Shorts to frame may be metallic connections,

such as a wire conductor contacting metal
through worn insulation. More often, shorts to
frame are resistive "leakage" paths caused by
contamination and/or moisture.
These leakage paths can result in unwanted
electrical noise on the metallic truck structure,
m d may result in improper operation.
Shorts to frame can be caused by:
accumulation of dirt
battery electrolyte leakage
motor brush dust
motor brush leads touching the housing
breakdown in insulation
bare wires
pinched wiring harness
improper mounting of circuit cards
Shorts to frame can occur a t numerous
locations on a truck, including:
batteries
motors
. cables, wiring, and harnesses
heat sinks
bus bars
solenoids
contactors
tenninal strips
switches
power panel insulation
circuit card mounts

To test for shorts to frame:

1. Turn the key switch OFF and disconnect
the battery connector.

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Toyota Orderpicker Service Manual Troubleshooting

Shorts to Frame Test

2. To test the battery for shorts to case,

connect a 12-volt test light to the battery
case from battery B+, and then to the
battery case from battery B-. If the light
lights a t all, even momentarily, there is a
serious problem with the battery, either
external contamination or internal damage.
DO NOT continue until this condition is
corrected. Your meter may be damaged if
you proceed before correcting this
condition.
Install another battery in the truck and
repeat this procedure from step 1.
If the test light does not light, continue to
the next step.
3. With the battery disconnected from the
truck, use a digital volt/ohm/ammeter on
the ampere function to measure the leakage
current from the battery case to battery B+
and from the battery case to battery B-.
Begin measuring a t the highest Ampere
scale and work toward the lowest. A reading
of more than 1 mA (0.001 A) indicates a
serious short. DO NOT continue until this
condition is corrected. Your meter may be
damaged if you proceed before correcting
this condition.
Install another battery in the truck and
repeat this procedure from step 1.
If the current is less than 0.2 mA
(0.0002 A), go to step 4. If the current is
greater than 0.2 mA (0.0002 A) and less
than 1 mA (0.001 A), remove the battery
from the truck, then continue with step 4.
Ensure the battery case does not touch the
truck frame during the remaining tests.
4. With the battery disconnected (or removed
and disconnected) from the truck, use a
digital ohmmeter to measure the resistance
from truck frame to truck B+, to truck B-
(NOT battery B+ and B-), and to all fuses
and motors. A reading of less than 1000
ohms indicates a serious short. DO NOT
continue until this condition is corrected.
Your meter may be damaged if you proceed
before correcting this condition.
a. To identify the cause of the short to
frame, disconnect circuit components
until the low resistance condition

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Troubleshooting Toyota Orderpicker Service Manual

Shorts to Frame Test

disappears. Do not reconnect

components one at a time, but leave
them disconnected until the low
resistance reading disappears. Prevent
disconnected terminals or connectors
from touching truck frame or other
conductive surfaces.
b. The most likely areas to check are:
motors
power cables
power circuit components
control circuit components
c. Repair or replace the component
causing the low resistance condition,
Then repeat Step 4.
d. Reconnect all other components
previously disconnected, one a t a time,
measuring resistance between steps. If a
reading is less than 1000 ohms when
reconnecting a component, that
component or its wiring is defective;
repair or replace a s appropriate.
e. When, after all components are
reconnected, you get readings greater
than 1000 ohms, continue with the next
step.
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/arnmeter on the current
function meter to measure leakage current
to the truck frame from Bc, B-, and all
fuses and motor terminals. Begin
measuring at the highest ampere scale and
work toward the lowest. If the current is
less than 1mA (0.001 ampere), go to step 7.
If the current is more than 1 mA
(0.001 ampere), continue this step below.
a. To identify the cause of the short to
frame, disconnect circuit components
until the leakage current reads less than
0.001 A (1 mA). Do not reconnect
components one a t a time, but leave
them disconnected until the leakage
current reads less than 0.001 ampere
(1mA). Prevent disconnected terminals

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

Shorts to Frame Test

or connectors from touching truck frame

or other conductive surfaces.
b. The most likely areas to check are:
motors
heat sinks
power cables
power circuit components
control circuit components
c. Repair or replace the component(s)
causing the leakage current.
Repeat step 6.
d. Reconnect all other components
previously disconnected, measuring
current between steps. If a reading is
more than 1 mA (0.001 A) when
reconnecting a component, that
component or its wiring is defective.
Repair/replace a s appropriate.
7. When, after all components are
reconnected, you get a reading less than
1 mA (0.001 ampere) there is no short to
frame condition with the truck or the
battery. If you previously removed the
battery from the truck, re-install the
battery.

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Troubleshooting Toyota Orderpicker Service Manual

Shorts to Frame Test

s Shorts t o Frame Test

Turn the key switch

OFF and disconnect
the battery
1
I
With battery connector
disconnected. measure
leakage
w
current from batten
case to battery B+ and to
L
connector.
battery B-. current setting
I I of meter, then
L m r k down.

light from battery

case to battery B+,
then from case to

Yes No

Install another Remove battery

battery. from truck.
A serious
problem exists
with the battery. Yes
DO NOT
continue until 4
this condition is
corrected, or
meter damage v
- may result.
Go to Chart

Figure 5- 1: Shorts to Frame Test

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Toyota Orderpicker Service Manual Troubleshooting

Shorts to Frame Test

. With battery connector

disconnected (or
disconnnected/removed),
measure resistance from
- Do NOT
conthue until
resistance
measures
truck frame to truck B+, > 1000 ohms, or
to truck B- meter damage
(NOT battery B+/B-),
& to all fuses & motors.

A resistance

than 1000
v------p~o------l
1 connectorl
switch Turn
ON. ke$
71
Reconnect the battery
I
1
Disconnect a circuit
component and
measure current
again. (Do not
reconnect previously
disconnected

I
1 components.)
Yes
!4 I

Disconnect a circuit Measure leakage

r-i
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
than 1000 ,. all components one a t a
time, measuring current
between steps.

Yes Yes
I
Repair or replace the 1 Truck has no
component last
disconnected. Reconnect all battery if previously
components one a t a time, / removed.
measuring resistance '

between steps. 1
I

Figure 5-1: Shorts to Frame Test (Cont.)

0 0 7 0 0 - ~ ~12Issued:
2 9/10/98
Troubleshooting Toyota Orderpicker Service Manual

Electric Motor Tests

Electric Motor Tests

Motor Types
Shunt-
S2 or E2 or 0 2
Refer to Figure 5-2.
A shunt-wound or series-wound drive Series-
Wound
motor has four external connections: two
Drive Motor
armature (A), and two field ( S , E, or Dl.
A1 S1 or E l or D l
A series-wound lift motor has only two
external connections because the armature
and field windings are connected internally.
A permanent magnet motor has only two S or D
external connections because the field is Series-
produced by an internal permanent Wound Lift
magnet. Motor
NOTE: Field connections may be labeled S.
Shunt-wound motor field connections
may be labeled E. Series wound motor
field connections may be labeled D.

Open Circuit Motor Test

An open circuit is one in which the electrical
circuit within the motor has been broken. This
can be caused by:
Permanent A2
bad brushes or brush springs Magnet
a broken wire in the field or armature Motor
winding
a loose or bad connection
Refer to Figure 5-2 for the following procedure:
1. Isolate the motor from the truck circuit by 5-2:
~i~~~~ Motor circuits
removing the power cables. Use two
wrenches to avoid twisting the terminal
stud.
2. With the motor a t room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
motor.

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Toyota Orderpicker Service Manual Troubleshooting

Grounded Motor Test

3. You should observe the following

measurements:

4. If the meter indicates high resistance in the

armature, check the condition of the
brushes before replacing the motor.
5. If you find an open circuit in a
series-wound motor, the motor must be
disassembled by a motor rebuilding facility
to isolate the problem to the field or
armature circuit.

Grounded Motor Test

In a grounded motor, a n electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
The ground may be caused by:
insulation breakdown
brush leads touching the motor housing
build-up of carbon dust or other
materials
To test for a grounded motor, follow the "Shorts
to Frame" test procedure.

Short Circuited Armature or Field

Winding
A short circuited winding is one in which the
insulation on the field or armature has broken
down at two or more points. The breakdown

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Troubleshooting Toyota Orderpicker Service Manual

Short Circuited Armature or Field Winding

creates a low resistance path, allowing current

to flow from one turn of the coil to another
adjacent coil turn, without actually flowing
through the coil wire. The result is a decrease in
total resistance of the motor winding and an
increase in the current flow. The severity of the
short circuit depends on its location.
A shorted motor may be indicated by:
Error Code: "M- Fault"
Slow or sluggish operation
Running faster than normal (suggests a
short in the field)
Overheating
Blowing a power fuse
Burning of brush wires
Severe burning or discoloration on
armature coil
Severe burning or discoloration on one
or two commutator segments every 90
of rotation.
These symptoms can be caused by problems
other than the motor itself
Brake too tight or dragging
Wheel bearings too tight
Faulty transmission
Binding in a n attached pump, hose, or
solenoid valve
Load wheels not aligned properly
Rail guided with drive tire not aligned
properly
Testing a motor for short circuited windings
requires special equipment a t a motor
rebuilding facility.

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Toyota Orderpicker Service Manual Troubleshooting
Hydraulic Troubleshooting Guidelines

Hydraulic Troubleshooting Guidelines

A CAUTlON
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.

1. Lower the camage fully.

2. Ensure that the forks are level.
3. When you check voltage a t solenoids, make
sure hydraulic lines and components are
fully installed.
4. Whenever possible, keep the key switch
OFF and the battery connector
disconnected.

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Troubleshooting Toyota Orderpicker Service Manual

General
General topics covered in this section are:
Leakage (external and internal)
System contamination
General hydraulic "tips"
Hydraulic oil
Specific Hydraulic Troubleshooting in this
section includes:
Lift/Lower system
Hydraulic pump problems
Miscellaneous hydraulic components
NOTE: It is important to keep accurate records
of all hydraulic inspections and work
performed on the trucks. Such records
are helpful in determining:
Repair and maintenance costs
Reliability of components
Durability of hydraulic fluid
Scheduling of maintenance

Hydraulic Leakage
Hydraulic leakage can cause load drop, load
drift, bouncing carriage and noisy pumps.
Wipe all connections clean when checking for
leaks. Remember. leaking fluid is likely to run
down the underside of pipes and drip a t low
spots. Many situations cause hydraulic leakage.
Any leakage inspection should include
operating units a s well as connections.

Use extreme caution while looking

for high pressure hydraulic leaks.
Personal injury may result if struck
by a high pressure stream of
hydraulic fluid.
Faulty Flexible Connectors
When installing a flexible connector, avoid
twisting it which creates a strain on the joint.

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Toyota Orderpicker Service Manual Troubleshooting

Hydraulic Leakage

Fitting
Do not spring a tube into place before
tightening a fitting. The resultant stress may
cause a leak.

Cracked or Bad Tubing Flare

Inspect all tubing before installation. Make sure
when making the flare that it is the right size.

Foreign Material in the Flare

Make sure the flare is clean before installation.

Defective Threads
Check for leakage around the threads when
installing new tubing.

Dirt Around 0-Rings

Thoroughly clean and lubricate any O-rings
before installation.

Wrinkled or Flattened Tube

Use a known-to-be-good tube bender and
carefully bend the tube.

Worn Packings
Examine packings for wear and leakage around
the cylinder pistons. If the packing is too tight,
abnormal friction and wear will occur. See that
cylinders are securely anchored and that
pistons are in alignment. Misalignment is a
cause of heavy wear of both pistons and
packings. Worn packings should be replaced
since they many times cause internal leakage. If
truck operation is sluggish, check the packing
inside the cylinder.

Bad Connections
When checking connections to pumps,
cylinders, manifold valves, etc., be sure to
observe both pressure and suction sides.
Pressure side leaks can be found by wiping
connections and observing the accumulations
of oil after brief truck operation. Brushing soap
solution on joints can be helpful. Air leaks on
the suction side of various components can
cause considerable trouble; listen for these
leaks; they may lead to air bubbles in hydraulic

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Troubleshooting Toyota Orderpicker Service Manual

Hydraulic Leakage

oil. Suction leaks are always difficult to find,

but they rate high in importance.

Drive Coupling Alignment

Check the alignment of the drive coupling
between the motor and pump. Also, make sure
the usual motor checks suggested in the
electrical maintenance section are performed.
Be sure hydraulic fluid from a leak is not
seeping onto the field windings and armature.

System Contamination
System contamination can cause erratic or
slugghsh operation of lift or auxiliary functions,
load drift, load drop, clogging, leaking, and
damage to the valve/pump parts.

Packing Disintegration
Examine rod surfaces which contact the
packing. If these are nicked or scratched, they
should be resurfaced or replaced.

Cylinder and Piston Packing Wear

If a hydraulic cylinder is disassembled, inspect
the inside of the cylinder housing. If the inside
cylinder surface is scored, packing grit is
probably in the hydraulic fluid.

Hydraulic System Oxidation

Oxidation can cause internal rusting and
sludge. Use a top grade oil with additives. See
the Lubrication Equivalency Chart in the
Appendix.

Opening Hydraulic System

Whenever a hydraulic system is opened, all
hoses should be capped or plugged to keep out
dirt and moisture-laden air. Examine pipe
fittings and hoses to be certain there are no seal
particles, nicks, burrs, or dirt present when
reassembling the parts. Wipe all fittings before
reconnecting them.

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Toyota Orderpicker Service Manual Troubleshooting

Hydraulic Leakage

Clogged Filter

If the filter becomes clogged in less than the

recommended change interval, the bypass valve
will allow contaminants into the system.
Inspect, clean and/or replace the element
whenever contamination is evident.
NOTE: If severe contamination occurs, drain
the system, flush all components and
replace the oil and filter.

A CAUTION
Never use pipe joint compound on
hydraulic fittings. Joint compounds
can dissolve, contaminating the oil.

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Troubleshooting Toyota Orderpicker Service Manual

Maintenance Tips

Maintenance Tips

Dip in clean kerosene or equivalent light

Cleaning Hydraulic solvent.
Components Wash them off.
Blow them dry using dry, compressed air.
Replacing or Dip cartridge in hydraulic oil. Ensure O-
Reinstalling Hydraulic ~g is well lubricated. Screw them in by
Cartridge Valves hand until the outer O-ring touches the
manifold.
Use a wrench to tighten them. Tighten
cartridge 1/2 turn then back off 1 /4 turn.
Continue this process until cartridge is
tight. Tightening O-ring components in this
manner will prevent damage to the O-ring
seal.
Replacing or Immerse in hydraulic oil those components
Reinstalling Hydraulic with spring chambers and activate the
Seals spring to remove any air.

NOTE: After locating and repairing any leak or

other problem, fill the reservoir and
bleed the system.

A CAUTION
When clamping lift/lower manifold in
vise, ensure valve body is not
damaged which might void warranty.
Follow these procedures to avoid future
hydraulic problems.

Check regularly for the correct level and for

Hydraulic Oil the presence of contaminants or bubbles.
Reservoir Oil Change semi-annually.
Reservoir
Clean semi-annually.
Strainer
New Oil Use only clean containers. Pass all oil added
to the reservoir thru a 25 micron rated filter.
cap Air Check for possible clogging.
Vent
Return Filter Replace semi-annually.

A CAUTION
Do not use brake fluid in the
hydraulic system.

00700-CL22 1 Issued: 911 0198

Toyota Orderpicker Service Manual Troubleshooting

Lift/Lower Hydraulic Troubleshooting

The following table is designed to refer service
personnel to diagnostics and/or procedures
which should aid in pinpointing and eliminating
problems in the lift/lower hydraulic system.
The procedures referred to by number (1-5) will
be found below. When they are indicated, follow
them in the order suggested.

If... Then...
The load drifts Lift relief valve may be faulty or
excessively (more misadjusted. (#'s 4,1,2,3,5)
than 3 inches in Load holding check valve may be faulty. (#'s
10rninuteswitha 1,2,3,5)
3000# load). Emergency lowering valve may be faulty or
misadjusted. (#'s 4,1,2,3,5)
L/L SOL may be faulty. 1,2,3,5)
( # I s

The forks begin to

drop while LIFT is Lift relief valve may be faulty. (#'s 4,1,2,3,5)
actuated.

Suggested Procedures - Lift/Lower

These checks and procedures are designed to
aid in locating the cause of trouble in lift/lower
system.
1. Check the operation of the indicated
component:
Solenoids: Remove, energize, watch for
spool or poppet motion, listen for click of
plunger.
Relief Valves: Check poppet for sticking;
back off adjustment (counterclockwise)
if necessary.
2. Check the indicated component for
contamination:
Visually inspect for metal chips. grit,
teflon tape bits.
Remove foreign material.
Inspect sealing surfaces for damage.

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Troubleshooting Toyota Orderpicker Service Manual
--

Lift/Lower Hydraulic Troubleshooting

3. Check O-rings and backup ~ g sReplace

;
seals if:
Nicked
Extruded
Deformed
If doubt exists
4. Readjust relief valves to factory
specification.
5. Replace the indicated component. If any
doubt exists about the operation or
condition of a component, we recommend
replacement.

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Toyota Orderpicker Service Manual Troubleshooting

Hydraulic Problems

Pump Problems

Trouble Probable Cause Remedy

Pump Not Check all strainers and flters
Delivering Fluid intake pipe in reservoir restricted. for dirt and sludge. Clean if
Fluid necessary.
Check the inlet connections to
determine where air is being
drawn in. Tighten any loose
Air leaks at the intake. Pump not priming.
connections. See that the fluid
in the reservoir is at the proper
level.
Completely drain the system.
Fluid viscosity incorrect. Add new filtered fluid of the
proper viscosity.
Coupling or shaft sheared or disengaged. Repair/replace pump.
Insufficient use a pressure gauge to
Pressure System relief valve set too low.
correctly adjust the relief valve.
Build-Up
Complete loss
of flow from broken relief inlet or pressure line. Replace/repair as required.
Pump
Noisy pump Oil supply low. Fill reservoir.
caused by Oil too heavy. Change to proper viscosity.
Cavitation 'oil filter plugged. Clean filters.
Suction line plugged or too small. Clean line and check for size.
Oil Oil supply low. Fill reservoir.
-
overheating Drain reservoir and refill with
Contaminated oil.
clean oil.
Setting of relief valve too high or too low. Set to correct pressure.
Drain reservoir and r e f a with
Oil viscosity incorrect.
proper viscosity oil.
Shaft Replace shaft seal. If replacing
Worn shaft seal.
leahage shaft seal does not stop leakage,
Broken diaphragm seal or back-up gasket.
the pump should be
Bearings out of position.
disassembled and checked or
Excessive internal wear.
replaced.
Air leaking into suction line. Tighten fittings.
Drain and fill reservoir with
Wrong kind of oil.
non-foaming oil.

00700-~~22 1
Issued: 9/10/98
Troubleshooting Toyota Orderpicker Service Manual
Hydraulic Problems

Trouble Probable Cause Remedy

Pump making Check the fluid condition and if
Noise necessary, drain and flush the
Pump intake partially blocked.
system. Refill with clean fluid of
the correct viscosity.
Check the inlet connections and
seal to determine where air is
being drawn in. Tighten any
Air leaks at the intake or shaft seal. (Oil in
loose comections and replace
reservoir would probably be foamy).
the seal if necessary. See that
the fluid in the reservoir is at
the proper level.
Check if the shaft seal bearing
or other parts have been
Coupling misalignment. damaged. Replace any damaged
parts. Realign the coupled
shafts.

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

List of Troubleshooting Charts

GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .5.26
END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . 5.27

Wiring Charts

W-1: Truck Functions Partially . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28

Hydraulic Charts

H-1: Hydraulic Lift/Lower Problem . . . . . . . . . . . . . . . . . . . . . . . .5.29

H-2: No Lift; Lift Motor/Pump Won't Turn . . . . . . . . . . . . . . . . . . .5.30
H-3: No Lift; Lift PumplMotor Rotate . . . . . . . . . . . . . . . . . . . . . . 5-34
H-4: Load Drifts Down while Forks are Elevated . . . . . . . . . . . . . . 5-36
H-5: Cannot Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38

Travel Charts

T- 1: Travel Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 1

T-2: No Travel in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
T-3: Travel in One Direction Only . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
T-4: Problem with Slow Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
T-5: Truck Does Not Accelerate Properly . . . . . . . . . . . . . . . . . . . . 5.45
T-6: Truck Does Not Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
T-7: No Slow travel When Mast Elevated Above S11 Mast Switch . . 5.52
T-8: Slow travel Speed Occurs All the Time . . . . . . . . . . . . . . . . . .5.54
Click here for
information on
Brake pedal
operation change

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Troubleshooting Toyota Orderpicker Service Manual
List of Troubleshooting Charts

GEN1: General Troubleshooting

,
Gather a s much
information as you
can about
the problem.
bTl What is the problem? 1 Eliminate unlikely
causes. i
/
I
I
I
Where did it happen?
I
When did it happen?

I
Select and prioritize
What functions are affected? the most likely
causes.

1 I What conditions trigger the problem?

/ Talk directly to the

Check each likely
cause, using the tests
operator or foreman. in this manual.
I

Operate the truck

1 Check all other truck
functions before
yourself. returning the truck
to service.

Using the schematics

if necessary, iden*
all components which
could cause the
1 problem.

Figure 5-3: GENl General Troubleshooting

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

(END I: End of Troubleshooting Procedure

I
/ Operate the truck a s it
''
I Make sure ALL wires.
hoses, and cables that
you removed have been
j was being operated when
I the problem occurred.
/ re-attached correctly. 1
1 Venfy the problem does
not recur. I
1 1

' i Have the driver operate

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

Make sure any

component that was
I Fill out any required
drained has been refilled
forms.
with the correct level of I
i fluid. !
i

1' Create the same

conditions that occurred
If you contacted your
Authorized Toyota Dealer
to discuss the problem,
This is especially
important if the
solution you
1
I
when the problem first 1
happened.
call them again to let
I them know what fmed the ,
found is not in the
troubleshooting
I
I problem. I -
chart.

j End of Troubleshooting

Figure 5-4: END1 End of Troubleshooting Procedure

00700-CL221 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual
List of Troubleshooting Charts

W-1:Truck Functions Partially;

Some Functions Do Not Work When Commande

Visually check the

wiring in the control
handle and where the
wiring leaves the
handle. Look for

Yes I

Use a digital volt

meter and check for
continuity of wires
per the schematics.

Yes

Use a digital volt

meter and check for
Repair or replace
continuity of wires in
measurements wires a s required.
the control handle

Verify the problem

still exists. Repeat
Repair or replace
W- 1. If you return
wires a s required.
here, go to General
Troubleshooting.

A
Yes

Visually check the

wiring and
connectors in the
area of the traction
Go to Chart r-5
Go to Chart
v
Go to Chart

power amplifier.

7
Figure 5-5: W-1: Truck Functions Partially

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting
List of Troubleshooting Charts

(H-1: Hydraulic Lift/Lower Roblem 1

load?
elevated?

Go to Chart

Go to Chart
P-FXT 1

Is lift cutout
activated? m
\ / I
I N o 1
Replace check
valve.

Change Chart

rl
Go to Test 14. Go to Test 14.
battery. H-4-2 END 1

rflOl
Chart
Yes

Run Calibrte.

I
Yes

Figure 5-6: H-1: Hydraulic Lift/Lower Problem

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Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

H-2: No Lift; Lift Motor/Pump Won't Turn; \

( All O t h e r Functions OK

1 Check for B+ at
MM-2 with reference
to TP4.
i

I I
Yes Yes
I I

Check for B+ at
FU3-2.

uGo to Chart
QGo to Chart

Repair or replace fuse

Is B+ present? Check fuse FU3. Is fuse FU3 OK?
N o 1 F U 3 as necessary.

I '
I

Yes
~
I

Yes

1 GO to chart I

Figure 5-7: H-2: N o Lift: Lift Motor/Purnp Won't Turn

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

Check for B+ at TP3,

with respect to TP4.

Repair or replace
Check connections at
No connections a s
TP3.
necessary.

Yes Yes I

Check for B+ at
motor tenninal D.

Figure 5-7: H-2-2

6Go to Chart

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Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

+ Check for B+ a t
armature terminal
"A".

Is B+ present? No+
Remove motor and
test.
Is the motor OK?
Rebuild or replace
motor a s necessary.

Yes

Check for B+ a t the

M- terminal of the lift
power amplifier.
Q
Yes

Go to Chart
0 I

Go to Chart

Check connections to Repair or replace

Is B+ present? No+ the lift power connections as
amplifier. necessary.

0 Yes

Go to Chart

Figure 5 -7 : H-2-3
0 Yes

Go to Chart 97
I

Go to Chart

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

Run Test (Category 1.

Class 2.Test 6) for
pot VR2.

Repair or replace pot

Q
Yes
I

Go to Chart
6Go to Chart

Figure 5-7: H-2-4

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Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

\I H-3: No Lift; Lift

All Other

Test the lift pressure

of the hydraulic
system and compare
it with the speed of

0 Yes

Go to Chart
Yes

Check proportional
valve for proper
operation.
0 I

Go to Chart

Proportional
valve a s necessary.

Yes I

Figure 5-8: H-3: No Lift; Lift PumplMotor Rotate

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Toyota Orderpicker Service Manual Troubleshooting
List of Troubleshooting Charts

/ Check the lift pump

for proper operation.

Repair or replace lift

Is lift pump OK?
pump as necessary.

Yes I

I GO to chart i

0 0 7 0 0 - ~ ~ 21 ' Issued:
2 9/10/98
Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

/H-4: Load Drifts Down While Forks Are)

Elevated. All Functions Are GK.

A
With key switch off
and carriage down,
make sure the lift
high pressure relief
valve is adjusted
properly. See
Component
Procedures.

:::IN0_
Adjust lift high
pressure relief valve.
adjusted OK? See Component

.
Procedures.

Yes

With key switch off,

battery disconnected,
and carriage lowered,
remove high pressure
relief valve. Check for
contamination and spring
tension on the plunger.

tension on the
contamination? pressure relief valve.

I I
Yes Yes

Remove
contamination. Flush
hydraulic system.
Replace filter. Install
new fluid.

Figure 5-9: H-4: Load Drifts Down while Forks are

Elevated

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

contamination and
free movement at Replace SOL2.
Load Holding
Solenoid S O U .

I
Yes

Remove
Is there free contamination. Flush
movement a t hydraulic system. b
Replace filter. Install
new fluid.

I
Yes

With key switch on,

measure the voltage
at Load Holding
Solenoid (SOL2).

/ \ I
I s voltage a t
ace display
SOL2 approx.
conuol, cara.
---,

Yes
I

Ven@ problem still

exists. Repeat H-4. If
you return here, go to
General
Troubleshooting.
1

1- !
Go to Chart

00700-CL221 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual
List of Troubleshooting Charts

H-5:C a n n o t Pick Up a Load; Hydraulic Functions Work;

Lift Pump I s On; Travel I s OK

Check the battery.

See Component
Procedures.

.. - r----l
Recharge or replace

With the key switch

off, check the lift
motor and brushes.
6
Go to Chart

Yes
I

With the key switch

off, check the MM
contactor tips.
k9
Go to Chart

Figure 5-1 0 : Cannot Pick Up a Load

00700-CL22 1 Issued: 9110/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

+
With all hydraulic component controls installed
and functioning, key switch on:
Check the hydraulic pump by measuring With key switch off,
pressure. battery disconnected,
Use a hydraulic pressure gauge capable of & carriage lowered,
measuring 0-5000 psi. check REL 1 high
Connect gauge to pressure test port PT on main pressure relief valve
manifold in tractor. for signs of
With no load on forks, lift carriage to maximum contamination or
height and continue to lift against the stops. restricted movement.
You should see approximately 1900-2200 psi of
pressure a t PTl.
I

Adjust lift pressure.

See Component
Procedures.

Yes I I Yes I

1
Look for hydraulic
leaks or damaged
hydraulic components. Change the hydraulic Go to Chart
Venfy problem still Pump. H-5-3
exists. Repeat H-5.
If you return here,
go to General

Yes

Verrfy problem still

exists. Repeat H-5.
If you return here,
go to General

I
Yes

1 Go to chart / Flush hydraulic

L'
Go to Chart
system. Replace
frlter. Install new
fluid.

Figure 5-10: H-5-2

00700-CL221 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual
List of Troubleshooting Charts

.
Change the hydraulic /
I
I

contamination

1
Yes I
Flush hydraulic
system. Replace
filter. Install new
fluid.

Figure 5-10: H-5-3

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Toyota Orderpicker Service Manual Troubleshooting
List of Troubleshooting Charts

T - 1 : Travel Problem \
I

u
AU Hydraulic functions OK
I

I I
I
No Go to Chart

i
Yes

travel in both

I
Yes

I
Yes I

1 GO to Chart / 1 GO to c h a r t / ! Go to Chart
j:
Go to Chart

Figure 5- 1 1: T-1: Travel Problem

00700-CL22 1 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

c T-2: No Travel in Either Direction

0 6
Go to Chart

Figure 5-1 2: T-2: N o Travel in Either Direction

Go to Chart

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

{T-3: Travel in One Direction Only

)

'J
Go to Chart

Figure 5-1 3: T-3: Travel in One Direction Only

6
Go to C h a r t

00700-CL221 issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual
List of Troubleshooting Charts

s 1
T-4: Problem With Slow Travel

Check speed limit

(Tuning Mode C4)

0Go to Chart Go to Chart

END1.

Figure 5- 14: T-4: Problem with Slow Travel

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

T-5: Truck Does Not Accelerate Prope

or Slow Travel
I

Return to
service.

Chart

Figure 5-1 5: T-5: Truck Does Not Accelerate Properly

00700-CL22 1 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

I With key switch off,

1 check motor and
brushes. See
Component
Procedures.
I__?____

Replace power
arnpliiler.

Yes

1 Return to /
I service.

1 Go to Chart /

Figure 5-1 5: T-5-2

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Toyota Orderpicker Service Manual Troubleshooting
--

List of Troubleshooting Charts

/ T-6: Truck Does Not Travel. \

MM Contactor Energizes Properly When Travel Is Requested.

Component
on the floor.
No

Is there a
restriction?

Yes

1 Clear the restriction.

- Yes
I
Check the contactor
bus bars. The bars
should be present,
with no cracking or
I burning evident.

< Is/are the bus

bar(s) OK? t-' 1 Replace the bus
bar(s).

I
Yes

1 Go to Chart 1

Figure 5-1 6: T-6: Truck Does Not Travel

0 0 7 0 0 - ~ ~ 2 2Issued:
.1 9/10/98
Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

1 With kev switch off,

the mM
contactor assembly
for freedom of
1 1 1
I I 1
Replace the
contactor.
1
1
Ldo movement.

Yes

With key switch on:

Use DVM to measure
B+ at FU2-2 (+) with
respect to JPB- (-1.

< I s B+ present? \)----NO+ Replace fuse FU2. 1

L
Yes

i p ' r Go to Chart !

Figure 5- 16: T-6-2

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

With key switch off,

check the drive motor
brushes. See Replace the brushes.
Component
Procedures. 1

Yes

With key switch off,

test drive motor. See
Component
Procedures.

Replace or repair
drive motor.

I
i
Yes

1 Go to Chart 1 / Go to Chart /

Figure 5- 16: T-6-3

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Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

Turn key switch off. Jack

+
.
/with kev switch off.
check f i r continuity
1 1 Repair or replace a s
& block truck. With key
switch on and deadman
closed. use DVM to
of drive motor cables: measure voltage TB (+) to
FU2 to TB+ TS [-) with
throttle on.

from 0 to B+ in

I
Check throttle
potentiometer:
Perfom Analyzer
Test 12.No. 2
, , Remove and replace
o
-.n power
amplifier.

0Go to Chart

-No Replace traction

power arnpwer.

Figure 5- 16: T-6-4

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Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

With truck jacked up

and blocked, key
switch off, release the
1 With key off, remove
brake drum. See
Component
brake by pulling the
handle down into the
Procedures. I
operating position.
Turn the brake drum
manually, by hand.

Remove drive motor

from unit. See
Component
Procedures.

\\\\baud^/'
turn freely by /

Yes

V e e problem still
exists. Repeat T-6.
If you return here, go
Repair, adjust, or
replace the brake.
F
Replace or replace
the drive unit.
Replace or replace
drive motor.
to General

1 Go to Chart 1

Figure 5-1 6 : T-6-5

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Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

T-7: No Slow Travel When Mast Is Elevated Above S l l (Mast Switch).

Other Functions OK.

+
Run Test 1 1 -ESY21,
in hmlyzer Mode
correctly?
( 2 4 Mast Switch)

Yes

Replace Sl 1 switch.

Check for continuity

of wiring to the
switch.
0
Go to Chart

Repair or replace
wiring.

Figure 5-1 7: T-7: No Slow travel When Mast Elevated

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

Replace the traction

power ampWier
power amplifier.

Check for continuity

and shorts.

Repair or replace
No+ b
wiring as

Yes
1
Verify problem still
exists. Repeat T-7.
If you return here, go
to General
Troubleshooting.

Figure 5-1 7: T-7-2

0Go to Chart r--+--l
Go to Chart

00700-CL22 1 Issued: 9/10/98

Troubleshooting Toyota Orderpicker Service Manual

List of Troubleshooting Charts

T-8: Slow Travel Speed Occurs All The Time.

With key switch ON.

truck jacked up, Remove the drive
Getting full % to deadman on, and motor from the drive
Traction Power brake locked: unit. See Component
Amplifier? turn the brake drum Procedures.
manually by hand. I

k I
Yes
I

Is truck set to a Check the battery.

No+ See Component Yes
Procedures.

I
No

Go to Chart
Repair or replace
Set to full speed. Is battery OK? T-8-2 drive unit.

6Go to Chart

No
Remove brake drum.
See Component
Procedures. Repair or replace
drive motor.

c.9
Go to Chart

Repair or adjust
brake assembly.

Figure 5-1 8: T-8: Slow travel Speed Occurs All the Time

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Troubleshooting

List of Troubleshooting Charts

With key switch off,

check for mechanical
binding of the load
wheels.

Yes

Go to Chart
T-8-3 0
Go to Chart

Figure 5- 18: T-8-2

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Troubleshooting Toyota Orderpicker Service Manual

x-
List of Troubleshooting Charts

With key
deadman switch
closed on,
(handle Check for continuity . l -
engaged). & caniage and shorts: Replace or repair
lowered, use a DVM to TB+ to F2 wiring.
measure B+ across power TB- to TP4
amplifier from TB+ to TB-.
No No

v
Go to Chart

Yes Yes
I l----!
Verify problem still
Remove and test the
exists. Repeat T-8. If
power amplifier. See
you return here, go to
Component
General
Procedures.
Troubleshooting.

Replace power
amplifier.

1
I
Yes

With key switch off,

test the drive motor &
brushes. See
Component
Procedures.

Figure 5-1 8: T-8-3

L'
Go to Chart

L'
Go to Chart
6Go to Chart

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Electrical Codes and Tests

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

General

General

Separate codes and tests are required to

troubleshoot the lift truck core electronic
functional management system and the steer
controller guidance system. Each series of
codes/tests are so arranged in this chapter. The
core system codes and tests are displayed on
the Operator's Display; the steer controller
guidance codes a n d tests are displayed on both
the Operator's Display and the Steer Controller
Card display. The Steer Controller Card display
is not normally visible to the operator. Any
maintenance codes related to steering/
guidance will be displayed on the Operator's
Display and Steer Controller Card; any codes
associated with the traction/lift systems will be
displayed on the Operator's Display only.
The specific codes a n d tests are preceded by a
description of the modes of operation related to .
the conduct of the tests. These instructions
include the test menu structures, menu entry
and maneuvering, a n d change/update
procedures. Comprehensive listings of the
various tests are also provided.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Modes of Operation

Modes of Operation

Figure 6- 1 on page 6-4 shows the menu

structure for the different operating modes.

Overview

Self-diagnosis Mode
Self-diagnosis mode is the normal running
mode. No passwords are required to enter self-
diagnosis mode.

Analyzer (AnL) Mode

Analyzer mode is the error analysis mode. Both
primary and secondary passwords are required
to enter analyzer mode. Once the analyzer mode
is activated, the display will show "Analyzer."

Tuning (Tuning) Mode

Tuning mode is used to change settings. Both
the primary and secondary passwords are
required to enter tuning mode. Once the tuning
mode is activated, the display will show
'Tuning."

Calibrate (Calibrte) Mode

Calibrate mode is used to set values that are
used upon power-up. A unique secondary
password, a s well a s the primary password, is
required to enter calibrate mode. Any lift truck
whose display card does not have stored
calibrate values will be disabled until calibrate
mode is run. The truck's display will scroll "Run
Calibrate Mode" until it is performed. Calibrate
mode is used to learn (set) the values for the
traction pot, the lift/lower pot, steering, wire
frequency, and wire guidance offsets,

Configure (Configur) Mode

Configure mode is used to set unique truck
features. The primary and a unique secondary
password are required to enter configure mode.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
- -

Overview

Self-diagnosis

Run Calibrate Mode

Error Code
Weight (if installed)
- Primary Password
Secondary Password
C1 - C 4
C6-C9
Secondary Password CA, CB, CC
/ Calibrate Traction Pot
Lift/Lower Pot
Weight (if installed)
Steering
-Secondary Password Wire Frequency
Wire Guidance Offsets
I
1 Analyzer

t- Category 0 , Class 0

Category 1, Class 1
-Exit AnL

ESYl - ESY14
ESY21 - ESY26
ESY29 - ESY35
ESY40 - ESY46

Category 1, Class 2 0- 5
I20 - 34

Category 1. Class 3

Category 1, Class 4 -
L-:
Category 2, Class 1 -T- TOP
Top BDI Led
= Most recent error
I .
bottom BDI Led
= 10th Most recent error

Figure 6-1 : Menu Structure for the Different Modes

6-4 00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Overview

ql
Modes

G Modes

- Category 3, Class 3 ESYl2 - ESY14

ESY21 - ESY26
ESY29 - ESY35
ESYIO - ESY46

- Category 3. Class 4 7ESYl2 - ESY 14

ESY21 - ESY26
ESY29 - ESY35
ESY40 - ESY46

- Category 4. Class 1 01 250

023-~-

Category 5, Class 1 0 1- 0 6

Category 6. Class 1

TI
LPA
TPA
Secondary Password
I
Configure
English/Metric
Lift Limit with Bypass
Weight (pressure transducer)
Travel Alarm.Forward and Reverse
Travel Alarm,Reverse only
Lower Deceleration
Sidegate Switches
120"/180 Mast Limit Switches

-
Wire Guidance
Rail Guidance

Secondary Password
I
i----Disable Brush Wear Indicator -7BU'I On
- BWI Off

Figure 6- 1 : Menu Structure for the Different Modes (Continued)

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Passwords

Passwords

The Toyota orderpicker lift truck uses two levels

of password, primary and secondary.
Both passwords are required for entrance into
all modes except self-diagnosis.
A unique secondary password is required to
disable the brush wear warning, start the hour
meter, or to activate analyzer, calibrate,
configure and tuning modes.

Entering the Primary Password

1. Press the power control and hour meter
select switches simultaneously (system
should respond with a short beep).
2. Within 10 seconds, press the UP arrow
(system should respond with a short beep).
3. Within 10 seconds, press the DOWN arrow
(system should respond with a short beep).
4. Within 10 seconds, press the UP and
DOWN arrows simultaneously and hold
them for 2 seconds (system should respond
with a short beep after 2 seconds).
Acceptance of the primary password will be
indicated by the word "PRIMARY appearing on
the display. If a switch is not pressed within the
10 second limit, the system will default back to
the self-diagnosis mode.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Disable the Brush Wear Warning

Disable the Brush Wear Warning

Entering the Secondary Password

1. Enter the primary password.
2. Within 10 seconds, press the power control
select switch (system should respond with a
short beep).
3. Within 10 seconds, press the DOWN arrow
switch (system should respond with a short
beep).
Acceptance of the secondary password will be
indicated by the word "BWI On" or BWI Off'
appearing on the display. To return the system
to self-diagnosis mode, press the hour meter
switch. To toggle between "BWI On" and "BWI
Off', press the UP or DOWN arrow switch, then
press the hour meter switch to save and return
to self-diagnosis mode. If the BWI icon located
on the display is not on, "BWI ON" can not be
toggled to "BWI OFF". The BWI can be disabled
only once between brush replacement. When
OFF, it will remain off for 8 traction hours and/
or 8 lift hours. After that time, the system will
revert back to ON and limit top traction speed
to 2.5 m.p.h. and/or limit top lift speed to 25%
of maximum.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Start the Hour Meter

Start the Hour Meter

The Toyota Orderpicker lift truck is shipped

from the factory in a Demo mode. The operator
display will show TOYOTA. . . TRUCK IN DEMO
MODE and the buzzer will sound once an hour
until Demo mode is deactivated when 100
deadman hours of operation is reached or when
the secondary password is entered to start the
hour meters.

Entering the Secondary Password

1. Enter the primary password.
2. Within 10 seconds, press the hour meter
select and power control select switches
simultaneously (system should respond
with a short beep).
3. Within 10 seconds, press the UP arrow
switch (system should respond with a short
beep).
Acceptance of the secondary password will be
indicated by the word "Meter On" appearing on
the display for 1 second before the system
returns to the self-diagnosis mode. Entering the
secondary password automatically causes the
hour meters to come on.
NOTE: If hour meters have not been started
after 100 hours of operation, they will
automatically start.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Self-diagnosis Mode

Self-diagnosis Mode

No passwords are required to enter self-

diagnosis mode. Self-diagnosis mode performs
a system self-check prior to allowing lift truck
operation. Time and date displays are available
after the self-check is complete.
Self-diagnosis mode is the normal running
mode and will detect errors in the traction, lift/
lower, and electric steer systems. When errors
are detected, a buzzer will sound and a
corresponding error code will be displayed. All
other modes are entered through self-diagnosis
mode.

Maneuvering within
Self-diagnosis Mode
During power-up the display will show
'TOYOTA" for a minimum of two seconds, then
go to one of four displays:
Time or Date (whichever was last displayed)
Run calibrate mode
Error code
Weight (option)
Use the DOWN arrow switch to scroll through
time, date, and weight (if available). Only the
time and date may be adjusted.

Adjusting The Date

Press the power control switch, the months will
flash on and off at a 1 second rate. Use the UP
or DOWN arrow switches to change the month.
Press the power control switch again, the
months will stop flashing and the days will
blink on and off. Use the UP or DOWN arrow
switches until the desired day is reached. Press
the power control switch a third time to move to
the year selection. With the years blinking,
press the UP or DOWN arrow switches until the
desired year is reached. Press the power control
switch one more time to stop the year from
blinking and end the adjustment of the date
setting. Date format example: 07/ 12/98.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
-- -- -

Maneuvering within Self-diagnosis Mode

Adjusting The Time

Press the power control switch, the hours will
flash on and off at a 1 second rate. Use the UP
or DOWN arrow switches to change the hours.
Press the power control switch again,the hours
will stop flashing and the minutes will blink on
and off. Use the UP or DOWN arrow switches
until the desired minute is reached. Press the
power control switch a third time to stop the
minutes from blinking and end the adjustment.
The PM will automatically switch to AM (or AM
to PM) as the hours change from 11 to 12. Time
format example: 5: 10:45.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Analyzer (AnL) Mode

Analyzer (AnL) Mode

Analyzer mode is the error analysis mode. Both

primary and secondary passwords are required
to enter analyzer mode. Once the analyzer mode
is activated, the display will show "Analyzer".

Entering the Secondary Password

1. Enter the primary password.
2. Within 10 seconds, press the power control
select switch (system should respond with a
short beep).
3. Within 10 seconds, press the UP and
DOWN arrow switches simultaneously
(system should respond with a short beep).
"Analyzer" will appear on the display indicating
acceptance of the secondary password.

Entering Analyzer Mode

To enter Analyzer Mode, press the power control
switch. The 8-character display will display
"AnL" in the left most segments and the right
most segments will display "00". The left "0" will
be flashing. The left number is the category
number, the right number is the class number.

Maneuvering within Analyzer

Mode
Category or class numbers may be changed
using the UP or DOWN arrow switches. Press
the power control select switch to activate the
class (right) number. The class number will be
flashing on and off. Press the UP or DOWN
arrow switches until the desired class number
is displayed. Once the class number is flashing,
the "AnL" changes to "run." Once the desired
number is displayed, press the power control
select switch. The class number will stop
flashing and the "run" will disappear and be
replaced by a test result.
To end a test and start another one, press the
power control select switch to activate the class
number. The display will return to "run." If the
test is from the same category, press the UP or
DOWN arrow switches to change to the desired

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Maneuvering within Analyzer Mode

class number. Press the power control select

switch to enable the test. If the desired test is
from a different category, set the class number
to "0". Press the power control select switch
activating the category (left) number. The
category number will start flashing and "run"
will change to "AnL."Use the u p or down arrow
switches to select the desired category, then
press the power control select switch. When the
"AnL"changes to "run,"select the class number
a s directed above.
To end "Analyzer" mode, set the class number
to "0." Press the power control select switch to
activate the category number and change "run"
to "AnL."Set the category number to "0." With
"00" displayed, press the power control select
switch. The "00" will be replaced by "Yn" with
the "n"flashing. The "AnL"will be replaced by
"End." Press the UP arrow switch to cause the
'Y' to start flashing, then press the power
control select switch to exit analyzer mode and
return to self-diagnosis mode.

00700-CL221 Issued: 911 0/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Tuning (Tuning) Mode

Tuning (Tuning) Mode

Tuning mode is used to change settings. Both

primary and secondary passwords are required
to enter tuning mode. Once the tuning mode is
activated, the display will show 'Tuning".

Entering the Secondary Password

1. Enter the primary password.
2. Within 10 seconds, press the hour meter
select switch (system should respond with a
short beep).
3. Within 10 seconds, press the hour meter
select switch and the power control select
switches simultaneously (system should
respond with a short beep).
'Tuning" will appear on the display indicating
acceptance of the secondary password.

Maneuvering within Tuning Mode

Use the power control select switch to
increment through the tuning mode selections.
The display will indicate first the tuning code,
then the level setting. The level setting uses all
8 characters on the display. Settings that were
changed become permanent only when the
hour meter switch is pressed, exiting the
Tuning mode. The left most character
represents weak or low end setting. The right
most character represents strong or high end
setting. Only one character is lit at the lowest
setting. As settings increase, additional
characters are lit until maximum setting has
been reached.
Eleven tuning adjustments are possible.

Tuning
Action Result Adjustment
Code
Lift Power Amplifier The factory default will show a strong
soft start Lift acceleration setting (1-8 segments on). Moving
C1
(acceleration rate) down from the "8" will soften the lift
acceleration, provided C2 is set to 1.

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Maneuvering within Tuning Mode

Tuning Action Result Adjustment

Code
Lift Power Amplifier Provides a faster The factory default will show strong
response time after acceleration out setting (1-8 segments on). Moving
activation (quick of neutral in down from the "8" will change the
C2 start) response to fast initial lift quick start to a slower

+
.%
&1% 4A changes in
throttle
response.

ey\w'
1 command.
Battery charge meter Changes the The factory default will show a s a mid-
correction discharge profile setting (1-5 segments on). Moving up
or down from the "5" will change the
C3
discharge profile by 5% per character.
An "8" sets the fastest discharge
profile.
Maximum traveling Limiting the The factory default will show the
speed limiter maximum travel highest setting (1-8 segments on).
C4 speed Moving down from the "8" will change
the maximum travel speed by 0.5
mph per character.
Throttle Brake Sets the amount The factory default will show as a
(coast) of braking minimum setting of (1 segment on)
torque when the which means there is no neutral
C6
handle is braking. Moving up from the "1" will
returned to increase the neutral braking.
neutral
Maximum lifting Limiting the The factory default will show as a

I C7
speed limiter maximum lift
speed
maximum setting (8 segments on).
Moving down from the "8" will
decrease the maximum allowed lifting
speed. 8 = maximum speed.
Traction acceleration Adjusts the time it The factory default will show a setting
rate takes to get to of 1-5 segments on. Moving up or
C8 full speed down from the "5" will change the
traction acceleration. 8 = most
aggressive.
Lift interrupt set Sets the cutout The factory default will show a s a
level level for the BDI maximum enable setting (7).Moving
or it disables the u p to 8 disables lift interrupt. Moving
cutout down increases which LED lift cutout
occurs.
7 = 0 LEDs
C9
6 = 1 LED
5 = 2 LEDs
4 = 3 LEDs
3 = 4 LEDs
2 = 5 LEDs
1 = 6 LEDs

6-14 00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
- --

Maneuvering within Calibrate Mode

Tuning Adjustment
Action Result
Code
Lift Power Amplifier Maximum The factory default will show as a mid-
lower deceleration possible PWMs setting (1-5 segments on). The
following represents the maximum
possible PWM on to the proportional
CA solenoid:
1 = 100% (no deceleration)
2 = 80%,3 = 7096, 4 = 60°/o,
5 = 50%,6 = 40% 7 = 30%
8 = 20% (maximum deceleration)
Wire Guidance Sets truck 1 = 6.25 KHz
Frequency frequency to 2 = 5.2 KHz
CB
match frequency 3 = Other
of the floor.
Distance From Wire Sets distance and Quit
(DFW)and Heading angle DFW STOP
Angle (HA) settings 3.0 in. - 1.2 in. in 0.2 in. increments
DFW SLOW
1.6 in. - 0.6 in. in 0.2 in. increments
CC HA STOP
4.0 deg. - 2.0 deg in 0.2 deg.
increments
HA SLOW
2.0 deg. - 0.6 deg. in 0.2 deg.
increments
Wire Acquire Speed Sets wire-acquire The factory default (1.0 m.p.h.) will
(Acquires) for speed (from 1.0 show a setting of 8 segments on.
tractor -first m.p.h. to full Moving up or down will change the
direction speed, in 0.1 wire acquire speed.
m. p.h. 8 (segments) = 1.0 m.p.h.
increments. The 7 = 1.5
CD
active speed 6 = 2.0
limiting values 5 = 2.5
will take 4 = 3.0
precedence). 3 = 4.0
2 = 5.0
1 (segment) = 5.7 m.p.h.
Cycle through the menu by repeatedly pressing the power control switch. Use the UP or DOWN
arrow switches to change the value.

Exiting Tuning Mode

There are 3 methods to exit tuning mode,
returning to self-diagnosis mode:
Press the hour meter switch
Cycle the key switch
No activity within 2 minutes

00700-CL221 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual
- --- -

Manuevering within Calibrate Mode

Calibrate (Calibrte) Mode

Calibrate mode is used to set values that are

used upon power-up. Any lift truck whose
display card does not have stored calibrate
values, will be disabled until calibrate mode is
run. The truck's display will scroll "Run
Calibrate Mode" until it is performed. Calibrate
mode is used to learn (set) the values for the
traction pot, the lift/lower pot, wire frequency
(wire guided orderpickers), wire guidance
offsets (wire guided orderpicker), the pressure
transducer (option), and reset the Traction and
Lift Power Amplifier.

Entering the Secondary Password

1. Enter the primary password.
2. Within 10 seconds, press the DOWN arrow
switch (system should respond with a short
beep).
3. Within 10 seconds, press the hour meter
select switch and the power control select
switches simultaneously (system should
respond with a short beep).
"Calibrte" will appear on the display indicating
acceptance of the secondary password.

Entering Calibrate Mode

Both primary and secondary passwords are
required to enter calibrate mode. Once the
calibrate mode is activated, the display will
show "Calibrte."
Press the hour meter select switch to get
beyond the "Calibrte" display.

Maneuvering within Calibrate

Mode
When the power select switch is pressed to
advance beyond the "Calibrte" display, the
display changes to 'Tractpot." Press the UP or
DOWN arrow switches to scroll through menu

00700-CL22 1 Revised: 2/15/00

 Toyota Orderpicker Service Manual Electrical Codes and Tests

Maneuvering within Calibrate Mode

1 selections. This will allow you to bypass items

not needing calibration.
If the traction pot input is to be calibrated,
press the power control select switch. This
centers the scale and sets the end points for
maximum forward and reverse at 2 times the
deadband value. If a higher value is read as the
truck is run in normal mode, the set value will
change to the new value unless it is outside the
maximum range value. Once the traction pot is
learned, the display will flash "DONE" for 1
second then display "LiftPot."
If the "Liftpot" is to be calibrated, press the
power control select switch. This centers the
scale and sets the end points for maximum
speed u p and down at 2 times the deadband
value. If a higher value is read a s the truck is
run in normal mode, the set value will change
to the new value unless it is outside the
maximum range value. Once the lift pot is
learned, the display will flash "DONE" for 1
second then display "Steering".
If "Steering" input is to be calibrated, press
power control select switch. The display will
switch from "Steering" to scrolling: "Jack up
drive unit and block vehicle; press power
control select switch when ready."

A CAUTION
Truck must be jacked up or incorrect
values will be learned, resulting in drive
unit chatter once back in self-diagnosis
mode.

The message will continue to scroll until power

control select switch is pressed. After pressing
power control select switch, the following
message scrolls across the screen: "Step on
deadman to start test." After stepping on the
deadman, the following message scrolls across
the screen: "Calibrating steer unit." Power is
now applied to the steer motor. The drive unit
turns first in one direction, then the other
direction. This process determines the
minimum power to steer the drive unit. After
determining the minimum power, the drive unit
is steered 80' to the left and 45' to the right.
This determines the steering rate. If the system

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Configure (Configur) Mode

does not sense either the position feedback or

the Home sensor, the Calibrte sequence will be
considered a failure. A failure causes the
following message to appear: "Unable to
calibrate... press power control select switch to
continue." When the calibrate process is
complete, the display will flash "Done" for 1
second and then go to the next component to be
calibrated.
Calibrating wire frequency is only required if
the wire frequency is set to "Other" in Tuning
Mode.
NOTE: Code 1P will appear when "Other" is
selected and Tuning Mode is exited.
Ignore it and proceed with the calibrate
procedure.
In this case, calibrating guidance is a three-step
process:
1. Calibrate wire frequency.
2. Calibrate wire guidance offsets.
3. Calibrate wire frequency again. .
To calibrate wire freqency, press the power
control select switch. The display will switch
from "WireFreq" to scrolling: "Calibrating guide
wire input. To abort, press power control select
switch." If a valid frequency is not found, the
following message is scrolled: "Unable to
calibrate... press power control select switch to
continue." After the frequency and amplitude of
the guide wire have been learned, the display
will flash: "Done" for 1 second, then go to the
next component to be calibrated.
If 'Wire guidance offsets" are to calibrated,
press the power control select switch.
Steering must be calibrated prior to
calibrating wire guidance offsets.
Steering does not need to be recalibrated
everytime there is a need to calibrate
wire guidance offsets.
The display will switch from 'Wire guidance
offsets" to scrolling: "Press auto/manual switch
to auto." After the switch has been switched to
AUTO, the following will be displayed: "Drive on
wire until straight, then coast. Press auto/
manual switch to manual when stopped." If
unable to learn, the following will be scrolled:
"Unable to calibrate.. . press power control

00700-CL22 1 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Maneuvering within Calibrate Mode

select switch to continue." If the calibrate

procedure is completed correctly, the following
message will flash: "Done" for 1 second, then go
to the next component to be calibrated.
If the "Weight" option is available and needs to
be calibrated, press the power control select
switch when "weight" appears on the display.
The following message will scroll across the
display: "Lower forks to floor, then lift 3 inches."
When the lift message stops scrolling across the
display, the following message appears: "Press
the hour meter select switch when finished."
While the display card is learning the Uft system
pressure, "calibrating weight" will scroll across
the display. When learning is complete, the
display will indicate "DONE."
If "PwrArnpDf' is to be entered, press the power
control switch then use the UP or DOWN
arrows to toggle between " ~ e s e t N"
? and
"Reset? Y." If the traction and lift power
amplifiers are to be reset, press the power
control switch when "Reset? Y is being
displayed. When the power amplifiers are being
reset, the display will show "setting!" The
display will then return to TractPot."
Press the power control select switch twice to
skip over calibrating weight.
Press the hour meter select switch to end
calibrate mode.

00700-CL221 Revised: 2115/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Manuevering within Calibrate Mode

Configure (Configur) Mode

Co gure mode is used to set unique truck

features.

Entering the Secondary Password

1. Enter the primary password.
2 . Within 10 seconds, press the hour meter
select switch and the power control select
switches simultaneously (system should
respond with a short beep).
3. Within 1 0 seconds, press the DOWN arrow
switch (system should respond with a short
nfi
beep).
"Configur" will appear on the display indicating
acceptance of the secondary password.

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Entering Configure Mode

Entering Configure Mode

Press the power control select switch to get
beyond the "Configur" display.

Maneuvering within Configure Mode

Configure mode is used to enable lift truck
features that are not available on all models.
Enabling of the options is achieved by pressing
the power control select switch to scroll through
the list. The UP arrow switch will activate the
option, the DOWN arrow switch will make the
option inactive.
Options that may be included on this lift truck
include:

Lift limit with bypass (C2)

Weight display (Pressure Transducer) (C3)
Travel alarm, Forward and Reverse (C4)
Travel alarm, Reverse only (C5)
Lower Deceleration (C6)
Sidegate switches (C7)
120"/ 180" Mast Limit switches (C8)
Wire Guidance (C9)
Rail Guidance (CA)
Two Stage lift (CB)

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code Summary Tables

Code Summary Tables

The following tables summarize informational,

performance limiting, and fault codes.
NOTE: The following "Effect" designations are
used throughout these tables:

"Effect" Designations
0 0 mph speed limit N 2.5mphlimit
1 mph speed limit Minimum power (traction
1
system)
D Traction system derating T Traction system shutdown
I Informational W Lowering system shutdown
L Lift system shutdown X Total shutdown

Informational / Performance Limiting

Code Condition Effect Related Tests
0 1 24" Mast Switch Not Crossed N ESY21
Limit Switches Do Not Agree (above 150"/180" and ESY31
O2 0,l
below 24")
Limit Switches Do Not Agree (above 150"/180" and ESY31
O3 0,l
below 60")
04 Limit Switches Do Not Agree (above 120" and below 24") 0,l ESY31
05 Limit Switches Do Not Agree (above 120" and below 60") 0,l ESY31
06 Limit Switches Do Not Agree (above 60" and below 24") 0,l ESY22
Limit Switches Do Not Agree (below 120" and ESY31
O7 0,l
above 180")
Lift Cutout Switch Does Not Agree (below either 60" or ESY23
O8 L
24" Lower Mast Switch)
09 Traction Power Amplifier POST Failed L,T Cat. 1,Class 2; Test 4
Traction Power Section (M-) Fault Cat. 1, Class 2; Tests
10 L7T
2. 3. 4

11
Traction HPD
'
I Cat. 1, Class 2;
Test 2
Traction SRO Cat. 1, Class 2;
12
Test2
Traction Throttle Out Of Range Cat. 1, Class 2;
13
Traction Pot Voltage
14 Spare

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Toyota Orderpicker Service Manual

Informational / Performance Limiting

Code Condition Effect Related Tests
15 Traction Power Amplifier Driver O u t p u t Current L,T
16 Traction Power Amplifier Contactor Welded L.T
17 Traction Precharge Fault L.T
18 Traction - Contactor Open L,T
19 Traction - Battery Undervoltage D.P.T Cat. 1,Class 2; No. 11
Traction - Battery Overvoltage Cat. 1, Class 2;
20 D*P*T No. 11
Traction Power Amplifier Thermal Cutback Cat. 1,Class 2; No. 3
Traction Power
21 D Amplifier
Temperature
Sensor
22 Spare
23 Lift Power Amplifier POST Failed L,T
Lift Power Section (M-) Fault Cat. 1, Class 2;
24 L'T Nos. 5, 6, 7, 8
25 Lift HPD L Cat. 1, Class 2; No. 6
26 Lift SRO L,T Cat. 1, Class 2; No.6
27 Lift Throttle O u t Of Range L,T Cat. 1,Class 2; No. 6
28 Lift - Contactor Driver Overcurrent L,T
29 Lift Contactor Welded L.T
30 Lift Precharge Fault L,T
31 Lift - Contactor Open L,T
32 Lift - Battery Undervoltage D.P,T Cat. 1,Class 2; No. 11
33 Lift - Battery Overvoltage D,P,T Cat. 1,Class 2; No. 11
Lift Power AmpMer Thermal Cutback Cat. 1,Class 2; No. 8:
Lift Power Amplifier
34 System
Temperature
Derating Sensor
Traction Throttle Out Of Range Cat. 1,Class 2; No. 2:
35
Lift pot Voltage
36 Lift Throttle O u t Of Range L,W Cat. 1,Class 2; No. 6
MM Sense O u t Of Range Cat. 1, Class 2 ; Test
37 T*L 10
38 Lift Sense O u t Of Range T,L Cat. 1, Class 2; No. 9
39 Traction Motor Hot 1 Cat. 1, Class 2;No. 3
Lift Motor Hot 25O10 full Cat. 1, Class 2;No. 7
40
speed

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 Toyota Orderpicker Service Manual

Informational / Performance Limiting

Code Condition Effect Related Tests
No Traction Power Amplifier CAN Communication
41 0
Received By Display Card
42 Parameter Setting Error In The Traction Power Amplifier 0
No Lift Power Amplifier CAN Communication Received By
43 L,W
Display Card
44 Parameter Setting Error In Lift Power Amplifier L, W
Traction Motor Temperature Sensor Circuit Not Temperature Test
45 0,L.W
Responding
47 Serial Communication Shutdown Error X
48 Brake Dump Solenoid Not Responding T
Travel Is Requested And No Movement Is Detected Cat 1,Class 3
49
Cat. 1,Class 2, NO. o
50 Lift Stalled L Cat. 1,Class 2, No. 5
51 Traction Proximity Sensors detected disconnected T Cat. 1, Class 3
60" Mast Limit Switch not crossed Cat. 1, Class 1,
66 N
ESY22
120" Mast Limit Switch not crossed Cat. 1, Class 1,
67 N
ESY30
-
150" Mast Limit Switch not crossed Cat. 1, Class 1,
68 1
ESY31
180" Mast Limit Switch not crossed Cat. 1, Class 1.
69 1
ESY31
73 Traction Power Section (field open) T,L,W Cat. 1, Class 2, No. 1
74 Traction Power Section (armature sensor) T,L,W Cat. 1, Class 2. No. 0
75 Traction Power Section (FLD sensor) T.L.W Cat. 1. Class 2, No. 1
76 Traction - Missing Contactor T,L,W
77 Lift Power Section (armature sensor) T,L,W Cat. 1, Class 2, No. 5
78 Li - Missing Contactor T,L,W
79 Software Incompatibility T.L,W

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Analog lnputs

Analog lnputs

Category 1 Class 2:
Test Operation Analog lnputs
In the test operation, traveling and lift/lower
are allowed while monitoring the sensor. The
tests within "12" are continually tested once
entered.
If the truck does not have a particular sensor
then skip over the test.
To enter the tests from the table:
1. Press the power control select switch. The
display will change from "12" to "0" in the
left most character and in the right most
characters the value read from the
corresponding input. The UP and DOWN
arrow switches are both used to change to a
different test number.
2. If an error occurs, the error code replaces
the test number.
3. The error code can be cleared from the
display by pressing the hour meter select
switch. The test number will then reappear.
The fault condition remains and the
Wrench icon will continue to flash on and
off.
4. To end the tests within "12" press the
power control select switch. "12" will
appear instead of the test number and
nothing else will appear on the display.

No. Item Description

Drive Motor Armature Current 0 amps in neutral. Up to 350 amps stalled.

Normal full speed current is 80 - 120 amps.

Drive Motor Field Current 0 amps in neutral. Max.reading when traveling

is 22 amps for 24 V truck. Field current is
normally high during acceleration and low (4
to 6 amps) during a steady state full speed
condition.

00700-CL22 1 Issued: 9/10/98 6-25

Electrical Codes and Tests Toyota Orderpicker Service Manual

Category 1 Class 2:

No. Item Description

2 Traction Pot. Voltage Neutral Position = 2.0 - 3.0 V, Full Forward =
0.4 - 1.5 V, Full Reverse = 3.5 - 4.6 V.

3 Traction Motor Temperature Sensor Reads in Fahrenheit. Room temperature/cold

motor 49°F to 90°F. Normal operation the
temperature is <232"F.

4 Traction Motor Power Amplifier. The Power Amplifier will linearly decrease the
Temperature Sensor driving current limit starting at 185°F and
shutting down traction at 203°F. Within the
derating region the braking current limits are
not reduced. The driving current is also
reduced to one-half the rated value when the
temperature inside the Power Amplifier is less
than - 13°F.

5 Lift Motor Armature Current 0 amps in neutral. If the motor is stalled there
will be full current going through it. Current
is higher with a load and higher in the
telescopic area vs. the free lift area of the
mast.

6 Lift Pot. Voltage Neutral Position = 2.0 - 3.0 V, Full lower - 0.4 -
1.5 V, Full lift = 3.5 - 4.6 V.

7 Not Used

8 Lift Motor Power Amplifier Temperature The Power Amplifier will linearly decrease the
Sensor lift current limit starting at 185OF and
shutting down traction at 203°F. The lifting
current is also reduced to one-haif the rated
value when the temperature inside the Power
Amplifier is less than -13°F.

9 Not Used

10 Pressure Transducer With the forks on the floor resulting in no

pressure in the hydraulic system the voltage
should be <1.15 V. A three stage vehicle
where the forks are raised off the floor the
voltage should be 1.15 to 1.6 V. In the
telescopic area the voltage should be >1.6 V.
If the pressure transducer is disconnected the
voltage will be greater than 4.8 volts. The
pressure transducer is rated to 5,000 psi.
With no pressure the output is 1.0 V. Each
1,000 psi increase will result in an additional
1 volt reading.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Category 1 Class 2:

No. Item Description

11 Battery Voltage ~ o l l o w the
s battery voltage

?/Gored Battery Voltage Displays "24 volts"

Voltage reading should be within 11.O - 13.0 V.

During a low battery voltage condition this
voltage may dip lower than 11.0 volts
momentarily especially during a high current
demand situation (lifting a load and braking).

15 / Not Used
16 / No Test
17 No Test

18 No Test

19 NoTest

The following are Steer Controller Guidance Tests: 20-33

20 12 Volt Supply on Steer Card Displays the steer controller power supply
voltage (+12 volts) a s sensed by the Steer
Controller Card.

21 Battery Sense Input on Steer Card Displays the battery voltage a s sensed by the
Steer Controller Card.

22 Drive Unit Rate of Rotation Displays the rate of rotation based on the steer
position encoder.
-

23 lraCtor Left Coil Displays the voltage of the left tractor guidance
coil a s sensed by the Steer Controller Card.

24 1 Tractor Right Coil Displays the voltage of the right tractor

guidance coil a s sensed by the Steer
Controller Card.

25 1 Load Left Coil Displays the voltage of the left load guidance
coil a s sensed by the Steer Controller Card.

26
27
I Load Right Coil

Tractor Near Wire Coil

Displays the voltage of the right load guidance
coil a s sensed by the Steer Controller Card.

Displays the voltage of the tractor near wire

guidance coil a s sensed by the Steer
Controller Card.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Category 1 Class 2:

No. Item Description

28 Load Near Wire Coil ~ i s ~ lthe
a ~voltage
s of the load near wire
guidance coil as sensed by the Steer
Controller Card.

29 Average Distance from Wire Displays the average distance from the guide
wire a s sensed by t h e Steer Controller Card.

30 Peak Distance from Wire Displays the peak distance from the guide wire
as sensed by the Steer Controller Card.

31 Average Heading Angle Displays the heading angle from the guide wire
as sensed by the Steer Controller Card.
32 Peak Heading Angle Displays the peak distance from the guide wire
as sensed by the Steer Controller Card.

33 Average Signal Displays the average wire signal strength from

the guide wire a s sensed by the Steer
Controller Card.

34 Steer Input encoder (carriage) The encoder current is measured and a n

Connection Voltage equivalent voltage is displayed. If the encoder
card is not connected or the encoder h a s
failed electrically the equivalent voltage will
be near 0 volts.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Tests

Test 11.Simple Test (ESY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Test 12 . Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Test 13 . Traction Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Test 14 . Throttlekift Command Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Test 21 . Error Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Test 33 . Switch Input Test: Momentary Interrupt Test . . . . . . . . . . . . . . . . . . . . . . . 6-37
Test 34 . Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test41-EncoderTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41
Test 51 . Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test 61 . Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 1 1 - Simple Test (ESY)

Test 1 1 - Simple Test (ESY)

Once the test number (category/class selection)
has been entered, use the up and down arrow
switches to select the desired test. The test
number will start blinking after it has been
displayed for one second. It will blink on and off
three times at a 1Hz rate; then perform the
selected test. After three blinks, the test
number will be replaced with a test result in the
right most segment of the display.
Use the hour meter select switch to retest the
same item and re-display the test number.
Use the power control select switch to end the
test and return to the category/class selection
display.
Unless otherwise specified tiavel, lift/lower, and
steering functions are disabled.

Related Codes and Tests

Category 3, Class 3: Analyzer Mode,
Momentary Interruption Test
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes a n d Tests

Test 1 1 - Simple Test (ESY)

Sub-Menu
T e s t Description Result
Test No.
Polling of Traction and Lift
ESYO 1 00
Controllers
ESY02 Stored fault codes and
through corresponding key switch Code - - h - -
ESY 1 1 hour meter reading
ESY12 Key switch Yes
ESY13 Deadman No/Yes Deadman
ESY14 Horn Switch No
ESY21 24" Mast Switch Yes
ESY22 60" Mast Switch Yes
ESY23 ~ifcghibit No
ESY24 BWI on Lift Motor No
ESY25 BWI on Traction Motor No
ESY29 Lift Sense No until lift, then Yes
ESY30 120" Switch (Option) Yes
ESY31 150" or 180" Switch (Option) Yes
ESY32 Left Sidegate Switch (Option) Yes
ESY33 Right Sidegate Switch (Option) Yes
ESY34 EPO Switch Yes
ESY35 Auto/Manual Switch (Option) No
ESY40 Steer Feedback Connector Yes
Wire Guidance Board Status
ESY41 Yes
(optional)
ESY42 Home Position Switch Yes
Home Proximity Switch
ESY43 Yes
Connector
Steer Input Encoder
ESY44 Yes
Connector
ESY45 Rail Switch Input (option) Yes
Rail Switch Connection
ESY46 Yes
(option)

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 12 - Analog Inputs

Test 12 - Analog Inputs

This test is continually tested once entered.
Travel, lift/lower and load handler functions
are allowed while monitoring the sensor.
The left most character represents the test
number. The right character represents the
value read from the corresponding input. The
UP and DOWN arrow switches are used to
change to a different test number.
If an error occurs, the code replaces the test
number after two seconds. Pressing the hour
meter select switch will clear the error code
from the display and cause the test number to
reappear on the display. The fault condition
remains and the Wrench icon will continue to
flash on and off.
Use the power control select switch to end the
test and return to the category/class selection
display.

Related Codes and Tests

Category 1, Class 2: Analyzer Mode, Analog
Inputs

Run Test:
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Test 13 - Traction Speed Sensor

Test 13 - Traction Speed Sensor
This test is run continually once entered.
Traveling is allowed during test operation to
monitor the sensor.
Press the power control select switch. the "13"
on the display will change to a "1" in the left
most character space. The right character will
display the value read from the corresponding
input. The UP and DOWN arrow switches are
used to change to another test.
If a n error occurs, an error code replaces the
test number within two seconds. Error codes
may be cleared from the display by'pressing the
hour meter select switch. The test number will
replace the error code on the display. The fault
condition remains and the Wrench icon will
continue to flash on and off.
Use the power control select switch to end the
test and return to the category/class selection
display.

Related Codes and Tests

Category 1, Class 3: Analog Mode, Traction
Speed Sensor

Run Tesk
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
The test is a success if the voltage displayed is
within these limits:

Sub-Menu
Test Description Result
Test No.
1 Value in km/h 0.0 km/h
2 Value in mile/h 0.0 mile/h

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 14 - Throttle/Lift Command Test

Test 14 - Throttle/Lift
Command Test
Press the power control select switch, the "14"
will be replaced by one of the sub-menu
numbers listed below. Use the UP and DOWN
arrow switch to change to another test. If a test
is not applicable to the vehicle being tested, it
will not display.

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

Sub-Menu
Test Description Result
Test No.
Displays the throttle
% request from the
Display Card and
TO Throttle
the % the power
amplifier is
reading.
Displays the lift %
request from the
Display Card and
LO Lift the O h the power
amplifier is
reading.

NOTE: Test 17 will display throttle % in the ,

following format: T- - -<space>- - -.

Test 18 will display lift % in the following
format: L- - -<space>- - -.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Test 2 1 - Error Code Display

Test 21 - Error Code Display

This test is used to display the last ten error
codes and the corresponding key switch hours.
The LEDs of the battery discharge indicator
represents the error code being displayed. The
top LED on the battery discharge indicator
represents the most recent error, the bottom
LED represents the oldest error. The error code
and key switch hour readings alternate on the
display at a 1 Hz rate. The UP and DOWN arrow
switches are used to move through the LEDs.
Use the power control select switch to end the
test and return to the category/class selection
display.

Related Codes and Tests

Category 3, Class 3: ESY02-11

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 33 - Switch Input Test

Test 33 - Switch Input Test

This test checks the switches to see if there is a
connection. Press the power control select
switch, the "33" will be replaced by "ESY12." If
the switch is open, the buzzer will sound. The
buzzer is turned off by pressing the hour meter
select switch. The buzzer is reactivated when
another switch is selected. Use the UP and
DOWN arrow switches to move through the test
options. Press the power control switch to end
the switch tests.

Related Codes and Tests

Category 1, Class 1: Analyzer Mode, Simple
Test (ESY)

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Test 33 - Switch Input Test

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 34 - Continuity Test

Test 34 - Continuity Test

This test checks the switches to see if there is a
connection. Press the power control select
switch, the "34" will be replaced by "ESY12." If
the switch is closed, the buzzer will sound. The
buzzer is turned off by pressing the hour meter
select switch. The buzzer is reactivated when
another switch is selected. Use the UP and
DOWN arrow switches to move through the test
options. Press the power control switch to end
the switch tests.

Related Codes and Tests

Category 1, Class 1: Analyzer Mode, Simple
Test (ESY)

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
The test is a success if the voltage displayed is
within these limits:

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 Toyota Orderpicker Service Manual Electrical Codes and Tests

Test 34 - Continuity Test

1 S;'ir:t" / Test Description I

I
Result

11 ESY12
ESY13
ESY14 /
Key switch
Deadman
Horn Switch I
Yes
No/Yes Deadman
No 1
ESY21 24" Switch Yes
ESY22 60" Switch Yes
1 ESY23 I Lift Inhibit (Option) 1 No 1

1 ESY24
ESY25
BWI on Lift Motor
BWI on Traction Motor
/
No
No

Lift Sense
No until Lift. then
Yes I
I1 ESY30

ESY31 1
120" Switch (Option)
150" Switch
180" Switch (Option) I
Yes
Yes
Yes 1
ESY32 Left Sidegate (Option) Yes
ESY33 Right Sidegate (Option) Yes
I/ ESY34 I EPO Switch 1 Yes 1

1 ESY35
ESY40
Auto/M Switch (Option)
Steer Feedback Connector 1
No
Yes

/I ESY41
Wire Guidance Board Status
(Option)
Yes

/
I I

ESY42 Home Position Switch Yes 1

Home Proximity Switch
ESY43 Yes
I
Connector

/1 ESY44

ESY45 I
Steer Input Encoder
Connector
Rail Switch Input (Option) I
Yes
Yes 1
Rail Switch Connection
ESY46 Yes
(Option)

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Test 4 1 - Encoder Test

Test 41 - Encoder Test

Press the power control select switch, the "41"
will be replaced by one of the sub-menu
numbers listed below. Use the UP and DOWN
arrow switch to change to another test. If a test
is not applicable to the vehicle being tested, it
will not display.
02 ONLY: Either an "0"or a n "F" will display in
the space after the "A" or "B". "0"represents On
or high signal from the encoder. "F" represents
Off or low signal from the encoder.

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

Sub-Menu
Test Description Result
Test No.
01 Drive Unit Encoder 151
02 Steer Wheel Encoder A_, B-

NOTE: O=ON or F=OFF after the A or B means a

high or low signal from the encoder.
Test 01 will display a value between 0
and 255 while the drive unit is rotating.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Test 51 - Output Test

Test 51 - Output Test

R e s s the power control select switch, the "51"
will be replaced by "01 ." Each output test is
entered in the "Off' state. Exiting from an
output test returns the setting to "Off." Press
the hour meter select switch to toggle the
output to "On." Use the UP and DOWN arrow
switches to select another test.

Related Codes and Tests

Category 5, Class 1: Output Test

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
The test is a success if the voltage displayed is
within these limits:

Sub-Menu
Test Description Display Result
Test No.
01 Display LEDs Leds
02 Sound (audible) Ramp
03 Brake Dump Solenoid On/Off 24V On / OV Off
04 No Test
05 Load Holding Solenoid On/Off 24V On / OV Off
06 Proportional Solenoid Ramp 0 - 24 Volts

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Electrical Codes and Tests Toyota Orderpicker Service Manual
- -

Test 6 1 - Software Versions

Test 61 - Software Versions

Press the power control select switch. Use the
UP and DOWN arrow switches to select another
test.

Run Test:
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
The test displays the current software version
installed on the truck. An example follows:

Component Version
Display Card DM 01.0
Steer Controller . SM 02.5
Tractor I / F Card TI 01.2
Lift Power Amplifier LPA 10.44
Traction Power Amplifier TPA 23.43

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Lift Truck Error Codes

Lift Truck Error Codes

Display Messages:
NEUTRAL? - Displayed when the tractor handle
is out of the neutral position before the
Deadman is activated.
LIFT? - Displayed when the lift actuator is out
of the neutral position before the Deadman is
activated.
EPO? - Displayed when the EPO button on the
platform has been pressed or there is a fault in
its related circuitry. When the EPO button is
pulled back out, only lower is allowed. The
display will change from displaying EPO? to the
following scrolling message: TRAVEL AND LIFT
DISABLED.. .TURN KEY OFF/ON TO RESET.
SIDEGATE? - Displayed when the Left, Right, or
Both Sidegates are up.

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Electrical Codes a n d Tests Toyota Orderpicker Service Manual

Code 0 1

Code 01

Code Title Code 01 - 24" Mast Switch Not Crossed

Reason 24" Mast Switch indicates still closed (not crossed) after
approximately 6 seconds of lifting.

System Response

Alarm Sounds Yes

Operator Display Code 01

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 mph

Lift/Lower System Operational

How to Clear Cross switch or cycle key switch OFF/ON

Tests to Run See Below

Run Test:
Category 1, Class 1, ESY2 1
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 02

Code 02

1 Code Title I Code 02 - Limit Switches Do Not Agree

Reason Indicates above the upper 150" or 180" optional mast
switch and below the lower 24" mast switch.

System Response

1 ~ l a r msounds Yes

Operator Display Code 02

Traction Power LED = Heartbeat

Amplifier
1 Lift Power Amplifier 1 LED = Heartbeat

1 Performance Limits
l1 Travel System

Lift/Lower System 1
1.0 mph if drive unit <10 degrees
0 mph if drive unit >10 degrees

operational

How to Clear Cycle the key switch OFF/ON

Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 03

Code 03

Code Title Code 03 - Limit Switches Do Not Agree 1

1 System Response
r
I
Indicates above 150" or 180" switch and below the 60"
mast switch.

I!
Alarm Sounds Yes

Operator Display Code 03

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

1 Performance Limits I I
Travel System 1.0 mph if drive unit <10 degrees
0 mph if drive unit >10 degrees

Lift/Lower System Operational

How to Clear Cycle the key switch OFF/ON

Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 04

Code 04

Code Title Code 04 - Limit Switches Do Not Agree

Reason Indicates above 120" switch and below 24" switch.

System Response

Alarm Sounds Yes

Operator Display Code 04

Traction Power LED = Heartbeat

Amplifier
Lift Power Ampliier LED = Heartbeat

Performance Limits

Travel System 1.0 mph if drive unit <10 degrees

0 mph if drive unit >10 degrees.

Lift/Lower System Operational

How to Clear Cycle the key switch OFF/ON

Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 0 5

Code 05

Code Title Code 05 - Limit Switches Do Not Agree

Reason Indicates above 120" switch and below 60" switch.

System Response

Alarm Sounds Yes

Operator Display Code 05

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 1.0 mph if drive unit <10 degrees

0 mph if drive unit >10 degrees.

Lift/Lower System Operational

How t o Clear Cycle the key switch OFF/ON

Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
--

Code 0 6

Code 06

Code Title Code 06 - Limit Switches Do Not Agree

Reason Indicates above 60" switch and below 24" switch.

System Response

Alarm Sounds Yes

Operator Display Code 06

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 mph if drive unit <10 degrees

1.0 mph if drive unit >10 degrees.

Lift/Lower System Operational

How t o Clear Cycle the key switch OFF/ON

Tests t o Run See Below

Run Test:
ESY21
ESY22
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 0 7

Code 07

Code Title 1 Code 07 - Limit Switches Do Not Agme

Reason Indicates below 120" and above 180" switch.

1 System Response
/I Alarm Sounds 1 Yes

Operator Display Code 07

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

/ Performance Limits
Travel System 1.0 mph if drive unit <10 degrees
0 mph if drive unit >10 degrees.

/ Lift/Lower System / Operational I

I Cycle the key switch OFF/ON
I
Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 08

Code 08

Code Title Code 08 - Lift Cutout Switch Does Not Agree

Reason Indicates above the cutout switch and below the 60"
lower mast switch
I

System Response

Alarm Sounds Yes

Operator Display Code 08

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System No restrictions

Lift/Lower System Inoperative

How to Clear Cycle the key switch OFF/ON

Tests to Run See Below

Run Test:

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 0 9

Code 09

Code Title / Code 09 - Trackon Power Amplifier POST Failed

Reason Self-diagnosis error

System Response

Alarm Sounds Yes

Operator Display Code 09

I1 Traction Power
Amplifier
LED = Code: 1, 2

Lift Power Amplifier / LED = Heartbeat

/ Performance Limits
I Travel System I Inoperative

l Lift/Lower System Inoperative; traction power amplifier drops out power

contactor (MM)

:I How to Clear

Tests to Run
Replace the Traction Power Amplifier if problem is not
cleared by cycling the key switch OFF/ON

None

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 Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 10

Code 10

Code Title -
Code 10 Traction Power Section (M-)Fault
Reason 1. M- shorted to B- ; 2. Field winding fault; 3. Armature
or field current sensor fault.

System Response

Alarm Sounds Yes

Operator Display Code 10

Traction Power LED = Code: 1, 3

Amplifier
Lift Power Amplifier LED = Heartbeat
Performance Limits

I Travel System Inoperative

Lift/Lower System Inoperative; traction power amplifier drops out power
contactor (MM)
-
How to Clear Cycle the key switch OFF/ON

Tests t o Run See Below

Run Test:
Category 1. Class 2: Tests 0, 1
Check for the following: (replace if defective)
Cabling a t B- and M- a t the traction
power amplifier
Loose field wiring in motor or connection
Open field winding in motor or
connection
Defective Traction Power Amplifier
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
NOTE: Correct any other error codes that may

I appear in the truck's memory before

clearing this code.

00700-CL221 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 11

Code 11

Code Title Code 11 - Traction HPD

Reason Deadman signal from Tractor Interface Card to Traction
Power Amplifier interrupted.
System Response

Alarm Sounds Yes

Operator Display Code 11
Traction Power LED = Code 2 , 2
Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Operational
How to Clear Cycle the key switch OFF/ON
Tests to Run See Below

Run Tests:
Category 1. Class 2: Test 2
Check wiring from JT1-2to JPR10-6.
NOTE: If wiring ok, replace Traction Power
Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 12

Code 12

Code Title Code 12 - Traction SRO

Reason Defective power amplifier - Code should not be active

System Response

Alarm Sounds Yes

Operator Display Code 12

Traction Power LED = Code 2, 3

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Operational

How to Clear Cycle the key switch OFF/ON

Tests to Run None

NOTE: If error occurs after key switch is cycled,

replace the Traction Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 13

Code 13

Code Title Code 13 - Traction Throttle Out o f Range

Reason Traction power amplifier receiving an out of range
traction command.

System Response

Alarm Sounds Yes

Operator Display Code 13

Traction Power LED = Code 2, 1

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Operational

How t o Clear

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 2: Traction
Potentiometer Voltage
1. Run "Calibrte."
2. If test fails, check potentiometer and wiring.
3. If test passes, replace Traction Power
Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 14

Code 14

Code Title Spare - no definition

Reason

System Response

Alarm Sounds

Operator Display

Travel Power Amplifier

Lift Power Amplifier

Performance Limits

Travel System
- -

Lift/Lower System

How t o Clear

Tests t o Run

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 15

Code 15

Code Title Code 15 - Traction Power Amplifier Contactor Driver

Output Over current
Reason Traction power amplifier driver output over current

System Response

Alarm Sounds Yes

Operator Display Code 15

Traction Power LED = Code 3, 1

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Operational

How t o Clear Cycle key switch ON/OFF

Tests to Run N/A

NOTE: If error occurs after key switch is cycled,

replace Traction Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 16

Code 16

Code Title -
Code 16 Traction Power Amplifier - Main Contactor
Welded
Reason Traction power amplifier - welded main contactor

1 System Response
I I
/ Alarm Sounds
I

Yes I
/ Operator Display I Code 16 I/
Traction Power LED = Code 3, 2
Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

1 Lift/Lower System 1 ~noperative

1

I/
How to Clear Cycle key switch OFF / ON

Tests to Run See below

1. Check that the contactor cycles OFF/ON.

Main Contactor might be welded.
Coil driver on Tractor Interface Card is
shorted, allowing the contactor to stay
energized.
2. Replace a s required.
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 17

Code 17

Code Title Code 17 - Traction Recharge Fault

Reason Traction Power Amplifier internal voltage too low a t
start-up.

System Response

Alarm Sounds Yes

Operator Display Code 17

Traction Power LED = Code 3, 3

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative; traction power amplifier drops out power

disconnect contactor (MM)

Lift/Lower System Lift Inoperative

How to Clear Cycle key switch OFF / ON

Tests t o Run See below

Check for external short, or leakage path to B-

on external B+ connection of Traction Power
Amplifier.
NOTE: If error occurs after key switch is cycled,
replace Traction Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 18

Code 18

Code Title -
Code 18 Traction - Contactor Open
Reason Traction power amplifier - main contactor detected
open - defective power amplifier.

System Response

Alarm Sounds Yes

Operator Display Code 18

Traction Power LED = Code 3.4

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Lower Operational, Lift Inoperative

How to Clear Step OFF/ON Deadman

Tests t o Run See below

Check that the contactor cycles OffjOn.

If contactor never closes:
Check wiring from Tractor Interface
Card to MM contactor (JPR3-7&9 to
MM -Y&x).
If code appears before depressing brake:
Check brake switch.
Check Steer Card.
Check Tractor Interface Card.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 18
If ok, check voltage across MM contactor
using a V.O.M.
If there is voltage present during
power -up, replace the contactor
If there is no voltage across the
contactor:
Check the wiring from JT1-17 to
JPR10-8
If ok, connect a V.O.M. from JT1-17
to TP4. If there is approximately
3-5 volts present, the Tractor
Interface Card is ok.
If during power-up, the voltage a t
JT1-17 with reference to TP4 never
goes low, replace the traction power
amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
NOTE: Correct any other error codes that may
appear in the truck's memory before
clearing this code.

00700-CL22 1 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 19

Code 19

Code Title Code 19 - Traction - Battery Undervoltage

Reason Traction power amplifier measures the battery voltage
to be too low.

System Response

Alarm Sounds Yes

Operator Display Code 19

Traction Power LED = Code 4, 1

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System At 70% of nominal battery voltage measured a t the

Traction Power Amplifier (approximately 16.8 volts),
the traction power amplifier starts to cut back the
current.
At 70%-4 volts (approximately 12.8 volts), the travel
system is inoperative.

Lift/Lower System Operational

How to Clear Cycle key switch OFF / ON

Tests to Run 1. Check Battery

2. See Below.

Run Test:
Category 1, Class 2: Test 11
If test fails:
a. Replace the battery.
b. Replace Traction Power Amplifier.
NOTE: For information on how to use analyzer "I-

mode, refer to "Modes of Operation" on

page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 2 0

Code 20

Code Title Code 20 - ~radtion- Battery Overvoltage

Reason Traction power amplifier measures the battery voltage
to be too high.

1 System Response I I
I/ Alarm Sounds I yes
I
1 Operator Display 1 Code 20 I1
Traction Power LED = Code 4 . 2
Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System At 17% (approximately 4 volts) above nominal battery

voltage, the traction power amplifier starts to cut back
the current.
At 33%(approximately 8 volts) above, traction is
inoperative.

/I Lifi/hwer System 1 Operational 1

I/ H to clear
OW I Cycle key switch OFF / ON
I
I/ Tests to Run / Check Battery
I
Run Test:
Category 1, Class 2: Test 1 1
Check the following:
Battery disconnected during
regenerative braking.
Vehicle operated with charger attached.
N O TE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 21

Code 21

Code Title Code 21 - Traction Power Amplifier Thermal Cutback

I

Traction power amplifier checks for >85 Degrees C (185

F) or <-25 Degrees C (- 13 F).

I System Response
I
/ Alarm Sounds I yes

1 Operator Display 1 Code 21

Traction Power
Amplifier
/ Lift Power Amplifier / LED = Heartbeat
--

/ ~erformanceLimits I
Travel System Current Limitation

I/ Lift/Lower System I Operational

I1 How to Clear

Tests to Run
1. Allow time for Traction Power Amplifier to cool.
2. Cycle key switch OFF / ON

See Below

Run Test:
Category 1, Class 2: Test 4. Traction Power
Amplifier Temperature Sensor
Possible Cause:
Excessive load on vehicle
Improper mounting of Traction Power
Amplifier
Operation in extreme environments
Corrective Action:
1. Attach temperature probe to the Power
Amplifier heat sink and perform test. Truck
display and probe should approximately
track each other.
2. If test fails, replace the Traction Power
Amplifier.
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual
Code 22

Code 22

Code Title Spare - no definition

Reason

System Response

1 Alarm Sounds

Operator Display

Traction Power
Amplifier
/ Lift Power Amplifier
I
Performance Limits

Travel System

Lift/Lower System

How to Clear

Tests to Run

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 23

Code 23

Code Title Code 23 - Lift Power Amplifier POST Failed

Reason Self-diagnosis error

System Response

Alarm Sounds Yes

Operator Display Code 23

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED=Code 1 , 2

Performance Limits

Traction System Inoperative; lift power amplifier drops out power

disconnect contactor (MM)

Lift/Lower System Lift Inoperative, Lower Operational

How to Clear Cycle key switch OFF/ON; if problem does not clear,
replace lift power amplifier.

Tests to Run None

N O T E: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 24

Code 24

Code Title Code 24 - Lift Power Section (M-) Fault

Reason 1. M- shorted to B-, 2. Field winding fault, 3. Armature
or field current sensor fault.

System Response

Alarm Sounds Yes

Operator Display Code 24

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED = Code 1 , 3

Performance Limits

Travel System Inoperative; lift power amplifier has dropped out power
disconnect contactor (MM)

Lift/Lower System Lift Inoperative, Lower Operational

How to Clear Cycle the key switch OFF / ON

Tests t o Run See Below

Run Test:
Category 1, Class 2: Test 5
Check for the following (replace if defective)
Lift Power Amplifier
Cabling a t B- & M- at the Lift Power
Amplifier
NOTE: If error occurs after key switch is cycled,
replace Lift Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 25

Code 25

Code Title -
Code 25 Lift KPD
Reason Deadman signal from Tractor Interface Card to Lift
Power Amplifier intenupted

System Response

Alarm Sounds Yes

Operator Display Code 25

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED = Code 2 , 2

Performance Limits

Travel System Operational

Lift/Lower System Lift Inoperative, Lower Operational

How t o Clear Cycle the key switch OFF / ON

Tests t o Run See Below

Run Test:
Category 1, Class 2: Test 6
Check wiring from JL1-2 to JPR10-15
If wiring ok, replace Lift Power Amplifier.
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 26

Code 26

Code Title Code 26 - Lift SRO

Reason Defective Lift Power Amplifier - code should not be
active

System Response

Alarm Sounds Yes

Operator Display Code 26

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED = Code 2.3

Performance Limits

Travel System No restrictions

Lift/Lower System Lift Inoperative, Lower Operational

How t o Clear Cycle the key switch OFF / ON

Tests to Run None

If error occurs after key switch is cycled, replace

Lift Power Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 27

Code 27

Code Title Code 27 - Lift Throttle Out of Range

Reason Lift power amplifier receiving an out of range lift
command.

System Response

Alarm Sounds Yes

Operator Display Code 27

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED = 2, 1

Performance Limits

Travel System No restrictions

Lift/Lower System I Inoperative

How to Clear

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 6 - Lift
Potentiometer Voltage
1. Run Calibrte.
2. If test fails, check potentiometer and wiring.
3. If test passes, replace Lift Power Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9 / 1 0 / 9 8
Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 28

Code 28

Code Title Code 28 - Lift Power Amplifier - Contactor Driver

Output Overcurrent
Reason Lift power amplifier driver output overcurrent.

System Response

Alarm Sounds Yes

Operator Display Code 28

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Code 3, 1

Performance Limits

Travel System Inoperative

Lift/Lower System Lift Inoperative, Lower Operational

How to Clear Cycle key switch OFF/ON

Tests to Run None

If error occurs after key switch is cycled, replace

Lift Power Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 29

Code 29

Code Title Code 29 - Lift Power Amplifier - Main Contactor

Welded
Reason Lift power amplifier - welded main contactor.

System Response

Alarm Sounds Yes

Operator Display Code 29

Travel Power Amplifier Energized (In)

Lift Power Amplifier LED = Code 3 , 2

/ Performance Limits
I p e l system I Inoperative

I/ ~ i f f / ~ o a cSystem
r
1 Lift Inoperative, Lower Operational

/
- -

[How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
1. Check that the contactor cycles OFF/ON.
Contactor may be welded.
Coil driver may b e shorted on Tractor
Interface Card, allowing the contactor to
stay energized.
2. Replace a s required.
NO TE: If error occurs after key switch is cycled,
replace Lift Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 30

Code 30

Code 30 - Lift Recharge Fault

1
Code Title
Reason Lift power amplifier internal voltage too low a t start-up.
System Response

Alarm Sounds Yes

Operator Display I Code 30

I
Traction Power Energized (In)
Amplifier
Lift Power Amplifier LED = Code 3, 3

Performance Limits

Travel System Inoperative

Lift/Lower System Inoperative: lift power amplifier has dropped out power
disconnect contactor (MM)

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Check for external short, or leakage path to B-

on external B+ connection of Lift Power
Amplifier.
NOTE: If error occurs after key switch is cycled,
replace Lift Power Amplifier.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 3 1

Code 31

Code Title Code 31 - Lift-Main Contactor Open

Reason Lift Power Amplifier - Main contactor detected open.

System Response

Alarm Sounds Yes

Operator Display Code 31

Traction Power Energized (In)

Amplifier
Lift Power Amplifier LED = Code 3 , 4

Performance Limits

Travel System Inoperative

Lift/Lower System Lift Inoperative, Lower Operational

How to Clear Step OFF/ON Deadman

Tests to Run See Below

Category 1, Class 2: Test 3

Check that the contactor cycles Off/On.
If contactor never closes:
Check wiring from Tractor Interface
Card to MM contactor (JPR3-7&9 to
MM-y&).
If ok, check voltage across MM contactor
using a V.O.M.
If there is voltage present during
power-up, replace the contactor.
If there is no voltage across the
contactor:
Check the wiring from JL1-17 to
JPR10-17.
If ok, connect a V.O.M. from JL1
to TP4.If there is approximately
3-5 volts present, the Tractor
Interface Card is ok.

00700-CL22 1 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 31

If during power-up, the voltage a t

JL1-17 with reference to TP4 never
goes low, replace the lift power
amplifier.
NOTE: If error occurs after key switch is cycled,
replace the Lift Power Ampmer.
For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.
NOTE: Correct any other error codes that may
appear in the truck's memory before
clearing this code.

00700-CL22 1 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 32

Code 32

Code Title -
Code 32 Lift - Battery Undervoltage
Reason Lift power amplifier measures the battery voltage to be
too low.

System Response

Alarm Sounds Yes

Operator Display Code 32

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Code 4, 1

~erformandeLimits

Travel System No restrictions

Lift/Lower System At 70% of nominal battery voltage measured at the Lift

Power Amplifier (approximately 16.8 volts), the
traction power amplifier starts to cut back the
current.
At 70%-4 (approximately 12.8 volts), lift is inoperative.

How to Clear Cycle key switch OFF / ON

Tests to Run Check Battery

Run Test:
Category 1, Class 2: Test 11
1. Replace battery.
2. Replace Lift Power Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 33

Code 33

Code Title Code 33 - Lift - Battery Overvoltage

Reason Lift power amplifier measures the battery voltage to be
too high.

1 System Response I I
/I Alarm Sounds I yes

/ Operator Display 1 Code 33

/
Traction Power
Amplifier
LED = Heartbeat
1
Lift Power Amplifier I - --

LED = Code 4, 2

Performance ~ i m i t s

Travel System No restrictions

Lift/Lower System At 17% (approximately 4 volts) above nominal battery

voltage, the traction power amplifier starts to cut back
the current.
At 33%(approximately 8 volts) above, lift is
inoperative.

How to Clear Cycle key switch OFF 1 ON

Tests to Run Check Battery

Run Test:
Category 1, Class 2: Test 11
1. Check to see if battery was disconnected
during regenerative braking.
2. Check to see if vehicle was operated with
charger attached.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 34

Code 34

Code Title Code 34 - Lift Power Amplifier Thermal Cutback

Reason Lift power amplifier checks for >85 degrees C (185 F) or
<-25 degrees C (- 13 F).

System Response

Alarm Sounds Yes

Operator Display Code 34

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Code 4 , 3

Performance Limits

Travel System No restrictions

Lift/Lower System Current Limitation

How t o Clear Allow time for Lift Power Amplifier to cool

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 8 - Lift Power
Amplifier Temperature Sensor
Possible Cause:
Excessive load on vehicle
Improper mounting of Lift Power
Amplifier
Operation in extreme environments
Corrective Action:
1. Attach a temperature probe to the Power
Amplifier heat sink and perform the test.
The display and probe should
approximately track each other.
2. If test fails, replace the Lift Power Amplifier.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 35

Code 35

Code Title Code 35 - Traction Throttle Out of Range

Reason Display card reading a n out of range traction pot.

System Response

Alarm Sounds Yes

Operator Display Code 35

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

1 Lift/Lower System I Operational

1
1 HOW to clear 1 Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 2 - Traction
Potentiometer Voltage
1. Run Calibrte.
2. Check wiring to Carriage Interface Card.
3. Check wiring from Camage Interface Card
to Display Card.
4. Check potentiometer voltage.
If wiring and potentiometer voltage ok,
replace the Carriage Interface Card. If not
corrected after replacing the Carriage
Notifies Card, replace the Display Card.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 36

Code 36

Code Title Code 36 - Lift Throttle Out of Range

Reason Display card reading a n out of range lift pot.

System Response

Alarm Sounds Yes

Operator Display Code 36

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Operational

Lift/Lower System Inoperative

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 6 - Lift/Lower
Potentiometer voltage
1. Run Calibrte.
2. Check wiring to Carriage Interface Card.
3. Check wiring from Carriage Interface Card
to Display Card.
4. Check potentiometer voltage.
If wiring and potentiometer voltage ok,
replace the Carriage Interface Card. If not
corrected after replacing the Carriage
Interface Card, replace the Display Card.
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Electrical Codes a n d Tests Toyota Orderpicker Service M a n u a l

C o d e 37

Code 37

Code Title Code 37 - MM Sense Out of Range

Reason Voltage on the output side of the contactor does not
agree with the expected value.

System Response

Alarm Sounds Yes

Operator Display Code 37

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Inoperative

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Check to be sure the contactor cycles Off/On.

If yes, check F5
If F5 ok, check wiring from F5-2 to
JPR3- 10
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

0 0 7 0 0 -C L 2 2 1 Issued: 9 / 1 0 / 9 8
Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 38

Code 38

Code Title -
Code 38 Lift Sense Out of Range
Reason Voltage at LM- does not agree with expected value when
lift potentiometer is activated.

System Response

Alarm Sounds Yes

Operator Display Code 38

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Inoperative

How t o Clear Cycle key switch OFF / ON

Tests t o Run See Below

Run Test:
Category 1, Class 2: Test 5
ESY29
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 39

Code 39

Code Title Code 39 - Traction Motor Hot

Reason Traction motor temperature above upper limit.

System Response Yes

Alarm Sounds

Operator Display Code 39

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Limited to 1 mph

Lift/Lower System Operational

How to Clear Allow time for traction motor to cool

Tests to Run See Below

Run Test:
Category 1, Class 2: Test 3
Possible Cause:
Excessive load on vehicle
Faulty traction motor thermistor
Operation in extreme environments
Corrective Action:
1. Attach temperature probe to the traction
motor near the thermistor, and perform
test. Truck display and probe should
approximately track each other.
2. If test fails, replace the thermistor.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 41

Code 41

Code Title Code 41 - No Traction Power Amplifier CAN

Communication Received by Display Card
Reason Display Card h a s not received a message in l o o m s
from the Traction Power Amplifier.

System Response

Alarm Sounds Yes

Operator Display Code 41

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Limited to 0 mph

Lift/Lower System Not Operational

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
Category 6, Class 1: Software Version
1. Check software versions using Test 61.
If all of the software versions display,
communications are ok.
If none of the software versions display,
the Display Card may be defective or the
over-the-mast connection HD 1-2 & 4 to
JP5-2 & 4 may be open.
2. If only the software version for the traction
power amplifier does not display, the
traction power amplifier may be defective.
Perform the following:
a. Check wiring from Tractor Interface
Card to Traction Power Amplifier;
JPR10- 1 & 2 to JT2-3 & 6. Repair a s
needed.
b. If wiring ok, replace Traction Power
Amplifier.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
Code 41
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9'/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 42

Code 42

Code Title Code 42 - Parameter Setting Error in Traction Power

Amplifier '
Reason Parameters could not be set in the Traction Power
Amplifier.
System Response

Alarm Sounds Yes

Operator Display Code 42
Traction Power LED = Heartbeat
Amplifier
Lift Power Amplifier LED = Heartbeat
Performance Limits

Travel System Limited to 0 mph

Lift/Lower System Not operational
How to Clear Cycle key switch OFF / ON
Tests t o Run See Below

Run Test:
Category 6 ,Class 1: Software Version
The transmit portion of the Traction
Interface Card may be faulty.
1. Check the software version in the Traction
Power Amplifier. If all of the software
version display, communication is ok.
If software version does not display,
Display Card or Power AmpWier may be
defective. Perform the following:
Check wiring from Traction Interface
Card to Display Card; JPR10-1 & 2 to.
JT2-3 & 6. Repair a s needed.
2 . Go to Calibrte and reset the power amplifier
default values (PwrAmpDf).
Traction Power Amplifier may be faulty.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Revised: 2/15/00

Electrical Codes a n d Tests Toyota Orderpicker Service Manual

Code 43

Code 43

Code Title -
Code 43 No Lift Power Amplifier CAN
Communicatian Received by Display Card
Reason Display Card has not received a message in looms
from the Lift Power Amplifier.

System Response

Alarm Sounds Yes

Operator Display Code 43

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Inoperative

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
Category 6, Class 1: Software Version
The transmit portion of the Traction
Interface Card may be faulty.
1. Check the software versions using Test 61.
If all of the software versions display,
communication is ok.
If none of the software versions display,
the Display Card may be defective or the
over-the-mast connection HD1-2 & 4 to
JP5-2 & 4 may be open.
2. If only the software version for the Lift
Power Amplrier does not display, the Lift
Power Amplifier may be defective. Perform
the following:
Check wiring from Tractor Interface
Card to Lift Power Amplifier; JPR10-10
& 11 to JL2-3 & 6. Repair a s needed.
3. If wiring ok, replace Lift Power Amplifier.

00700-CL22 1 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 43

NOTE: For information on how to use analyzer

mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 44

Code 44

Code 44 - Parameter Setting Error in Lift Power

Code Title
/ Amplifier
Reason Parameter(s) could not be set in the Lift Power
Amplifier.

System Response

Alarm Sounds Yes

Operator Display Code 44

Traction Power
Amplifier
/I Lift Power Amplifier
LED= Heartbeat
I/
I LED= Heartbeat

1 Performance Limits
1/
I/ Travel System ~noperative

1 Lift/Lover System I -- --

Inoperative
--

1 HOW to clear 1 Cycle key switch OFF / ON I

Tests to Run See Below

Run Test:
Category 6 , Class 1: Software Version
The transmit portion of the Traction
Interface Card is faulty.
1. Check the software version in the Lift Power
Amplifier. If all of the software versions
display, communication is ok.
If software version does not display,
Display Card may be defective. Perform
the following:
Check wiring from Tractor Interface
Card to Lift Power Amplifier; JPR10- 10
& 11 to JL2-3 & 6 . Repair a s needed.
2. Go to Calibrte and reset the power amplifier
defaults (PwrAmpDfl.
3. The Lift Power Amplifier may be faulty.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9110/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 45

Code 45

Code Title Code 45 - Traction Motor Temperature Sensor

Circuit Not Responding
Reason Test circuit sends out-of-range readings

System Response

Alarm Sounds Yes

Operator Display Code 45

Travel Power Amplifier LED= Heartbeat

Lift Power Amplifier LED= Heartbeat

Performance Limits

Travel System Speed limit: 1.0 mph

Lift/Lower System Not Limited

How to Clear Repair

Tests to Run See Below

Run Test:
Temperature Test
Category 1, Class 2: Test 3
1. Check wiring from traction motor
thermistor'to the Tractor Interface Card.
2. Check resistance of thermistor. When the
motor is cold, the resistance should be
approximately 2000 ohms.
3. The sensing circuitry on the Tractor
Interface Card may have failed.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 47

Code 47

Code Title Code 47 - Serial Communication Failure

Reason Carriage Interface card not communicating with
Display

System Response

Alarm Sounds Yes

Operator Display Code 47

Travel Power Amplifier LED= Heartbeat

Lift Power Amplifier LED= Heartbeat

Performance Limits

Travel System Inoperative

Lift/Lower System Inoperative

Load Handler

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

1. Check wiring from JPS2 Display connector

to Carriage Interface Card.
If ok, go to step 2.
2. Carriage Interface Card or Display Card
may be faulty.
NOTE: For information on how to use analyzer
mode. refer to "Modes of Operation" on
page 6-3.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 48

Code 48

Code Title Code 48 - Brake Dump Solenoid Not Responding

Reason Brake dump solenoid not responding

System Response

Alarm Sounds Yes

Operator Display Code 48

Travel Power Amplifier LED= Heartbeat

Lift Power Amplifier LED= Heartbeat

Performance Limits

Travel System Speed limit: 1.0 mph

Lift/Lower System Lift Inoperative, Lower Operational

Load Handler

How to Clear Cycle key switch OFF / ON

Tests t o Run See Below

Run Test:
Category 5, Class 1: Test 03
Check wiring from brake dump solenoid to
Carriage Interface Card.
If wiring ok, check voltage across the
solenoid coil. If a voltage is present and
the brake dump solenoid will not
activate, replace the brake dump
solenoid.
If there is no voltage, replace the
Carriage Interface Card.
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 49

Code 49

Code Title Code 49 - Travel Is Requested And No Movement Is

Detected
Reason Armature current greater than 250 amps, and
movement from the traction proximity sensor not
detected for 5 seconds.

System Response

Alarm Sounds Yes

Operator Display Code 49

Travel Power Ampmer LED= Heartbeat

Lift Power Amplifier LED= Heartbeat

Performance Limits

Travel System Inoperative

Lifk/Lower System Operational

Load Handler

How to Clear 1. Return handle to Neutral to reset.

2. Cycle key switch OFF / ON
Tests to Run See Below

Run Test:
Category 1, Class 3: Traction Speed Sensor
If test fails:
Check wiring from SP1 and SP2 to Steer
Controller.
Check gap of SP1 and SP2 to the brake
hub. The gap between the upper surface
of the brake drum and the tip of the
proximity switch should be .12" - .16".
N O TE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 50

Code 50

Code Title Code 50 - Lift Stall Protection

Reason Request is greater than 80% and lift current is greater
than 450 amps. for 60 seconds.

/ System Response
Alarm Sounds Yes

Operator Display Code 50

Travel Power Amplifier LED= Heartbeat

Lift Power Amplifier LED= Heartbeat

Performance Limits

Travel System Not limited

Lift/Lower System Inoperative

1 Laad Handler

1 How to Clear
I

I
Tests to Run See below.
I
Run Test:
Category 1, Class 2: Test 5
Category 1, Class 2: Test 6
N O T E: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 51

Code 51

Code Title Code 51 - Connect Detect - S P l h SP2

Reason Proximity sensors SP1 & SP2 have failed and/or ground
connection is open.

System Response

Alarm Sounds Yes

Operator Display Code 51

Travel Power Amplifier LED: Heartbeat

Lift Power Amplifier LED: Heartbeat

Performance Limits

Travel System Disabled

Lift/Lower System Operative

Load Handler

How to Clear Cycle key switch OFF / ON

Tests to Run See Below

Run Test:
Category 1, Class 3: Traction Speed Sensor
1. Check wiring from SP1 & SP2 to Steer
Controller.
2. If wiring is ok, check gap between sensors
and the brake drum. The gap between the
upper surface of the brake drum and the
tip of the proximity switch should be
.12"-.16". Adjust gap if necessary.
a. A s the brake drum rotates, the LED at
the end of each speed sensor should be
"ON" when over metal and "OFF" when
not over metal.
b. Replace the sensor that does not
perform according to step 2a.
3. If wiring and sensors are ok, replace Steer
Controller Card.

00700-CL22 1 Revised: 9/23/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 51

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 51

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Steer Controller Guidance Systems

Steer Controller Guidance Systems

Codes and Tests

Detailed step-by-step procedures for each test
are contained herein.

Error Codes
NOTE: In addition to the 8-character error code
display, the Wrench icon will flash on
and off until the error is corrected.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 1 P

Code 1 P
I Code Title I Guidance Not Calibrated
Reason When the Auto/Manual switch was placed in
the "Auto" position, the wire guidance
I I parameters were out of range. I
System Response 1. Alarm sounds: Yes
2. Display: Guidance Not Calibrated
3. How code appears sequentially on the
Steer Controller Card:

How to Clear
I
Calibrate Guidance
I
NOTE: This code will only occur on trucks with
wire guidance.

Possible Causes and Checks:

1. Perform the wire guidance and wire
guidance offset portion of Calibrte.
2. The wire guidance option is not properly
installed.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 52

Code 52
No Display Card Communications
Code Title
Received By The Steer Controller.
Reason Communications have slowed enough (or
stopped) so that 100 m s h a s passed without
a message being received by the Steer
Controller.
System Response sounds: Yes
2. Display: CODE 52
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

Fl
How to Clear If cycling the keyswitch OFF/ON does not
clear this code then follow the procedure
below.

Possible Causes and Checks:

1. This code could be the result of static
electricity or shorts to frame. Check and
clean all static straps. Check for shorts to
frame.
2. Poor connections or loose wires could
generate enough electrical noise to cause
this code (i.e., steering encoder).
3. Check the cable connections between the
Steer Controller and the Display Card.
4. Check the CAN Error LED on the Steer
Controller. If the Heartbeat LED is blinking
a t a rate of approximately 60 times per F~gure6-2: Steer Controller Card - Code 52
minute, the Steer Controller is OK.
5. If the CAN Error LED is On and the
Heartbeat LED is OK, the problem may be
in the cable connecting the Display Card
and the Steer Controller.
NO TE: Remember to r u n Calibrte if any boards
are replaced.

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 53

Code 53

1 Code Title
No Steer Controfier Communications
Received By Display Card.
Reason The Display Card has not heard from the
Steer Controller for more than 100 ms.

/ System Response 'Iarm sounds:

2. Display: CODE 53
3 . Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear If cycling the keyswitch OFF/ON does not

clear this code then follow the procedure
below.

Possible Causes and Checks:

1. This code could be the result of static
electricity or shorts to frame. Check and
clean all static straps. Check for shorts to
frame.
2. The transmit portion of the Steer Controller
is defective.
Go into Tuning mode. Check the
software version in the Steer Controller.
If the version is displayed,
communications are working. If the
version is not displayed, the Steer
Controller may be defective. F~gure6 - 3 Steer Controller Card - Code 53
3. Check the cable connections between the
Steer Controller and the Display Card.
4. Check the CAN Error LED on the Steer
Controller. If the Heartbeat LED is blinking,
a t a rate of approximately 60 times per
minute, the Steer Controller is OK.
5 . If the CAN Error LED is On and the
Heartbeat LED is OK, the problem may be
in the cable connecting the Display Card
and the Steer Controller.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 59

Code 59

/I Code Title
CAN Transmission Buffer Detected By
Display
- . Card.

Reason During power-up or run time, the Display

Controller fails to transmit w i t h 100 ms.
This is reported by the Display.
System Response 1. Alarm sounds: Yes
2. Display: CODE 59
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear If cycling the keyswitch OFF/ON does not

clear this code then follow the procedure
( below.

Possible Causes and Checks:

1. This code could be the result of static
electricity or shorts to frame. Check and
clean all static straps. Check for shorts to
frame.
2. The Display Card may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 5 F

Code 5F
No CAN Communications Received By
Code Title Display Controller From Tractor Interface
Card.
Reason Display has not received data from the
Tractor Interface Card for more than 100

System Response
1 A'arm sounds: Yes
2. Display: CODE 5F
3. ~ ~ e e d - ~ i m
0.0
i t mph
: (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear If cycling the keyswitch OFF/ON does not

clear this code then follow the procedure
1 below.

Possible Causes and Checks:

1. This code could be the result of static
electricity or shorts to frame. Check and
clean all static straps. Check for shorts to
frame.
2. The transmit portion of the Traction I/F
Card is defective.
Go to Category 6, Class 1. Check the
software version in the Traction I/F
Card. If the version is displayed,
communications are working. If the
version is not displayed, the Steer
Controller may be defective.
3 . Check the cable connections between the
Steer Controller and the Display Card.
4. The Steer Controller may be defective.
5. The Display Card may be defective.
6. The Traction I/F Card may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 66

Code 66

Code Title Code 66 - 60" Mast Switch Not Crossed

Reason 60" Mast Switch indicates still closed (not crossed) after
approximately 6 seconds of lifting.

System Response

Alarm Sounds Yes

Operator Display Code 66

-

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 mph

Lift/Lower System Operational

How to Clear Cross switch or cycle key switch OFF/ON

Tests to Run See Below

Run Test:
Category 1, Class 1, ESY22
NOTE: For information on how to use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 67

Code 67

Code Title Code 67 - 120" Mast Switch Not Crossed

Reason 120" Mast Switch indicates still closed (not crossed)
after approximately 6 seconds of lifting.

System Response

Alarm Sounds Yes

Operator Display Code 67

Traction Power LED = Heartbeat

Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 m p h

Lift/Lower System Operational

How to Clear Cross switch or cycle key switch OFF/ON

Tests t o Run See Below

Run Test:
Category 1, Class 1, ESY30
NOTE: For information on how to u s e analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 68

Code 68

1 Code Title I Code 68 - 150" Mast Switch 1 I/

150 Mast Switch indicates still closed (not crossed)
after approximately 6 seconds of lifting.

1 System Response
1 Alarm Sounds 1 Yes
/I Operator Display 1 Code 68
I/
LED = Heartbeat

Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 mph

I( Lift/Lower System I Operational /I

1 How to Clear I Cross switch or cycle key switch OFF/ON 1
/ Tests t o Run I See Below I/
Run Test:
Category 1, Class 1, ESY31
The Carriage Interface card may be faulty.
NOTE: For information on how t o use analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL22 1 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 69

Code 69

Code Title -
Code 69 1 8 0 Mast Switch Not Crossed
Reason 180" Mast Switch indicates still closed (not crossed)
after approximately 6 seconds of lifting.

System Response

Alarm Sounds Yes

Operator Display Code 69
Traction Power LED = Heartbeat
Amplifier
Lift Power Amplifier LED = Heartbeat

Performance Limits

Travel System 2.5 mph

Lift/Lower System Operational

How to Clear Cross switch or cycle key switch OFF/ON
Tests to Run See Below

Run Test:
Category 1, Class 1, Test 33 ESY31
NOTE: For information on how to u s e analyzer
mode, refer to "Modes of Operation" on
page 6-3.

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 7 3

Code 73
Code Title -
Code 73 Traction Power Section (field open)
[software versions DM 2 1.4 and TA 2 1 1 . ~ ~ 1
Reason The traction motor field or connection was detected
open.
System Response
Alarm Sounds Yes
Operator Display Code 73
Traction Power , Energized (In) - LED = Code 1, 3
Amplifier
Lift Power Amplifier Energized (In) - LED = Heartbeat
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run See Below

Run Tests:
Category 1. Class 2: Test 1

Possible Causes:
1. Check field connections.
2. Check motor field winding. (The field
resistance, when the motor is at ambient,
should be approximately 0.9 to 1.1 ohms).
3. Defective traction power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6-11.

00700-CL22 1 Added: 02/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 74

Code 74
Code Title Code 74 - Traction Power Section (armature sensor)
[software versions DM 2 1.4 and TA 2 1 1 . ~ ~ 1
Reason The traction power amplifier has detected an armature
sensor fault.
System Response
Alarm Sounds Yes
Operator Display Code 74
Traction Power Energized (In) - LED = Code 1. 3
Amplifier
Lift Power Amplifier Energized (In) - LED = Heartbeat
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run See Below

Run Tests:
Category 1, Class 2: Test 0

Possible Causes:
1. Cabling at B- and M- at the traction power
amplifier.
2. Defective traction power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6- 11.

00700-CL22 1 Added: 02/15/00

 Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 75

I Code 75
Code Title Code 75 - Traction Power Section (FLDSensor)
[software versions DM 2 1.4 and TA 2 1 1.=I
Reason The traction power amplifier has detected a field current
sensor fault.
System Response
Alarm Sounds Yes
Operator Display Code 75
Traction Power Energized (In) - LED = Code 1, 3
Amplifier
Lift Power Amplifier Energized (In) - LED = Heartbeat
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run See Below

R u n Tests:
Category 1, Class 2: Test 1

Possible Causes:
1. Defective traction power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6-11.

00700-CL221 Added: 02/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 76

Code 76
Code Title Code 76 - Traction - Missing Contactor
[software versions DM 2 1.4 and TA 2 1 1 . ~ ~ 1
Reason The traction power amplifier has detected an open in the
MM sense circuit.
System Response
Alarm Sounds Yes
Operator Display Code 76
Traction Power Energized (In) - LED = Code 3, 4
Amplifier
Lift Power Amplifier Energized (In) - LED = Heartbeat
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run None -

Possible Causes:
1. Check wiring from the traction power
amplifier JT1-17 to Tractor Interface card
JPR10-8.
2. Defective Tractor Interface card.
3. Defective traction power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6- 11.

00700-CL221 Added: 02/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 77

Code 77
Code Title Code 77 - Lift Power Section (armature sensor)
[software versions DM 2 1.4 and LA 2 11.=I
The lift power amplifier has detected an armature sensor
fault.
1 System Response I /I
Alarm Sounds Yes
Operator Display Code 77
Traction Power
Amplifier
Energized (In) - LED = Heartbeat

/ Energized (In) - LED = Code 1. 3

I!
Lift Power Amplifier 1
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run See Below

Run Tests:
Category 1, Class 2: Test 5

Possible Causes:
1. Cabling a t B- and M- at the lift power
amplifier.
2. Defective lift power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6-11.

00700-CL22 1 Added: 02/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 78

Code 78
Code Title -
Code 78 - Lift Missing Contactor
[software versions DM 2 1.4 and LA 2 1 1 . ~ ~ 1
Reason The lift power amplifier has detected an open in the MM
sense circuit.
System Response
Alarm Sounds Yes
Operator Display Code 78
Traction Power Energized (In) - LED = Heartbeat
Amplifier
Lift Power Amplifier Energized (In) - LED = Code 3, 4
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Cycle the key switch OFF/ON.
Tests to Run None

Possible Causes:
1. Check wiring from the lift power amplifier
JL1-17 to Tractor Interface card JPR10-17.
2. Defective Tractor Interface card.
3. Defective lift power amplifier.

NOTE: For information on how to use analyzer

mode, refer to page 6-11.

00700-CL221 Added: 02/15/00

 Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 79

I Code 79
Code Title Code 79 - Software Incompatibility
Reason The lift power amplifier has been replaced with the new
style power amplifier and the traction power amplifier
software version is 10 or lower.
System Response
Alarm Sounds Yes
Operator Display Code 78
Traction Power Energized (In) - LED = Heartbeat
Amplifier
Lift Power Amplifier Energized (In) - LED = Heartbeat
Performance Limits
Travel System Inoperative
Lift/Lower System Inoperative
How to Clear Replace lift power amplifier.
Tests t o Run None

Possible Causes:
The traction power amplifier's software version
is less than or equal to 10 and the lift power
ampwier was replaced with the new style power
ampwier. Replace the lift power amplifier with
one that is the same style a s the lift power
arnpmer needing replacement.

NOTE: For information on how to use analyzer

mode, refer to page 6-11.

00700-CL221 Added: 02/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 79

This page intentionally left blank

00700-CL22 1 Added: 02/15/00

Toyota Orderpicker Service Manual Electrica,lCodes and Tests

Code 91

Code 91
Code Title Drive Unit Turned >lo0While Guiding On Wire
Reason While guiding on the wire, the drive unit has
turned > 10'.
System Response sounds: Yes
2. Display: CODE 91
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

mm
How to Clear Step Off/On deadman pedal.

Possible Causes and Checks:

If drive unit IS actually turned greater than 10':
1. Calibrate steering.
2. Replace the Steer Controller.
If the drive unit I S NOT actually turned greater
than lo0:
1. Run Test 41 - Encoder Test - Drive Unit
Position Encoder Count.
2. Check the mechanical coupling between the
steer feedback encoder and the drive
assembly.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 92

Code 92
Code Title Tracking Limits Exceeded.
Reason The truck has drifted beyond the configured HS
Stop or DFW Stop values or the truck has been
driven off the wire guide.
System Response Alarm sounds: Yes
2. Display: CODE 92
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

Fi
How t o Clear Cycle key switch OFF/ON.

Possible Causes and Checks:

1. Check the connections at guidance
antennas.
2. The wire guidance antennas may be
connected backwards.
3. The output of the line driver may be
incorrect. Refer to the manufacturers
specifications if it requires adjustment.
4. Calibrate:
Steering
Wire guidance frequency (if equipped
with wire guidance)
Wire guidance offsets [if equipped with
wire guidance)
If this code occurs frequently while traveling
straight down the guide wire, recalibrate the
steering and then the wire guidance offsets.

00700-CL221 Revised: 2115/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 92

5. Run the following tests (Category 1,Class 2:

12):
12-23 - Left tractor guidance coil
voltage.
12-24 - Right tractor guidance cpil
voltage.
12-25 - Left load guidance coil voltage.
12-26 - Right load guidance coil voltage.
12-27 - Tractor near wire coil voltage.
12-28- Load nearwirecoilvoltage.
The values for tests 12-23 - 12-26 should all be
close to same.
6. There may be a problem in the warehouse
floor. Drive the truck on the wire in other
aisles to determine if a pattern for the
problem can be established. Run the
following tests (Category 1 ,Class 2: 12): (See
NOTE below)
12-29 - Average distance from wire.
12-30 - Peak distance from wire.
12-31 - Average heading angle
magnitude.
12-32 - Peak heading angle.
12-33 - Average wire signal strength.
NOTE: Tests 12-29 through 12-33 are only
valid if the truck is able to track on the
guide wire a t a speed greater than 4.0
mph.
7. Inspect/clean the static straps under the
truck.
8. Check for shorts to frame.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

00700-CL221 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 93

Code 93
Code Title Tractor Antenna Signal Lost When Locked On The
Guide Wire.
Reason The guide wire is not being sensed by the tractor coil
pair when locked on the guide wire or the truck has
been driven off the guide wire.
System Response Alarm sounds: Yes
2. Display: CODE 93
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer Controller
Card:

FiF!
-
How to Clear Cycle key switch OFF/ON.

Possible Causes and Checks:

NOTE: This code may appear when the truck is
driven off the end of the guidewire.
1. Check the connections a t guidance
. antennas.
2. There may be an intermittent problem in
the warehouse floor. Drive the truck on the
wire in other aisles to determine if a pattern
for the problem can be established.
3. The output of the line driver may be
incorrect. Refer to the manufacturers
specifications if you suspect it is not.
4. Venfy that the truck is configured to the
correct wire guidance frequency.
5. Run the following tests (Category 1 ,Class 2:
12):
12-23 - Left tractor guidance coil
voltage.
12-24 - Right tractor guidance coil
voltage.
12-25 - Left load guidance coil voltage.
12-26 - Right load guidance coil voltage.
12-27 - Tractor near wire coil voltage.
12-28 - h a d near wire coil voltage.

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 94

Code 94

Code Title Load Antenna Signal Lost When Locked On The

Guide Wire
Reason The guide wire is not being sensed by the load coil
pair when locked on the guide wire.
System Response sounds: Yes
2. Display: CODE 94
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

mfl
How to Clear Cycle key switch OFF/ON.

Refer to the "Possible Causes and Checks" for

Code 93.

00700-CL22 1 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual
Code 96

Code 96

Code Title Wire Lost

Reason The guide wire is not being sensed by either set of
coil pairs.
System Response Yes
2. Display: CODE 96
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

flm
How t o Clear Cycle key switch OFF/ON.

Refer to the "Possible Causes and Checks" for

Code 93.

00700-CL221 Revised: 211 5/00.

Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 9C

Code 9C

Load Left. Load Right. And Load Near Wire

Signal Failed.
Reason The truck is moving while on the wire and the
guidance signals are not fluctuating at all.
System Response 'Iarm sounds: Yes
2. Display: CODE 9C
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1 . The Filter Card may be defective.
2. The Steer Controller may be defective.
3. The Tractor or Load Sensors may be
defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
- -

Code 9E

Code 9E

I Code Title I Track And Hold Signal Failed. I

Reason The truck is moving while on the wire and the
guidance signals are not fluctuating at all.
System Response 1. Alarm sounds: Yes
2. Display: CODE 9E
3. ~ ~ e e d ~ i m i tmph
0.0 : (dump brake)
4. How code appears sequentially on Steer
Controller Card:

l How to clear
I
I Turn keyswitch OFF/ON. I
Possible Causes and Checks:
1. The Filter Card may be defective.
2. The Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 9F

Code 9F
Code Title Wire Guidance Board Not Installed.
Reason Filter Card not connected to the Steer Controller or
the truck was configured for wire guidance when
the option is not installed.
System Response 1. Alarm sounds: Yes
2. Display: CODE 9F
3. Speed Limit: 0.0 mph (dump brake)
4. HA code appears sequentially on Steer Controller
Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. The code can occur if the Filter Card has
become disconnected to the Steer
Controller. Check that the Filter Card is
properly attached to the Steer Controller.
2. Check for continuity between A10 and A1 1
on the Filter Card:
If there is continuity, then replace the
Steer Controller
If there is no continuity, replace the
Filter Card.
NOTE: Remember to run Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 9 H

Code 9H
Tractor Left,Tractor Right, And Tractor Near
Code Title
Wire Signal Failed.
Reason The signal from the tractor antenna is not being
received bv the Filter Card.
System Response sounds: Yes
2. Display: CODE 9H
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How t o Clear Turn keyswitch OFF/ON.

Refer to the "Possible Causes and Checks" for

Code 93.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code 9J

Code 9J
Code Title Load Antenna S$gnalToo High.
Reason Near wire voltage is greater than 4.75 volts.

System Response 1. Alarm sounds: Yes

2. Display: CODE 9J
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer Controller
Card:

pi
How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. The output of the line driver may be
incorrect. Refer to the manufacturers
specifications if you suspect it is not. (If the
output of the wire is less than
approximately 0.5 volt while over the wire,
the truck will not sense the guide wire.)
2. Calibrate wire guidance frequency.
3. Calibrate the wire guidance offsets.
4. Run the following tests (Category 1,
Class 2: 12):
12-23 - Left tractor guidance coil
voltage.
12-24 - Right tractor guidance coil
voltage.
12-25 - Left load guidance coil voltage.
12-26 - Right load guidance coil voltage.
12-27 - Tractor near wire coil voltage.
12-28 - Load near wire coil voltage.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code 9K

Code 9 K
Code Title Tractor Antenna Signal Too High
Reason Near wire voltage is greater than 4.75 volts.

System Response 1. Alarm sounds: Yes

2. Display: CODE 9 K
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

mfl
How to Clear '
Turn keyswitch OFF/ON.

Refer to the "Possible Causes and Checks" for

Code 9J.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code 9L

Code 9 L
Code Title Guide Wire Signal Too High At Both Coil Pairs.
Reason The line driver may be out of adjustment.

System Response 1. Alarm sounds: Yes

2. Display: CODE 9L
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

FiKi
How t o Clear Turn keyswitch OFF/ON.

Refer to the "Possible Causes and Checks" for

Code 9J.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code C O

Code CO
Code Title Manual Steering Input Error.
Reason One channel from the steering position encoder is
intermittent.
System Response A'arm sounds: Yes
2. Display: CODE CO
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear
nm
Turn keyswitch OFF/ON.

NOTE: This code only appears on vehicles with

electric steering.

Possible Causes and Checks:

Run test: Test 41 - Encoder Test
Display Channel A of Steer Encoder.
Display Channel B of Steer Encoder.
NOTE: Remember to run Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code C1

Code C1
12V Power Supply Failure.
Reason +12 volts is not being sensed a t the Steer
Controller.
System Response 1. Alarm sounds: Yes
2. Display: CODE C1
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Check the battery condition.
2. Verify that the 12 volt LED on the Steer
Controller is On.
3. The truck battery voltage may be lower
than required.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code C2

Code C2
Code Title No Steer Position Home Reference Sensed.
Reason No input from the home sensor proximity switch
to the Steer Controller.

l1 System Response 1. Alarm sounds: Yes

2. Display: CODE C2
1 3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:
-

How to Clear Turn keyswitch OFF/ON.

N O T E: This code will only appear if there is no

input received from the home reference
proximity switch after SelfTest centering
has been completed.
If the home sensor proximity switch is
defective, a code C3 will appear when
auto-centering the drive unit after
SelfTest.Possible Causes and Checks:
1. Run test ESY42 - Display the Home Sensor
Proximity Switch Position.
2. Run test ESY43 - Home Proximity Sensor
Connection.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code C3

Code C3
Code Title No Steer Encoder Signal.
Reason a. No pulses are being sent from the steer position
encoder to the Steer Controller. See step 1 below.
b. No home sensor proximity sensor input was
received while trylng to center. See step 2 below.
c. There is an open circuit in the steer motor
system. See step 3 below.
System Response A'arm sounds: Yes
2. Display: CODE C3
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear
nm
Turn keyswitch OFF/ON.

Possible Causes and Checks

1. If this code occurs after the deadman pedal
is depressed:
a. Turn the truck off.
b. Jack the drive tire off the floor.
c. Turn the drive unit manually so that the
drive tire is not pointed straight ahead.
d. Turn the truck On and step on the
deadman pedal. If the drive unit does
not turn, replace the Steer Controller.
e. If the drive unit is auto-centered, turn
the truck Off and repeat step l b thru Id
with the drive unit turned in the other
direction.
2. If this code occurs while the drive unit is
trylng to center itself after powerup, the
home sensor proximity switch may be
defective - run Test ESY42.
3. If this code occurred while manually
steering, run Test 41 - Encoder Test. (If the
truck will not travel, this test will have to be
run under static maintenance).

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code C3

4. Check for an open the steer motor circuit.

5. Visually make sure that the pinion gear on
the steering gear reducer output shaft
turns a s the steer motor armature rotates.
If not, inspect the pinion gear on the end of
the steering gear reducer. If the pinion can
be pulled off by hand, replace the entire
steer motor/gear reducer assembly.
6. The steer motor or gear reducer may be
defective.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code C5

Code C5
Code Title 1 Steer Action Without Command.
Reason Steer position encoder pulses detected without
steer commanded to turn.
System Response 1. Alarm sounds: Yes
2. Display: CODE C5
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Run Test 41 - Encoder Test - Display the

Drive Unit Position Encoder Count.

2. Turn the truck On. After SelfTest, step on
the deadman; the drive unit should center.
If not:
Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code C6

Code C6
I Code Title Encoder/Steer Motor Mismatch.
Reason Drive unit turns opposite of commanded direction,

System Response 1. Alarm sounds: Yes

2. Display: CODE C6
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

Motor leads or Steer Position Encoder wiring
connected in reverse. Check connections by
tracing the circuit using an ohmmeter and
schematic.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code C9

Code C9
Code Title No Drive Power.
Reason No B+ to the Steer Controller.

System Response 1. Alarm sounds: Yes

2. Display: CODE C9
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer

ri
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Run Test 12-2 1 - Steer Controller Battery
Sense Voltage.
2. Fuse F1 may be defective.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code CA

Code CA
1 Code Title Steer Driver Failwe.
The steer controller has sensed an error in the
drive motor circuit.

I1 System Response 1. A l a r m sounds: Yes

2. Display: CODE CA
-
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How t o Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Run Tests:
12-20 - Steer Controller Power Supply
Voltage.
12-2 1 - Steer Controller Battery Sense
Voltage.
2. Check motor connections.
3. The truck battery voltage may be lower
than required.

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Electrical Codes a n d Tests Toyota Orderpicker Service Manual

Code CE

Code CE
1 Code Title I Home Proximity Sensor Not Connected. 1
Reason The Steer Controller senses that the Home
Proximity Switch is disconnected.
System Response 1. Alarm sounds: Yes
2. Display: CODE CE
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Check that the Home Roximity Switch is
connected to the Steer Controller a t JP2.
2. Run Test ESY43 - Home B o x Sensor
Connection.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code CF

Code CF
/I Code Title 1 Steer Input Command Failure. I/
Reason The drive unit did not receive feedback from the
Steer Position Encoder when a steering command
1 I was requested. I/
System Response 1. Alarm sounds: Yes
2. Display: CODE CF
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How t o Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Check the power connections to the steer
motor.
2. Check for an opening in the steer motor
circuit.
3. Inspect the pinion gear on the steer on the
steer motor. If the pinion can be pulled off
by hand, replace the entire steer motor
assembly. Visually make sure that the steer
gear on the drive unit turns a s the steer
motor output shaft rotates.
4. The steer motor or gear reducer may be
defective.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code CJ

Code CJ
Code Title Steer Input Encoder Disconnected.
Reason The Steer Input Encoder is connected to the
Display Card a t HD5. A signal sent from the
Display Card is s e n t to the Steer Input Encoder a t
HD5-5 a n d returns to the Display Card a t HD5-6.
If this signal is interrupted, this code will be
displayed.
System Response 1. Alarm sounds: Yes
2. Display: CODE CJ
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

01
Turn keyswitch OFF/ON.
How to Clear

Possible Causes and Checks:

1. Verify that the Steer Input Encoder is
properly connected to the display.
2. Run Test 41 - Encoder Test.
3. Check wires for intermittent connections.
4. Replace the Steer Input Encoder.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code CU

Code CU
I Steer Feedback Encoder Disconnected.
Reason The Steer Controller senses that the motor position
feedback encoder is disconnected.
1 System Response 1. Alarm sounds: Yes
2. Display: CODE CU
1 1 3. ~ ~ e e d i i m i0.0
t : mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Verify that the Steer Encoder is properly
connected to the Steer Controller.
2. Run test ESY40 - Steer Feedback Signal.
3. Check the wiring between the Steer Position
Encoder and the Steer Controller.
4. Replace the Steer Encoder.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code CY

Code CY
/ Code Title 1 Rail Guide Switch Disconnected.
Reason The truck is configured with rail guidance but
does not sense the rail guidance switch installed.
S y s t e m Response 1. Alarm sounds: Yes
2. Display: CODE CY
3. Speed Limit: 1.0 mph
4. How code appears sequentially on Steer
Controller Card:

/ How to Clear 1 Turn keyswitch OFF/ON. 1

Possible Causes and Checks:
NOTE: Perform steps1 thru 3 if the truck is
equipped with rail guidance switch.
1. Run Test ESY46.
2. Install the rail guidance switch.
3. Repair/replace the rail guidance switch
and/or wiring.
NOTE: Perform step 4 if truck is not equipped
with rail guidance switch.
4. Configure truck from rail guidance to wire
guidance or none.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code EC

Code EC

1 Code Title
Display Controller Card Operating System

/I
Error.
Reason Display Controller ~ & PPROM/Software
d failed/
I
PROM or RAM has defective locations.
System Response 1. Alarm sounds: Yes
2. Display: CODE EC
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

NOTE: None of the Program modes (Analyzer,

Calibrte, or Tuning) can be entered until
this code is cleared.

Possible Causes and Checks:

1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to kame. Check and
clean a l l static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Display Card PROM. If that
does not correct the problem, replace the
Display Card. See "Electrostatic Discharge
Damage" for proper procedures when
replacing the Display Card.
NOTE: Remember to run Calibrte if any PROM
or board is replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual
--

Code F1

Code F1
Code Title Display Controller Card COP Time-out.
Reason An intermittent connection on either the Display
Controller Card o r a device connected to the
Display Controller Card could cause this code.
System Response 1. Alarm sounds: Yes
2. Display: CODE F1
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch at least twice.
This problem could be a result of static
electricity or shorts to frame. Clean a n d
check all static straps for proper operation.
Inspect for shorts to frame.
2. Check for loose connections a t the Display
Controller Card.
3. If cycling the key switch does not clear this
code then replace the Display Controller
Card.
NOTE: Refer to "Electrostatic Discharge
Damage" for proper procedures when
replacing the Display Controller Card.
NOTE: Remember to r u n Calibrte if any board
is replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code F2

Code F2
Code Title Display Controller Card Invalid OPCODE.
Reason An intermittent connection on either the Display
Controller Card or a device connected to the
I/ I Display
- - Controller Card could cause this code.

/ S y s t e m Response 'Iarm sounds: Yes

2. Display: CODE F2
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

Flyl -
How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch at least twice.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper operation.
Inspect for shorts to frame.
2. Check for loose connections at the Display
Controller Card.
3. If cycling the key switch does not clear this
code then replace the Display Controller
Card.
NOTE: Refer to "Electrostatic Discharge
Damage" for proper procedures when
replacing the Display Controller Card.
NOTE: Remember to run Calibrte if any board
is replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code F3

Code F3
Code Title Display Controller Card CAN Or WSI Reset.
Reason Internal fault.

System Response 1. Alarm sounds: Yes

2. Display: CODE F 3
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How t o Clear T u r n keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch a t least twice.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper operation.
Inspect for shorts to frame.
2. Check for loose connections a t the Display
Controller Card.
3. If cycling the key switch does not clear this
code then replace the Display Controller
Card.
NOTE: Refer to "Electrostatic Discharge
Damage" for proper procedures when
replacing the Display Controller Card.
NOTE: Remember to r u n Calibrte if any board
is replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests
Code F7

Code F7
Code Title 1 Display Controller Card COP Not Enabled. 1
Reason I Internal fault.
I

I
S y s t e m Response 1. Alarm sounds: Yes
2. Display: CODE F7
3. spLed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Display Controller Card.
NOTE: See "Electrostatic Discharge Damage"
for proper procedures when replacing
the Display Controller Card.
Remember to r u n Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code F9

Code F9
Code Title Steer Controller -' COP Time-out.
Reason Steer Controller internal failure.

System Response 1. Alarm sounds: Yes

2. Display: CODE F9
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

/ How to Clear 1 Turn keyswitch OFF/ON.

Possible Causes and Checks:
1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Steer Controller.
NOTE: Remember to run Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code FA

Code FA
Code Title Steer Controller Invalid OPCODE.
Reason ESM internal failure.
I

System Response 1. Alarm sounds: Yes

2. Display: CODE FA
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Steer Controller.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code FB

Code FB
Code Title -
Steer Controller WSI. CAN Reset. /I
Reason ESM internal failure.
1. Alarm sounds: Yes
1
System Response
2. Display: CODE FB
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How t o Clear Turn keyswitch OFF/ON.

Possible Causes and Checks:

1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Steer Controller.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code FC

Code FC
1 Code Title I Steer Controller COP Not Enabled. I/
1 Reason I ESM internal failure.
System Response 1. A l a r m sounds: Yes
2. Display: CODE FC
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:
I

I How t o Clear I
Turn keyswitch OFF/ON.
I
Possible Causes and Checks:
1. Cycle the key switch Off/On several times
to see if the code clears.
This problem could be a result of static
electricity or shorts to frame. Clean and
check all static straps for proper
operation. Inspect for shorts to frame.
2. Replace the Steer Controller.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

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Electrical Codes a n d Tests Toyota Orderpicker Service M a n u a l

C o d e CL

Code CL
Code Title Speed PROX 2 disconnected.
Reason The proximity sensor is disconnected from the
Steer Controller or power/ground is missing.
1
System Response 1. A l a r m sounds: Yes
2. Electric Steering Display: CODE CL Inform
Service
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Corrective Actions and Checks:

1. Make sure that the proximity sensor is
connected to the Steer Controller a t JP2.
2. Check for +12 volts a t JP2-22 with respect
to TP4.
3. Check for broken/intermittent wires.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Code CP

Code CP
Code Title Speed PROX 1 disconnected.
Reason The proximity sensor is disconnected from the
Steer Controller or power/ground is missing.
System Response 1. Alarm sounds: Yes
2. Electric Steering Display: CODE CP Inform
Service
3. Speed Limit: 0.0 mph (dump brake)
4. How code appears sequentially on Steer
Controller Card:

How to Clear Turn keyswitch OFF/ON.

Corrective Actions and Checks:

1. Make sure that the proximity sensor is
connected to the Steer Controller a t JP2.
2. Check for +12 volts a t JP2- 18 with respect
to TP4.
3. Check for broken/intermittent wires.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

Code CP

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Toyota Orderpicker Service Manual Electrical Codes and Tests

Steer Controller Guidance System

Steer Controller Guidance System

Click here for information on

Analog Input Tests: (Category 1, Guidance tone issues
Class 2: 12)

12-20: Steer Controller Power

Supply Voltage
This test displays the steer controller power
supply voltage (+ 12 volts) as sensed by the Steer
Controller.

Related Codes and Tests:

Code C1 - +12V Power Supply Failure.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Expected Results
1. The Display Card will display the Steer
Controller 12 volt power supply voltage.
2. The test is a success if the current
displayed is within these limits:

Test Setup Value Displayed

None Required 11.0-13.0

If the reading is outside these limits, then the

test is a failure.

Possible causes of test failure:

1. The Steer Controller may be defective.
2. The truck battery voltage may be lower
than required.

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Electrical Codes and Tests Toyota Orderpicker Service Manual
-- --

12 - 21: Steer Controller Battery Sense Voltage

12 - 21: Steer Controller Battery
Sense Voltage
This test displays the battery voltage sense line
a s sensed by the Steer Controller a t JPS2-4
with respect to TP4.

Related Code and Test

Code C9 - No Drive Power.
N O TE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Expected Results
The Display Card will display the battery
voltage which the Steer Controller senses from
JPS2-4.
NOTE: Refer to Test 0 3 - Toggle the MM
Contactor
The test is a success if the current displayed is
within these limits:

Test Setup Value Displayed

MM Closed 4.74-5.25
MM Open 0.0-0.25

A successful test proves the Steer Controller is

properly reading the battery voltage sense line.
If the reading is outside these limits, then the
test is a failure.

Possible causes of test failure:

1. F l may be defective.
2. The connection between B+ and JPS2-4
may be open.
3. The connection between B- (TP4) and JPS2-
3 may be open.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 22: Maximum Drive Unit Rotation

12 - 22: Maximum Drive Unit

Rotation
This test displays the maximum rate of drive
unit rotation a s measured by the Steer
Controller. This input is from the steer position
encoder. This measurement is for reference only
and is not used in any error detection. The
technician might use this test if the steering is
not responding fast enough during wire
guidance.

Related Codes and Test

Code 91 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Tracking Limits Exceeded.
NOTE: For information on using Analyzer Mode,
refer to Modes of Operation in this
section.

Expected Results
1. The Display Card will display the maximum
turning rate of the drive unit which the
Steer Controller h a s stored from Calibrte
Mode.
2. The test is a success if the displayed
calibrte value is within these limits:

Test Setup 1 Value Displayed

pone Required 150 to 180

The value displayed is what the system stored

during the Calibrte Steer sequence. The value is
equal to approximately 1 second (100) to 2.5
seconds (250) per 180' of rotation. A successful
test proves that the Steer Controller has
properly "learned" the maximum turning rate.
If the reading is outside these limits, then the
test is a failure. If the value is outside the range
in the table above, r u n Calibrte Steer again.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 22: Maximum Drive Unit Rotation

Possible Causes and Checks:

1. Steering is not calibrated; run Calibrte for
steering.
2. Check for mechanical binding in the
steering system.
3. The power cables to the steer motor may be
defective.
4. Steer motor may be defective.
5. Steering Encoder may be defective.
6. Steer Controller may be defective.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 23: Display The Left Tractor Guidance Coil

12 - 23: Display The Left Tractor

Guidance Coil Voltage
This test displays the voltage of the left tractor
guidance coil as sensed by the Steer Controller.
Refer to Figure 6-4 to determine which coil this
test checks.

Related Codes and Tests

Code 9 1 - Drive Unit Turned > 10' While
Guiding On Wire.
Troctor Neor Wire
Code 92 - Tracking Limits Exceeded. Troctor Left
p s t 23)
Code 9H - No Signal - Tractor Antenna.
Code 9K - Tractor Antenna Signal Too High.
Code 9L - Guide Wire Signal Too High a t Both
Coil pairs. Lood Neor Wire

Procedure
Ensure that the truck is set to the proper
frequency. If the frequency used is not
standard, it must first b e calibrated.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
Load Left
(rest 25) - -- - -
Load R~ght
rest
26)

page 6-3.
Figure 6-4: Location of Wire Guidance Coils and Related
Expected Results Tests

1. The Display Card will display the voltage

which the Steer Controller senses from the
left tractor guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Test Setup Value Displayed

Tmck centered on wire 0.83-2.17
Truck not near wire <O. 5

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 23: Display The Left Tractor Guidance Coil Voltage

If the values are not a s shown above:

Run 12 - 24 through 12 - 26.
If either 12 - 23 and/or 12 - 24 fail and
then 12 - 25 and 12 - 26 pass, swap the
cables from the antennas at JPW 1 and
JPW2 and rerun the tests.
If the values displayed remain the
same then replace the Filter Card. If
that does not correct the problem,
replace the Steer Controller.
If the values change, check the wiring
to the antenna that is giving the
defective indication.
If the cables check OK, first, try cleaning
the sensor assembly of all dirt. If that
doesn't help then replace the antenna
which is giving the defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 24: Display The Right Tractor Guidance Coil

-
12 24: Display The Right Tractor
Guidance Coil Voltage
This test displays the voltage of the right tractor
guidance coil a s sensed by the Steer Controller.
Refer to Figure 6-5 for location of coil.

Related Codes and Tests

Code 9 1 - Drive Unit Turned > 10' While
Guiding On Wire.
Tractor Neor Wire
Code 92 - Tracking Limits Exceeded. Tractor Left
rest 27)
Tractor Rioht
pest 23) -
Code 9 3 - Not Near Wire - Tractor Coil Pair.
Code 9H - No Signal - Tractor Antenna Signal
Too High.
Code 9K - Tractor Antenna Signal Too High. Load Near Wire
28,1
Code 9L - Guide Wire Signal Too High a t Both
Coil pairs.

Procedure
Ensure that the truck is set to the Drover
Load Left
(Test 25) --- - -
:-rest 26)
4/ Load R~ght
* A

frequency. If the frequency used is not

standard, it must first b e calibrated.
I I I I
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on Figure 6-5: Location of W ~ r eGu~danceCoils and Related
page 6-3. Tests

Expected Results
1. The Display Card will display the voltage
the Steer Controller senses from the left
tractor guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Test Setup Value Displayed

Truck centered on wire 0.83-2.17
Truck not near wire <0.5

00700-CL221 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 24: Display The Right Tractor Guidance Coil Voltage

If the values are not as shown above:

Run 12 - 23, 12 - 25, and 12 - 26.
If either 12 - 23 and/or 12 - 24 fail and
then 12 - 25 and 12 - 26 pass, swap the
cables from the antennas a t JPWl and
JPW2 and rerun the tests.
If the values displayed remain the
same, replace the Filter Card. If that
does not correct the problem, replace
the Steer Controller.
If the values change, check the wiring
to the antenna giving the defective
indication.
If the cables check OK, try cleaning the
sensor assembly of all dirt. If that doesn't
help, replace the antenna giving the
defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 25: Display The Left Load Guidance Coil

-
12 25: Display The Left Load
Guidance Coil Voltage
This test displays the voltage of the left load
guidance coil a s sensed by the Steer Controller.
Refer to Figure 6-6 for location of coil.

Related Codes and Test

Code 9 1 - Drive Unit Turned > 10' While
Guiding On Wire.
Tractor Near Wire
Code 92 - Tracking Limits Exceeded. Tractor Leh Tractor R~ght
rest 23) st 24)
Code 94 - Load Antenna Signal Lost.
Code 9J - Load Antenna Signal Too High.
Code 9L - Guide Wire Signal Too High a t Both
Coil pairs. Load Near Wire
/ v a t 28)

-
Procedure
Ensure that the truck is set to the proper
frequency. If the frequency used is not
standard, it must first be calibrated. Load Left
psf 25)
44- - - -
Load R~ght
vest26)
-= c
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.
Figure 6-6: Location of Wire Guidance Coils and Related
Expected Results Tests

1. The Display Card will display the voltage

the Steer Controller senses from the left
tractor guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Test Setup Value Displayed

Truck centered on wire 0.83-2.17 -
Truck not near wire <0.5

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 25: Display The Left Load Guidance Coil Voltage

If the values are not as shown above:

Run 12 - 23, 12 - 24, and 12 - 26.
If either 12 - 25 and/or 12 - 26 fail and
then 12 - 23 and 12 - 24 pass, swap the
cables from the antennas a t JPWl and
JPW2 and rerun the tests.
If the values displayed remain the
same, replace the Filter Card. If that
does not correct the problem, replace
the Steer Controller.
If the values change, check the wiring
to the antenna giving the defective
indication.
If the cables check OK, first, try cleaning
the sensor assembly of all dirt. If that
doesn't help then replace the antenna
giving the defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
12 - 26: Right Load Guidance Coil Voltage

-
12 26: Right Load Guidance Coil
Voltage
This test displays the voltage of the right load
guidance coil a s sensed by the Steer Controller.
Refer to Figure 6 - 7 for location of coils.

Related Codes and Test

Code 91 - Drive Unit Turned > lo0While
Guiding On Wire.
Tractor Near Wire
Code 92 - Tracking Limits Exceeded. Troctor Left
p s t 27)
Troctor Riahl

Code 94 - Load Antenna Signal Lost.

rest 23)
$& 4241 '

Code 9J - Load Antenna Signal Too High.

Code 9L - Guide Wire Signal Too High a t Both
Coil Pairs.

Procedure
Ensure that the truck is set to the proper
frequency. If the frequency used is not
Load Left Load Rlght
standard, it must first be calibrated. rest 25) -----)--
- -. kst
261
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.
Figure 6-7: Location of Wire Guidance Coils and Related
Expected Results Tests
1. The Display Card will display the voltage
the Steer Controller senses from the left
tractor guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Test Setup Value Displayed

Truck centered on wire 0.83-2.17 '

Truck not near wire ~0.5

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 26: Right Load Guidance Coil Voltage

If the values are not as shown above:
Run 12 - 23, 12 - 24, and 12 - 26.
If either 12 - 25 and/or 12 - 26 fail and
then 12 - 23 and 12 - 24 pass, swap the
cables from the antennas at JPWl and
JPW2 and rerun the tests.
If the values displayed remain the same,
replace the Filter Card. If that does not
correct the problem, replace the Steer
Controller.
If the values change, check the wiring to
the antenna giving the defective
indication.
If the cables check OK, first, try cleaning
the sensor assembly of all dirt. If that
doesn't help then replace the antenna
giving the defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
N O T E: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests
-

12 - 27: Tractor Near Wire Coil Voltage

12 - 27: Tractor Near Wire Coil

Voltage
This test displays the voltage of the tractor near
wire guidance coil voltage a s sensed by the
Steer Controller. Refer to Figure 6-8 for location
of coil.

Related Codes and Test

Code 9 3 - Not Near wire - Tractor Coil Pair.
Code 94 - Not Near Wire - Load Coil Pair. Tractor Near Wire

Code 96 - Load Antenna Signal Lost. Tractor Left Tractor Right

(Test 23) est 24)

Code 9H - No Signal - Tractor Antenna.

Code 9K - Tractor Antenna Signal Too High.
I I
Procedure
Ensure that the truck is set to the proper
frequency. If the frequency used is not
standard, it must first be learned.
NOTE: For information on using Analyzer Mode, L WLeft
~ Load Right
(Test 25) (Test 26)
refer to "Modes of Operation" on
page 6-3.

Expected Results
Figure 6-8: Location of Wire Guidance Coils and Related
1. The Display Card will display the voltage
Tests
the Steer Controller senses from the tractor
near wire guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Test Setup Value Displayed

Truck centered on wire 1.44-3.01
Truck not near wire ~0.5

00700-CL22 1 Revised: 2/15/00

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 27: Tractor Near Wire Coil Voltage

If the values are not as shown above:
Run 12 - 28.
If 12 - 28 passes, swap the cables from the
antennas a t JPWl and JPW2 and rerun the
test.
If the values displayed remain the same,
replace the Filter Card. If that does not
correct the problem, replace the Steer
Controller.
If the values change, check the wiring to
the antenna giving the defective
indication.
If the cables check OK, try cleaning the
sensor assembly of all dirt. If that doesn't
help then replace the antenna giving the
defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Revised: 2/15/QO

Toyota Orderpicker Service Manual Electrical Codes and Tests
- - - - --

12 - 28: Load Near Wire Coil Voltage

-
12 28: Load Near Wire Coil
Voltage
This test displays the voltage of the load near
wire guidance coil voltage as sensed by the
Steer Controller. Refer to Figure 6-9 for location
of coil.

Related Codes and Test

Code 9 3 - Not Near wire - Tractor Coil Pair.
Code 94 - Not Near Wire - Load Coil Pair. Tractor Near Wire
(Test 27)
Code 96 - Load Antenna Signal Lost. Tractor Left
(Test 23)
.,
Tractor Riaht

Code 9H - No Signal - Tractor Antenna.

Code 9K - Tractor Antenna Signal Too High.

Procedure \, F:f2yeor Wire

Ensure that the truck is set to the proper

- -
frequency. If the frequency used is not
standard, it must first be calibrated.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
Load Left
(Test 25)
t /
- - - -
Load Right
(Test 26)

page 6-3.

Expected Results
Figure 6-9: Location of Wire Guidance Coils and Related
1 . The Display Card will display the voltage
Tests
the Steer Controller senses from the tractor
near wire guidance coil.
2. The test is a success if the voltage displayed
is within these limits:

Irest Setup I Value Displaved I1

1

ruck centered on
1.44-3.01
ruck not near wire 1 ~0.5

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
-

12 - 28: Load Near Wire Coil Voltage

If the values are not as shown above:

Run 12 - 28.
If 12 - 28 passes, swap the cables from the
antennas at JPWl and JPW2 and rerun the
test.
If the values displayed remain the same
then replace the Filter Card. If that does
not correct the problem, replace the
Steer Controller.
If the values change, check the wiring to
the antenna giving the defective
indication.
If the cables check OK, try cleaning the
sensor assembly of all dirt. If that doesn't
help, replace the antenna giving the
defective indication.

Possible causes of test failure:

If all tests fail:
1. Check line driver for proper operation.
2. The Filter Card may be defective.
3. The Steer Controller may be defective.
NOTE: Remember to r u n Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 29: Average Distance from Wire

-
12 29: Average Distance from
Wire
This test displays the average distance from the
guide wire a s sensed by the Steer Controller.

Related Codes and Tests

Code 91 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Tracking Limits Exceeded.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Go into Tuning Mode and record the Guide
Set DFW Stop value. The value is user
selectable and ranges from 1.5" to 3.2" (31
mm to 76 mm).
2. Lock onto the guide wire. Travel a t a speed
greater than 4.0 mph (6.4 km/hr).

Expected Results
1 . The Display Card will display the average
distance from the guide wire which the
Steer Controller calculates.
2. If the value displayed is 75% or greater
than the configured Guide Set Stop value,
there may be something wrong with the
guidance system.
3. A successful test proves that the Steer
Controller is properly measuring the
average distance from the guide wire.

Possible causes of test failure:

1. Check that the output from the line driver
is OK.
2. The tuned value for Guide Set DFW Stop is
too low; increase the value.
3. Calibrate the wire guidance offsets.
4. Calibrate the steering.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual
- - - --

12 - 30: Peak Distance from Wire

-
12 30: Peak Distance from Wire
This test displays the peak distance from the
guide wire as sensed by the Steer Controller.

Related Codes and Tests

Code 91 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Tracking Limits Exceeded.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Go into Tuning Mode and record the Guide
Set DFW Stop value. The value is user
selectable and ranges from 1.5" to 3.2" (31
rnm to 76 mm).
2. Lock onto the guide wire. Travel at a speed
greater than 4.0 mph (6.4 krn/hr).

Expected Results
1. The Display Card will display the peak
distance from the guide wire which the
Steer Controller calculates.
2. If the value displayed is greater than the
tuned Guide Set DFW Stop value, there
may be something wrong with the guidance
system.
3. A successful test proves that the Steer
Controller is properly measuring the peak
distance from the guide wire.

Possible causes of test failure:

1. Check that the output from the line driver
is OK.
2. The tuned value for Guide Set DFW Stop is
too low: increase the value.
3. Calibrate the wire guidance offsets.
4. Calibrate the steering.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 3 1 : Average Heading Angle Magnitude

-
12 31: Average Heading Angle
Magnitude
This test displays the average heading angle
magnitude from the guide wire as sensed by the
Steer Controller.

Related Codes and Tests

Code 9 1 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Tracking Limits Exceeded.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Go into Tuning Mode and record the Guide
Set HA Stop value. The value is user
selectable and ranges from 2.0' to 4.0'.
2. Lock onto the guidewire. Travel at a speed
greater than 4.0 mph (6.4 km/hr).

Expected Results
1. The Display Card will display the average
heading angle magnitude which the Steer
Controller calculates.
2. If the value displayed is 75% or greater
than the tuned Guide Set HA Stop value,
there may be something wrong with the
guidance system.
3. A successful test proves that the Steer
Controller is properly measuring the
average heading angle magnitude.

Possible causes of test failure:

1. Check that the output from the line driver
is OK.
2. The tuned value for Guide Set HA Stop is
too low; increase the value.
3. Calibrate the wire guidance offsets.
4. Calibrate the steering.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyoia Orderpicker Service Manual
-

12 - 32: Peak Heading Angle

12 - 32: Peak Heading Angle

This test displays the peak heading angle
magnitude from the guide wire a s sensed by the
Steer Controller.

Related Codes and Tests

Code 9 1 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Traclung Limits Exceeded.
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Go into Tuning Mode &d record the Guide
Set HA Stop value. The value is user
selectable and ranges from 2.0' to 4.0'.
2. Lock onto the guidewire. Travel a t a speed
greater than 4.0 mph (6.4 krn/hr).

Expected Results
1. The Display Card will display the peak
heading angle from the guide wire which
the Steer Controller calculates.
2. If the value displayed is greater than the
tuned Guide Set HA Stop value, there may
be something wrong with the guidance
system.
3. A successful test proves that the Steer
Controller is properly measuring the peak
heading angle from the guide wire.

Possible causes of test failure:

1. Check that the output from the line driver
is OK.
2. The tuned value for Guide Set HA Stop is
too low; increase the value.
3. Calibrate the wire guidance offsets.
4. Calibrate the steering.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 33: Average Guide Wire Signal Strength

12 - 33: Average Guide Wire

Signal Strength
This test displays the average wire signal
strength from the guide wire as sensed by the
Steer Controller.

Related Codes and Tests

Code 91 - Drive Unit Turned > 10' While
Guiding On Wire.
Code 92 - Tracking Limits Exceeded.
N O T E: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Acquire and lock onto the guide wire.

Expected Results
1. The Display Card will display the average
wire signal strength the Steer Controller
senses from the guide wire.
2. The test is a success if the current
displayed is within these limits:

Test Setup Value Displayed

Locked onto guide wire 60 to 140

A successful test proves that the Steer

Controller is properly measuring the average
wire signal strength from the guide wire.
If the reading is outside these limits, then the
test is a failure.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 33: Average Guide Wire Signal Strength

Possible causes of test failure and

checks:
1. Check the line driver output.
2. An antenna on the truck may be
disconnected or defective.
3. Check the continuity of the cables between
the antennas and the Filter Card.
4. The Filter Card may be defective.
5. The Steer Controller may be defective.
N O T E: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

12 - 34: Steer lnput Encoder

12 - 34: Steer lnput Encoder

This test displays the average wire signal
strength from the guide wire a s sensed by the
Steer Controller.

Related Codes and Tests

Code CJ - Steer Input Encoder disconnected
NOTE: For information on using Analyzer Mode,
refer to "Modes of Operation" on
page 6-3.

Procedure
1. Check Steer Input Encoder connections.
2. Check cable wiring.
3. Check Steer Encoder Code cable continuity
between pins 5 and 6 of HDS.
4. Change Steer Encoder Card.
5. Check voltage a t pin 1 with reference to B-.
Should be:
Connected - 3.68 to 3.74 volts
Disconnected - 2.45 to 2.60

Expected Results
If the reading is outside these limits, then the
test is a failure.

Possible causes of test failure:

1. Defective Steer Input Encoder.
2. Defective Steer Controller Card.
3. Open Circuit/Connections.
NOTE: Remember to run Calibrte if any boards
are replaced.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

12 - 34: Steer Input Encoder

This page intentionally left blank

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

Steer Controller Guidance System

Steer Controller Guidance System

Digital Input Tests

If the test does not appear in the menu for an
option when you think it should, either that
option is not enabled (through the Configure
Mode), or the truck does not have the latest
software.
NOTE: All tests are r u n in the Analyzer Mode.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

ESY35 AutolManual Switch

ESY35 Auto/Manual Switch

Using this test, the Auto/Manual input is
displayed. A successful test proves that the
Display and Carriage I/F circuits are correctly
reading the Auto/Manual input.

Related Codes and Tests:

None
This test directly shows the position of the
Auto/Manual input.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The following should be observed:

Switch Position Operator's Display

I Auto
0 Manual

If this is not observed, then the test is a failure.

NOTE: If the wire from the Auto/Manual switch
becomes disconnected, the system
defaults to Auto.

Possible causes of test failure, and

checks:
1. Check for a broken wire between the Auto/
Manual switch and the Camage Interface
Card.
2. The Carriage Interface Card may be
defective.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

ESY40 Steer Feedback Connector

ESY40 Steer Feedback Connector

This test determines if the Steer Controller sees
that a Steer Feedback Encoder is installed.

Related Codes and Tests:

Code CC - Steer Feedback Encoder Not
Connected.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The following should be observed:

Operator's Display Status

Yes Pass
No Fail

If this is not observed. then the test is a failure.

Possible cause of test failure:

1. The cable between the encoder and the
Steer Controller may not be properly
plugged into the Steer Controller a t JP1.
Inspect and verify the connection.
2. The cable between the encoder and the
Steer Controller may be defective. Check for
continuity.
3. Check for +5 volts at J P1-21 with respect to
JP1-12 on the Steer Controller. If the
voltage is not close to +5 volts, then replace
with the Steer Controller.
4. Check for this voltage with and without the
connector from the encoder connected to
J P1. If the voltage is good with the
connector disconnected form J P1 and
defective with J P 1 connected, there may be
a short between +5 volts and ground.
5. The Steer Controller may be defective.

00700-CL22 1 Issued: 9/10/98

Electrical Codes and Tests Toyota Orderpicker Service Manual

ESY4 1 Wire Guidance Board Status

ESY41 Wire Guidance Board Status

This test applies only to vehicles with wire
guidance option.
This test determines if the Steer Controller sees
that the Filter Card is installed.

Related Codes and Tests:

Code 9F - Wire Guidance Board Not Installed.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. When the test is run,the results will be a s
follows:

Filter Card Operator's Display

Installed Yes
Not Installed No i

If this is not observed then the test is a failure.

Possible causes of test failure:

1. The Filter Card may not be installed
properly.
2. The Steer Controller may be defective.
3. The Filter Card may be defective.

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Electrical Codes and Tests

ESY42 Home Position Switch

ESY42 Home Position Switch

This test is only for vehicles with electric
steering.
This test displays what the Steer Controller sees
from the home position proximity sensor.

Related Codes and Tests:

Code C2- No Steer Position Input.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. When the test is run, the results will be a s
follows:

If this is not observed, then the test is a failure.

Possible causes of test failure

1. The gap between the home proximity sensor
and metal is very important. If the gap is
too great, the voltage generated will not be
great enough for the Electric Steer Manager
to sense. The gap measured between metal
and the sensor must be between 0.060" -
0.100" (1.52 - 2.54 mm).
2. The home sensor proximity switch may not
be plugged in properly a t JP2 on the Steer
Controller. Inspect and verify connection.
3. Check for +12 volts a t JP2-2 1 and JP-23 on
the Steer Controller. If not there, replace
the Steer Controller. Inspect and verify the
connection.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

ESY42 Home Position Switch

4. Test the output of the home sensor

proximity switch. Connect a DVM to JP2-9
and JP2-23 on the Steer Controller. When
the sensor is over metal there should be
zero volts. When the switch is away from
metal, the reading should be approximately
10-12 volts. If the output is not as
described, replace the sensor and test
again.
5. If the checks are OK, replace the Steer
Controller.

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Toyota Orderpicker Service Manual Electrical Codes and Tests

ESY43 - Home Prox Sensor Connection

-
ESY43 Home Prox Sensor
Connection
This test determines if the Steer Controller sees
the home proximity sensor a t JP2.

Related Codes and Tests:

Code CE - Home Proximity Sensor Not
Connected.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The table below show the two possibilities:

If this is not observed then the test is a failure.

Possible causes of test failure:

1. The home proximity sensor may not be
installed or connected properly to the Steer
Controller.
2. There may be a broken wire between the
Steer Controller and the home proximity
switch.
3. There may be a short between +12 volts and
ground.

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Electrical Codes and Tests Toyota Orderpicker Service Manual
--

ESY44 - Steer Input Encoder Connection

-
ESY44 Steer Input Encoder
Connection
This test verifies that the Operator's Display
sees that the Steer Input Encoder is connected.

Related Codes and Tests:

Code CJ - Steer Input Encoder Disconnected.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The display will show the state of the input:

Display Card

Disconnecte

Possible causes of test failure:

1. There may be a broken wire between the
Steer Encoder and the Operator's Display.
2. Defective Steer Input Encoder.
3 . Defective Operator's Display

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Toyota Orderpicker Service Manual Electrical Codes and Tests

ESY45 - Rail Switch lnput

-
ESY45 Rail Switch lnput
This test will verify that the Steer Controller
sees the rail guidance input signal.

Related Codes and Tests:

None

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The display will show the state of the input

Position of Switch Operator's Display

Closed
Yes
(Rail Sensed)
Open
No
(Rail Not Sensed)

If this is not observed, then the test is a failure.

Possible causes of test failure:

1. There may be a broken or shorted wire
between rail guidance switch and the Steer
Controller.
2. The rail guidance switch may be defective
or not the correct type.
3. The Steer Controller may be defective.

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Electrical Codes and Tests Toyota Orderpicker Service Manual

ESY46 - Rail Switch Connection

ESY46 - Rail Switch Connection

This test will check that the Steer Controller
can see that a rail guidance switch is installed.

Related Codes and Tests:

Code CY - Rail Guide Switch Disconnected.

Procedure:
1. For information on using Analyzer Mode,
see "Modes of Operation" on page 6-3.
2. The display will show the state of the input:

Rail Switch Operator's Display

Connected Yes
Disconnected No

It this is not observed, then the test is a failure.

Possible causes of test failure:

1. There may be a broken of shorted wire
between rail guidance switch and the Steer
Controller.
2. The rail guidance switch may be defective
or not the correct type.
3. The Steer Controller may be defective.

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Toyota Orderpicker Service Manual Component Procedures

Component Procedures
Click here for information on updated switches

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 Service Manual Change History, Electrical Systems

Description Page# Date

1 Added Drive Unit Overhaul Procedure 7-25 4/15/11
2
3
4

Page 1 of 1
Component Procedures Toyota Orderpicker Service Manual

Component Locator Photos

Component Locator Photos

Chains and Pulleys

Figure 7-1 : Component Locations (Sheet 1 of 5)

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Toyota Orderpicker Service Manual Component Procedures

Component Locator Photos

Keyswitch Operator's Display

Emergency Power
Disconnect Button

Steering Wheel

Travel, Lift/
Lower
Control

Wire

- Guidance
On/Off
Switch
Lift Chains

Carriage
Interface
Card

\Wrote
eservoir

Brake
Dump
Deadman MaBter
Solenoid
Cylinder
(SOL1 2)

\
Deadman Pedal
\ Pallet Clarnr,
Release
Figure 7-1: Component Locations (Sheet 2 of 5)

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Component Procedures Toyota Orderpicker Service Manual

Component Locator Photos

Reservoir ESD jack Return Line Filter

/ Brake Assembly

Liit Pump
Motor (DMP

?'~raction
Amplifier

Lift Pump . L ~ i i t
Amplifier

Horn

LiWLower Steer Motor

Manifold (DMS) (DMD)
Figure 7-1 : Component Locations (Sheet 3 of 5)

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Toyota Orderpicker Service Manual Component Procedures

Component Locator Photos

Lift Pump
Output

\ Proportional Valve
SOL1
Check
Valve

Emergency
Lower Valve

Pressure Trans
(PRESS)

High Pressure ~oab Holding Lift/Lower Pressure Test

Relief Valve Solenoid SOL2 Manifold Connection
Figure 7-1: Component Locations (Sheet 4 of 5)

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Component Procedures Toyota Orderpicker Service Manual

Component Locator Photos

Figure 7-1 : Component Locations (Sheet 5 of 5)

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Toyota Orderpicker Service Manual Component Procedures

General Maintenance lnstructions

General Maintenance Instructions

Industrial lift trucks may become hazardous if

adequate maintenance is neglected. Only
trained technicians using approved procedures,
in adequate maintenance facilities, should work
on this or any other lift truck.

Maintenance Practices
1. Follow a scheduled lubrication,
maintenance, and inspection schedule.
2. Only qualified, authorized technicians are
permitted to inspect, maintain, adjust, and
repair this vehicle.

Remove rings, watches, and all jewelry

before doing any work on vehicle.

3. Before working on vehicle:

a. Lower load handling mechanism
completely to the floor.
b. All controls must be in neutral.
c. Release any trapped pressure in
hydraulic system.
d. Block the wheels to prevent movement
of the vehicle.
e. Disconnect battery connector.
f. Elevate drive tire off floor.

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Component Procedures Toyota Orderpicker Service Manual

Maintenance Practices

Use extreme care whenever the truck is

jacked up for any reason. Never block
the truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking. Use jack
stands or solid blocks to support truck -
Do not rely on jacks. Refer to "Jacking
Trucks".

g. Before working on mast or load handler,

support to prevent movement.
4. Work in a clean, dry, well vented area.
5. Avoid fire hazards. Have adequate fire
fighting equipment in the maintenance
area.
6. DO NOT use open flame or sparking devices
around the battery. The gasses given off by
the battery are highly explosive.
7. Use extreme caution when using flammable
cleaning solutions.
8. After working on vehicle, test all controls
and functions to assure proper operation.
More information pertaining to operating and
maintenance procedures may be obtained from:
American Society of Mechanical Engineers
(ASME)
22 Law Drive, Box 2900
Fairfield, New Jersey 07007-2900
Ask for the current version of ASME B56.1

Jacking Truck
Anyhme the truck is jacked up for any reason,
the service technician should take extra time
and caution to ensure that the truck will not tip
over or otherwise pose a hazard to anyone.
The following diagram (Figure 7-2) illustrates
the correct jacking points on the truck frame.
Whenever the truck is jacked up, there should
not be any load on the forks. The forks should
be lowered all the way to the lowest possible
point. Disconnect the battery and remove the

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Toyota Orderpicker Service Manual Component Procedures

Maintenance Practices

key. Always use solid blocks to support the

vehicle. Never rely on jacks or chains to hold
the vehicle.
When the truck is jacked u p a t the tractor-end
of the vehicle, it should not be lifted more than
two (2) inches (5.1 cm) off the floor. When
jacking on the side of the truck, the load wheels
should not be lifted off the floor more than one-
half (1/2") inch (1.3 cm).

Attach a chain to the top of the mast and

an overhead hoist to stabilize the mast if
jacking higher than described in this
procedure.

Jack here to elevate the

drive tire off the floor. Only jack in this area, no more
Jack no more than 2 than 1 /2" (1.3 cm) off the floor.
inches (5.1 cm) off the
floor. See CAUTION.
Figure 7-2: Correct Jacking Locations

A CAUTION
Be certain that the jack is not near the
guidance sensor on wire guided trucks!

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Component Procedures Toyota Orderpicker Service Manual

Welding Procedures

Welding Procedures
Before performing any electric resistance
welding on the truck, perform the following:
1. Turn the key switch off.
2. Remove the battery
3. Disconnect all cables going to the Display
Card.
4. Disconnect all cables going to the Steer
Controller.
5. Disconnect all cables going to the Carriage
Interface Card.
6. Disconnect all cables going to the Tractor
Interface Card.

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Toyota Orderpicker Service Manual Component Procedures

Electrostatic Discharge Damage

Electrostatic Discharge Damage

Electronic circuit boards used in the system are
sensitive and can be damaged by static
discharge.

A CAUTION
Before doing any welding on the vehicle,
follow the procedures outlined under
Welding Procedures.

Static discharges are created when non-

conductive material (plastic bags opened,
synthetic clothing, plastic-soled shoes) are
moved or separated. The built-up static will
discharge through nearby conductors such a s
the human skin. The static discharge could
appear a s a spark.

A CAUTION
It is very important to note that
potentially damaging static levels for
electronic components are not always
felt by a human or appear as a spark.

This condition could happen when a person

with a static charge potential touches a circuit
board. If the circuit board is not being held
properly, sensitive components on the circuit
board will be damaged.
When sensitive components are handled,
protective measures must be taken to prevent
damage which would result in the immediate
failure or degradation of the component.
The photos shown in the following figure
demonstrate the proper and improper methods
for holding a circuit board.

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Component Procedures Toyota Orderpicker Service Manual

Electrostatic Discharge Damage

PROPER IMPROPER
Figure 7-3: Proper/lmproper Method of Holding Circuit
Card

Proper Handling of Static Sensitive

Devices
A moving lift truck or electric motor can build
up a large charge which will discharge slowly
after the truck or motor has stopped moving. It
is important that proper precautions be taken
to assure that electronic components are not
damaged.
To avoid creating a destructive static discharge,
the technician should be grounded or
discharged BEFORE touching a circuit card.
Before removing a circuit card, disconnect the
battery then discharge the truck. Discharge the
truck by touching it with your hand or
attaching a device to the frame of the truck
which is connected to earth ground. The device
should have a resistance of 500,000 to
2,000,000 ohms to eliminate any potential for
shock hazard.
After discharging the truck. the circuit card
may be removed as follows:

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Toyota Orderpicker Service Manual Component Procedures

Electrostatic Discharge Damage

1. Place the static control wrist strap around

your wrist. It should fit snugly.
2. Connect the ground lead to the ESD
receptacle on the truck and the loose end to
the wrist strap.
3. Get into the correct position to remove the
circuit card.
4. DO NOT move your feet.
5. Remove the circuit card while observing the
correct card handling procedure on the
previous page.
6. When replacing a circuit card or an EPROM
or memory chip on a card, place the circuit
card immediately in a n anti-static bag.
7. If replacing an EPROM, take the card to a
clean area and place the card on a surface
which is conductive to antistatic. Use a
wrist strap having a nominal resistance of
1,000,000 ohms (minimum 500,000 ohms)
connected to common ground with the
work surface.

A CAUTION
EPROM pins are delicate and can be
bent or damaged easily if mishandled.
Before removing an EPROM, note the
position of the beveled corner. The new
EPROM must be installed in the same
orientation. Incorrectly installed EPROMS
could be damaged.

A CAUTlON
When working on sensitive electronics,
always wear a static discharge wrist
band and assure that it is properly
grounded to the truck frame before
touching any circuit card. The wrist band
and associated accessories should be
tested monthly to verify that everything
is working properly. A defective static
discharge wrist band will not alert you
that it is bad. The static discharge
components are:

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Component Procedures Toyota Orderpicker Service Manual

Electrostatic Discharge Damage

Wrist band (package of 25).

Field service kit includes static
dissipating work surface, ground
card, and wrist band.
Wrist strap tester.
Contact the Toyota Parts Division for
information. Follow the instructions included
with the field service kit.

Special Tools Required

Special tools required are:
PROM Removal Tool
Pin Extraction Tool

PROM Removal Tool

1. Use IC removal tool shown in Figure 7-4.
2. Look a t the socket for the IC in the board.
Note that two holes in opposite corners of
the socket. These holes are for the prongs of
the removal tool.
3. Spread the jaws of the removal tool apart s o
that its prongs will fit into the two socket
holes mentioned in the previous step. See
CAUTION.

A CAUTION
Failure to use the integrated circuit tool
may damageldestroy socket.

4. Gently squeeze the jaws of the tool together.

The tool will grasp and then withdraw the
IC from its socket.
5. To install a new IC into the socket:
a. Note that one corner of this type of IC is
beveled. Also note that the
corresponding corner of the socket is
also beveled.
b. Align these two beveled corners and
gently press the IC into the socket.

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Toyota Orderpicker Service Manual Component Procedures

Electrostatic Discharge Damage

A CAUTION
If forced, the EPROM can be installed
incorrectly (so the beveled corners do
not match). This will damage the EPROM
and/or socket board.

Figure 7-4: lntegrated Circuit Tool

6. Before installing an IC, lay it down on its

side and very carefully roll it toward the
bottom of the pins, using a light downward
pressure. This will bend the lower pins into
line (see Figure 7-5). Next, turn the IC over
and carefully bend the pins on the other
side in the same way.

Pin Straightening
Techniaue
Pins Bent Outward Pin Straightened

Figure 7-5: Preparing lntegrated Circuit for Insertion

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Component Procedures Toyota Orderpicker Service Manual

Electrostatic Discharge Damage

7. Orient the IC properly: notch on the end of

the IC should be in line with the notch in
the socket. Refer to Figure 7-6.
8. Carefully place the OC on the socket; make
sure all pins are seated over their
corresponding holes and push the IC
securely into place.
9. Check to be sure that all pins are mounted
into the socket holes. IC pins bent under
the device may appear to be correctly
installed.

Holes for rem&al tool prongs

are located in opposite corners
of socket

Figure 7-6: Installation of Integrated Circuit

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Toyota Orderpicker Service Manual Component Procedures

Adjustment and Repair

Adjustment and Repair

Power Section

Drive Transmission Service

Maintenance or replacement of components
used in the drive transmission are limited to the
following:
Steering Gear
Pivot Bearing and related
components
Drive Axle
Axle Oil Seal
Cover
Miscellaneous Hardware
The parts manual will list specific part
numbers for serviceable items. Any major
rework/service which the drive unit may
need will require the drive unit to be sent
back to the factory.

Drive Unit Removal

The tools required will vary slightly depending
on the type of steering system used. In general,
the following hand tools should be available:
14 rnm Apex (allen)
10 mm Apex
10 rnrn Socket
10 mm combination wrench
19 mm socket (bumper removal)
21 mm socket (wheel lug nuts)

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Component Procedures Toyota Orderpicker Service Manual
--

Power Section

1. Refer to Figure 7-7.

2. Disconnect battery.
3. Remove screws (1) holding bumper to.truck
(19 mrn socket), then bumper (2).
4. If the truck is wire guided, remove the
sensor near the front bumper.
5. If the drive tire is to be removed, loosen the
lug nuts, using a 19 mm socket.
6. Remove proximity sensor(s) and associated
hardware on the drive unit casting.
7. Remove drive motor. See Figure 7-8 and
related instructions.
N O T E: If the drive unit is the only item
requiring service, separating the brake
assembly from the drive motor is not
necessary.
8. Jack and block the tractor end so that the
weight of the truck is removed from the
drive tire. See WARNING.

Use extreme care whenever the truck is

jacked up for any reason. Never block
the truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath the vehicle while jacking. Use
jack stands or solid blocks to support
-
truck Do not rely on jacks. Refer to
"Jacking Truck".

9. Drain oil from the drive unit.

10. Unbolt the Lift/Lower manifold from the
drive unit casting.
'
11. Remove the steering mechanism. This will
either be a torque shaft for manual steering
or a motor/gear reducer assembly on
trucks with electric steering.

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Toyota Orderpicker Service Manual Component Procedures

Power Section

12. Remove cap screws (3)holding the drive

unit assembly to the tractor.
13. Slide drive unit toward front of tractor
(direction of arrow).
14. For reassembly, reverse Steps 1 through
Note the following for assembly:
Torque wheel nuts to 107 ft. lbs. (150
Nm).
Refill gearbox with proper lubricant.
Torque the drive unit mounting cap
screws (3)to 120 ft. lbs. (168 Nm).

Step 1 1

K
FRONT \

Figure 7-7: Removing Drive Unit

Drive Axle Seal Replacement

If the axle is removed for replacement or for any
other reason, replace the axle oil seal.
Tools required to replace the axle and axle oil
seal include:
4 mm Allen Wrench (for clamp nut)
Seal Pressing Ring
Clamp Nut Spanner Wrench
Bearing Puller
Torque Wrench
1 /2" Socket (for lowering cover)
Hydraulic or Arbor Press

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C o m p o n e n t Procedures Toyota O r d e r p i c k e r Service M a n u a l

Power Section

Seal Pressing Clamp Nut Spanner

Ring Wrench

Figure 7-8: Drive Unit Service Tools

-f>+&
If the drive unit has a
shim located under this
bearing, make sure that
7 T
,y/
- wLd"d5-
L -
--P-

T
8
?
:{
,; -5
'"

?k
it is installed when the - - t
M
drive unit is
reassembled.

Figure 7-9: Drive Unit Cross Section

Drive Unit Disassembly

1. Remove the drive unit.
2. Remove the lower cover on the drive unit
housing using a 1 /2" socket.

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Toyota Orderpicker Service Manual Component Procedures

Power Section

Axle Seal Clamp Nut

Axle / Lower Cover

Figure 7- 10: Drive Unit Components - Lower End

3. Use a 4 mm Allen Wrench to loosen the

screw in the clamp nut.
4. Use a spanner wrench to remove the clainp
nut from axle.
5. Press the axle out of the housing.
6. Use a bearing puller to carefully remove the
bearing cone from the axle. See Figure 7-
7 1

Bearing Puller
'A

Figure 7-1 1 : Removing Axle Bearing

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Component Procedures Toyota Orderpicker Service Manual

Power Section

7. Remove old axle seal.

8. Clean/inspect all components.

Drive Unit Assembly

1. After lubricating the lip of the new seal,
place new axle seal onto axle. This can be
done by hand.
2. Carefully place bearing cone onto axle.
Press onto axle. See Figure 7- 12.

Figure 7- 12: Pressing Bearing Cone onto Axle

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Toyota Orderpicker Service Manual Component Procedures

Power Section

3. Place axle assembly into housing. Mate axle

with main drive gear. See Figure 7-13.

Axle
Assembly

Main
Drive Gear

Figure 7-13: Assembly of Axle into Housing

4. Place seal pressing tool between seal and

tire mounting flange on axle. Refer to
Figure 7-14.

Seal
Pressing
Tool

Figure 7-1 4: Preparing Axle Seal for Assembly into Housing

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Component Procedures Toyota Orderpicker Service Manual

Power Section

5. Press the axle seal into the housing. The

seal must be flush with the housing.
6. Push the axle out of the housing just
enough to allow removal of the pressing
tool.
7. Push axle back in until bearing cone and
bearing cup make contact.
8. Install the clamp nut on the axle. To set the
bearing rollers, rotate the axle shaft and
torque the clamp nut to 150 in. lbs (17 Nm).
Loosen clamp nut. While turning the axle
shaft, torque the clamp nut to 40 in. lbs.
(4.52 Nm). Refer to Figure 7- 15.

Clamp Nut Spanner

Clamp Nut

Figure 7-1 5: Instollflorque Clamp Nut on Axle

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Toyota Orderpicker Service Manual Component Procedures

Power Section

9. Apply Loctite 242 then tighten the screw in

the clamp nut to prevent the clamp nut
from loosening. See Figure 7- 16.

4mm Allen
Wrench

Clamp Nut

Figure 7-16: Securing Clamp Nut by Tightening Retaining

Screw

10. Clean cover plate and mating surface.

Apply Permatex 6B to sealing surface. See
Figure 7-17.
11. Install cover. Tighten all screws equally to
20 ft.lbs. (28 Nm).
12. Apply No.2 Permatex to drain plug and
install.

Figure 7-1 7: Installing Cover

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Power Section

Drive Tire Replacement

1. Remove covers from tractor.
2. Turn the drive unit so the lug nuts on the
wheel can be loosened.
3. Disconnect battery.
4. Remove center section of bumper using a
19mm socket.
5. If the truck is wire guided, remove the
sensor near the front bumper.
6. Loosen lug nuts on drive wheel using a
19mm socket.
7. Jack up front of truck and block and
remove the drive tire. See WARNING.

Use extreme care whenever the truck is

jacked up for any reason. Never block
the truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking. Use jack
stands or solid blocks to support truck -
Do not rely on jacks. Refer to "Jacking
Truck."

8. With the drive tire removed, a new tread

surface can be installed. Press the old tire
off and press the new tire on the hub.
NOTE: If the pressure required to press the new
tire on the hub is less than five (5)tons,
replace the wheel hub.

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Toyota Orderpicker Service Manual Component Procedures

Power Section

9. Reinstall drive wheel on the truck. Torque

the lug nuts to 108 ft. lbs. (151 Nm). See
CAUTION.

A CAUTION
Installing the drive tire on the axle
backwards will have an adverse effect
on steering when the brake is applied.

10. Remove blocking and lower truck to floor.

11. Reinstall bumper; then test truck.

Drive Motor Removal

1. Disconnect battery.
2. Remove brake assembly.
3. Remove any proximity sensor(s) and
associated hardware on the drive motor.
4. Identifl, then remove power cables from
drive unit.
5. Remove screws holding motor to drive unit
using a 6 mm Apex.
6. The drive motor may now be removed.
7. For reassembly, reverse Steps 1 through 6
noting the following:
Clean motor flange. Apply a coat of
sealant to flange.
Clean screws. Apply Loctite 242 to
screws and torque equally to 13 ft.
lbs. (18 Nm).
Check brake adjustment.
The gap between the proximity
sensor(s) and metal should be
approximately 3/32" (2.3 mm).
8. If the pinion on the drive motor needs to be
installed:
Clean threads using Loctite primer
N.
Install key and gear.
Apply Loctite 242 to threads.
Torque nut to 45 ft. Ibs. (63 Nm).

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Component Procedures Toyota Orderpicker Service Manual

Step 2

Step 3

Figure 7- 18: Drive Unit Assembly

Skid Pad Replacement

Use the following information to determine if
the skid pads, located on either side of the
tractor, require service.

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Toyota Orderpicker Service Manual Component Procedures

Power Section

Use extreme care whenever the truck is

jacked up for any reason. Never block
the truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking. Use jack
stands or solid blocks to support the
-
truck Do not rely on jacks. Refer to
"Jacking Truck."

1. Locate truck on smooth level surface.

2. If the clearance between the skid pad and
the floor is more than 0.75" (19.1 mm) on
either side, replace the skid pad a s shown
in Figure 7- 19.
3. Apply Loctite 242 to threads on screws and
install new skid pads on power section
(both sides).

Skidpad
Skidpad

- -- --
- -
- --

0.75" (19.1 mm)

Max (Both Sides)
Figure 7- 19: Checking Skidpads

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Component Procedures Toyota Orderpicker Service Manual

Brake

Brake

Brake Adjustment
Brake adjustment should be checked regularly.
When the truck is carrying its rated load and
traveling at full speed on a level floor, the brake
should stop the truck within 6 to 10 feet. Do
not adjust the brake to stop the vehicle in less
than 6 feet.
Loosen the set screw (28).
Turn the plug (29) clockwise for quicker
stopping and counterclockwise to increase the
stopping distance.

Brake Inspection
If the brakes cannot be adjusted by the
adjustment procedure, inspect the brake shoes
(8). Use the following procedure:

Brake Inspection Procedure

1. Disconnect the battery.
2. Remove nut (1).
3. Hold the deadman pedal in the down
position to release pressure on the brake
drum (2).
4. Lift the brake drum (2) off.
Inspect the brake shoes (8).

1) IF... I THEN... 1
The brake material is Replace the brake
worn through, extremely shoes.
1 thin or loose on the shoe. I I
The brake shoes are Go to Step 5.
usable.

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Toyota Orderpicker Service Manual Component Procedures

Brake

5. Loosen the nut (12). Lift brake control lever

(11) off and reposition one or two serrations
to the left. Retighten nut (12).
6. Reassemble the brake drum.
7. Readjust plug (29) to give a stopping
distance of 6 to 10 feet.
8. After adjusting the stopping distance (Step
7), ensure the brake does not drag when
the deadman pedal is fully depressed.

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Component Procedures Toyota Orderpicker Service Manual

Brake Master Cylinder Replacement

Brake Master Cylinder Replacement

1. Lower carriage.
2. Disconnect battery.
3. Remove both console covers.
4. Disconnect and plug lines to master
cylinder (8), (9).
5. Remove cover in front of pin 6.
6. Remove pin (6).
7. Remove screws holding master cylinder (3).
(4)-
8. Repair/replace defective parts.
9. Adjust pedal height; see.Figure 7-20.

Figure 7-20: Deadman Pedal/Master Cylinder

10. For reassembly, reverse Steps 3-6.

11. Bleed brake system (refer to Figure 7-2 1).
12. Refill brake reservoir.
13. Test.

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Toyota Orderpicker Service Manual Component Procedures
- - -

Brake Master Cylinder Replacement

Brake Assembly Removal

1. Disconnect battery.
2. Loosen and remove the nut (1) holding the
brake drum (2). Refer to .
3. Depress and hold the deadman pedal down;
remove the brake drum; release the
deadman pedal.
4. Remove clamps holding the drive motor
power wires to the brake assembly.
5. Disconnect and plug hydraulic line to the
slave cylinder (23).
6. Remove 4 screws (14) holding brake
assembly to motor.
7. Remove brake assembly.
8. For reassembly, reverse steps 1-7.
9. Bleed the brake system.

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Component Procedures Toyota Orderpicker Service Manual

Brake Bleeding

Brake Bleeding
If the brake drags when the pedal is fully
depressed, bleed the air from the brake line and
slave cylinder using a pressure bleeding tank a s
shown in Figure 7-21.

Figure 7-21 : Brake Bleeding Set-Up

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Toyota Orderpicker Service Manual Component Procedures

Brake Bleeding

1. Lock Nut 17. Washer

2. BrakeDrum 18. Mounting Plate
3. Brake Drum Spacer 19. Switch Bracket
4. Screw 20. Screw
5. Washer 21. Lockwasher
6. Support Plate 22. Spring
7. Shoe to Shoe Spring 23. Slave Cylinder
8. Brake Shoe Assembly 24. f i s h Rod
9. Brake Actuating Cam Shaft 25. Brake Clevis
10. Washer 26. Pin
11. Brake Control Lever 27. Cotter Pin
12. Nut 28. Set Screw
13. Bolt 29. Brake Adjustment Screw
14. Screw 30. Spring
15. Washer 31. Woodruff Key
16. Screw 32. Motor Shaft
-69

/--\

Figure 7-22: Exploded View of Brake Assembly

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Component Procedures Toyota Orderpicker Service Manual

Deadman Switch Adjustment

Deadman Switch Adjustment

If the brake still drags after bleeding the brake,
or if a new master cylinder is installed, adjust
the deadman pedal using the following
procedure:
Adjust the yoke on the master cylinder
so the heel of the pedal travels
approximately 2- 1 /2"to 3- 1/2" from the
fully depressed position to the normal
(full up) position.
Adjust the deadman switch, on the
brake assembly, to remain on until the
deadman pedal has been released at
least 60%, but never over 80% of full
travel height.

i
1 I Compartment
Floor
~
i Deadman
Pedal F i I I trove 1
I
t
S e t 52 t o o c t u o t e 69% l o
80% o f i u l ! p e a o l l r o v e i !
I
I
!

Figure 7-23: Deadmon Switch (S2) Adjustment (Not to

Scale)

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Toyota Orderpicker Service Manual Component Procedures

Lift/Lower System

Lift/Lower System

Side Lift Cylinder Removal

1. Disconnect battery.
2. Remove console and tractor covers.
3. Disconnect all over-the-mast electrical
cables.
4. On vehicles equipped with cable steering,
remove the wire rope from the steering
system.
5. Using a chain hoist, or another suitable
lifting device, raise the carriage to slacken
the lift chains.
6. Remove the chain pulleys.
7. Remove the chain anchors from the mast
main frame. See NOTE.
NOTE: On trucks with an OALH of less than
102", the chain anchors are behind the
carriage frame. Lift the carriage enough
to gain access to the chain anchors on
the mast main frame.
8. Remove the n u t a t the top of the piston.
9. Remove the carriage stops.
10. Lift the carriage out of the telescopic.
11. Remove the nut from the bottom of the lift
cylinder housing.
12. Disconnect and plug the hydraulic line to
the bottom of the lift cylinder.
13. Place a sling attached to a hoist around the
cylinder to be removed.
14. Remove the shoulder bolt securing the
upper lift cylinder guide.
15. Lift cylinder may now be removed.
16. For reassembly reverse Steps 1-14 and
refer to Elevating Section Service Notes for
torques and assembly notes.
17. Bleed hydraulic system after reassembly.
Check for leaks.
18. Test all vehicle functions.

Side Lift Cylinder Service

1. Remove snap ring (10) from housing.

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Component Procedures Toyota Orderpicker Service Manual

Lift/Lower System

2. Remove oil seal (3).

3. Remove snap ring (2).
4. Pull piston out until piston stop forces
back-up ring (5),U-cup seal (1).back-up
ring (6),and adapter (15) out of housing.
5. Pull piston out of housing. Place piston on
cushioned stand using care not to damage
the piston surface.

Figure 7-24: 2 Stage Lift Cylinder (Top End)

6. Push piston lowering cushion (12) (bottom

end) in slightly at base of piston (Figure 7-
25).
7. Remove snap ring (9) and retaining ring
(16).
8. Release pressure on piston lowering
cushion (12) and remove.
9. Remove spring (11).
10. Remove seal (2)from piston lowering
cushion (12).
NOTE: When repacking the cylinder, replace all
packings. Refer to the parts catalog for
packing kit numbers.

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Toyota Orderpicker Service Manual Component Procedures

Lift/Lower System

Figure 7-25: 2 Stage Lift Cylinder (Bottom End)

Cleaning
1. Flush inside of housing and wipe piston
clean using kerosene or suitable industrial
solvent.
2. Inspect all surfaces for galling or heavy
scratches. Minor defects may be removed
using fine emery cloth.
3. Inspect all parts; replace as required.

Side Lift Cylinder Reassembly

1. All packings and O-rings must be dipped in
new, clean system hydraulic fluid before
assembly.
2. Lubricate inside of cylinder housing using
clean system hydraulic fluid.Reassemble
cylinder by reversing disassembly
procedure, noting the following:
Tighten piston plug (18) and piston (17)
using a strap wrench only. DO NOT
MAR CHROME PLATING ON PISTON. .
If items (17)and (18) were separated,
clean threads on piston plug (18) using
Loctite primer . Then apply Loctite to
threads. Tighten using a strap wrench
only.
Pressure test cylinder in less than fully
extended position at 4500 psi.
Plug fitting opening to prevent foreign
matter from entering cylinder.

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Component Procedures Toyota Orderpicker Service Manual

Lift/Lower System

Center Lift Cylinder Removal (3-Stage)

1. Disconnect battery.
2. Remove console and tractor covers.
3. Disconnect all over-the-mast electrical
cables.
4. On vehicles equipped with cable steering,
remove the wire rope from the steering
system.
5. Using a chain hoist, or another suitable
lifting device, raise the caniage enough to
slacken the lift chains.
6. Remove the lift chains from the equalizer on
the backside of the center lift cylinder.
7. Disconnect and plug supply hose a t bottom
of center lift cylinder.
8. Lift end cap off of center cylinder.
9. Remove nut from bottom of center lift
cylinder.
10. Support the cylinder with a sling attached
to a hoist.
11. Remove clamp supporting center cylinder.
12. Center cylinder may now be removed.
NOTE: TO remove the outboard lift cylinders,
refer to the two-stage lift cylinder
removal instructions. For service, refer
to Two-Stage Lift Cylinder Service.
13. For reassembly, reverse Steps 1- 12 and
refer to Elevating Section Service Notes for
torques and assembly notes.
14. Bleed hydraulic system after reassembly.
Check for leaks.

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Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

Center Lift Cylinder Service (3-Stage)

1. Remove snap ring (1) and oil seal (2).
2. Remove snap ring (3)in housing.
3. Pull piston out until the piston stop pushes
packing ring (41, packing (5),and adapter
(6)out.
4. Pull piston out of housing. Place piston on
cushioned stand using caution not to
damage surface.
5. Push plunger (7) in slightly a t base of
piston, see following figure.
6. Remove snap ring (8)and retaining ring (9).
7. Release pressure on plunger and pull out.
8. Remove spring (10) and seal (11).

\, I u
~/////*>>>%:w/zr%
F~gure7-26: Center Lift Cylinder, 3 Stage (Top End)

9. Do not separate piston (13) from piston

plug (14) unless absolutely necessary. If
disassembly is required, use a strap wrench
only. DO NOT MAR PISTON SURFACE.
NOTE: When repacking the cylinder, replace all
packings. See parts manual for packing
kits.

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Component Procedures Toyota Orderpicker Service Manual

Center Lift Cylinder Service (3-Stage)

Flow Control ;
T L
-

' 2'

Figure 7-27: Center Lift Cylinder, 3 Stage (Bottom End)

Cleaning Components
1. Flush inside of housing and wipe piston
clean using clean kerosene or suitable
industrial solvent.
2. Inspect all surfaces for galling or heavy
scratches. Minor defects may be removed
using fine emery cloth.
3. Inspect all parts; replace a s required.

Center Lift Cylinder (3-Stage)

Reassembly
1. All packings and O-rings (except O-ring,
item 15) to be dipped in new, clean system
hydraulic fluid before assembly. (See
Figure 7-28 and Figure 7-29).
2. Lubricate inside of cylinder housing using
clean, system hydraulic fluid.
3. Reassemble cylinder by reversing
disassembly procedure, noting the
following:
N O T E: To prevent damage to packings a t the ,

top of the cylinder, use the following

tools:
Service Driver - P/N 00590-05257-71
Service Guide - P/N 00590-05258-71

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Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

4. If removed, clean threads on piston plug

(16) using Loctite primer . Apply Loctite to
threads on piston plug. Tighten using a
strap wrench only. Do not mar chrome
plating on piston.
5. Pressure test cylinder in less than fully
extended position at 4500 psi.
6. Plug fitting opening to prevent foreign
matter from entering cylinder.

High Pressure Relief Valve Adjustment

1. Install a calibrated pressure gauge (3000
psi/20,682 kPa) in the test port (1).See
Figure 7-28.
2. Back out high pressure relief (2).
3. Check to see that the manual lower valve
(3)is closed.
4. Place a rated load 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 3-
stage trucks, continue lifting until the third
stage of the mast starts lifting.
6. Adjust the pressure relief valve to a
pressure 100 - 300 psi (689.4-2068 kPa)
greater than the values recorded in step 5.
This can be done by chaining the mast
sections together or adding more weight to
the forks.
7. After the adjustment is complete, tighten
the relief valve lock nut.
8. Check the lift system for proper operation.

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Component Procedures Toyota Orderpicker Service Manual

Center Lift Cylinder Service (3-Stage)

-
--
d
Single Speed Variable Speed ,-

Figure 7-28: Lift/Lower Manifolds

Lift/Lower Manifold Service

If the lift/lower manifold must be serviced, use
the following procedure (Refer to Figure 7-28).
NOTE: Cleanliness around the valve to be
serviced is very important.
1. Inspect the sealing surface for
contaminants. Clean the surface a s
needed, ensuring foreign material does not
go into the valve body.
2. Lubricate O-rings using clean hydraulic
fluid.
3. Refer to Figure 7-29 for specific service
information.
NOTE: This valve does not require bleeding.

0070-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

Tighten the valve cartridge 1 /2 turn,

then loosen 1 /4 turn. Continue with
sequence until a torque value of
120-150 inch lbs. (13.6 - 17.0 Nm) is
achieved. Tightening the valve in
this manner reduces the chance of
damaging the seal.
\

30-35 in. lbs.

(3.38 - 3.95 Nm)

\=
Tighten coil nut
holding coil to 4-5 ft.
lbs. (5.6 - 7 Nm)
Single Speed
Figure 7-29: Proper Installation of Proportional Valve

Bleeding Side Lift Cylinders

The lift cylinder should be bled after
maintenance has been performed on the lift
hydraulic system or when operation indicates
that air has entered the system. A bouncing
carriage is one indication that bleeding may be
necessary.

Procedure
1. Elevate the carriage so that bleed screws
are accessible. For trucks below 95" (241
cm) refer to Figure 7-30.

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Component Procedures Toyota Orderpicker Service Manual
- -

Center Lift Cylinder Service (3-Stage)

2. Loosen, DO NOT REMOVE, the bleed screw

near the top of the side cylinder just
enough to bleed the air from the cylinder.
See following CAUTION..

A CAUTION
The bleed screw should only be
loosened enough to allow the air to
escape.

3. When only oil flows from the cylinder,

tighten the bleed screw. Repeat the process
on the other cylinder.

Bleeding Center Cylinder

If the truck has a three-stage mast, it will have
a center cylinder. To bleed the center cylinder:
1. Elevate the camage enough to extend the
center piston a couple of inches (5
centimeters).
2. Carefully loosen (DO NOT REMOVE) the
bleed screw located on the side of the center
cylinder.

A CAUTION
The bleed screw should only be
loosened enough to allow the air to
escape.

3. When only oil flows from the cylinder,

tighten the bleed screw.

0070-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

Access hole for the

-7
"' "' 6
)-ri -

bleed screw. One is

located on either
I :
side. These are
I I 1 provided for trucks
with an OALH of less
- 1 than 95" (241 cm).
7
On taller trucks, the
'
G >
.\',
7

\
bleed screws are
accessible above
?

Bleed screw location for center

" - the overhead guard.
@P-
cylinder on three-stage masts. c -h-

-%
/
View is from tractor. -
- --- -

- -

-
---
. . . .
---
Figure 7-30: Access for Lift Cylinder Bleed Screws

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Component Procedures Toyota Orderpicker Service Manual

Center Lift Cylinder Service (3-Stage)

Directional/Speed Controller Removal From

Vehicle
With power disconnected and console cover in
operator's compartment removed:
1. Remove connector JPC2 from the caniage
interface board.
2. Remove screws holding controller assembly
to vehicle. Remove controller from truck.

Potentiometer Removal (VR1)

1. Remove screws holding cover (2). Refer to
Figure 7-31.

Potentiometer
Gear (9)

Figure 7-31 : Directional/Speed Control - Exploded View

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Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

2. Remove screws holding bracket (3).

3. Lift out VRl along with bracket (3).The
cable clamp on the outside of the housing
(1) may need to be removed.
4. Remove old shrink sleeve from pot (VR1)
terminals. Iden- wires for reassembly.
5. Unsolder wires.
6. Remove gear (9).
7. Remove nut holding potentiometer to
bracket.
NOTE: If potentiometer is the only item being
replaced, proceed to Step 4 of Assembly
Procedure on the following page.
8. Remove cap screw securing gear (8)to shaft
(5).
9. Support gear (8)with one hand and pull
shaft (5)out with the other.
10. Shaft (5) and spring (7) may now be
removed. Note quantity and position of any
spacers.
11. If spring (7) needs replacement, it may now
be removed and replaced.
NOTE: If spring is replaced, apply a light coat of
lubricant to new spring before
assembling onto gear (8).

A CAUTlON
-
Do not bend spring ears Fatigue failure
may result.

12. If oilite bearings (6) require replacement,

press old bearings out and new ones in.
NOTE: Bearings to be flush with inside of
housing. Use gear (8)as a gauge to
ensure proper distance between
bearings.

0070-CL221 Issued: 9110198

Component Procedures Toyota Orderpicker Service Manual

Center Lift Cylinder Service (3-Stage)

Directional/Speed Controller Assembly

1. Install gear (8)and spring (7) into housing
(along with any spacers previously
removed). Position ears of spring (7)
correctly around spirol pin in housing. Line
up holes in housing (1) and gear (8)and
slide shaft (5) into housing and gear.
2. Install cap screw to secure gear (8)to shaft
(5).Turn shaft 90' in both directions to
ensure free movement. Push and pull on
shaft (5),If excessive play is found, it must
be corrected.
3. Bend locating tab of potentiometer (VR1)
down so it does not engage bracket (3).
4. Place potentiometer (10) into bracket (3).
5. Replace washer/nut on potentiometer and
tighten only finger tight.
6. Slide new shrink sleeving (3/8" long) over
individual wires.
7. Solder wires onto new potentiometer.
8. Shrink sleeving over terminals and solder
joint.
9. Bend terminals over as shown.
10. Install gear (9) on potentiometer shaft. Set
screw in gear should be away from
potentiometer. Potentiometer shaft should
be flush with end of gear (9).
11. Carefully place bracket and potentiometer
back into housing. Specially formed teeth
assure proper alignment of the gears.
12. Install screws into bracket (3).
NOTE: DO not lubricate gears in controller
assembly.

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Toyota Orderpicker Service Manual Component Procedures

Center Lift Cylinder Service (3-Stage)

13. Connect a V O M to the wires between JPC2-

8 and JPC2-9.
14. With the travel control handle in the
neutral position, rotate the body of VRl
until a reading of 650 +/- 20 ohms is
obtained. This is a coarse adjustment.
15. Tighten nut securing VR1 in bracket (3).
16. Replace cover (2).
17. Reverse removal from vehicle instructions
Steps 1-4 to install controller assembly
back into vehicle.
18. Perform CALIBRTE mode for controls
before returning truck to service.

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Component Procedures Toyota Orderpicker Service Manual
-

Lift/Lower Return Spring Replacement

Lift/Lower Return Spring Replacement

1. Disconnect battery.
2. Remove two (2)set screws using a 3/32"
allen wrench.
3. Carefully, pull thumb lever straight off of
assembly. See NOTE.
NOTE: DO NOT rotate potentiometer shaft while
thumb lever is removed.
4. Remove old spring.
5. Apply a thin coat of lubricant to the new
spring. Install the new spring carefully
positioning spring ears around pin in the
handle housing. See CAUTION.

A CAUTION
Do not bend spring ears.

6. Carefully slide thumb lever onto pot shaft. .

7. Tighten the two set screws securely.
8. Perform LEARN mode.

Assembled View
Thumb Lever

Handle Housing

Figure 7-32: Lift/Lower Return Spring Replacement

0070-CL22 1 Issued: 9'/10/98

Toyota Orderpicker Service Manual Component Procedures

Lift/Lower Return Spring Replacement

VR2 Replacement
1. Disconnect battery.
2. Loosen two set screws (3/32"allen wrench)
holding the thumb lever. Pull thumb lever
off.
3. Remove screws (2). Separate control
handle halves.
4. Remove the shrink sleeving from the
terminals of the defective VR2.
5. Identify the wires so that you can install
them in the same location a s they occupy
now.
6. Unsolder the wires from the potentiometer
terminals.
7. Remove VR2 and its bracket from handle.
8. Separate VR2 from the bracket.

VR2 Carefully bend

\ terminals over close to
Heatshrink \ potentiometer body.

Figure 7-33: Lift/Lower Control Assembly, Potentiometer

Wiring

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Component Procedures Toyota Orderpicker Service Manual

Lift/Lower Return Spring Replacement

9. Slide shrink sleeving (3/8"/9.5 cm long

over wires.
10. Solder wires to the new pot in the s a q e
position a s they were removed.
11. Shrink sleeving over terminals. Bend
terminals over a s close to pot body as
possible.
12. Slide pot into the potentiometer bracket.
When properly installed, the locking tab
will mate with the potentiometer bracket.
13. Install the pot and bracket into the molded
handle half. Note that the potentiometer
bracket is keyed to allow only one
assembled position.
14. Reassemble the halves of the control
handle.
15. Slide thumb lever onto pot shaft. Tighten
set screws.
16. Perform CALIBRTE mode for controls
before returning truck to service.

0070-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

Elevating System Service Notes

Refer to Figure 7-34 through Figure 7-41.

0070-CL22l Issued: 9/10/98

Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

\ +
Install using
4
-I
,
Loctite 242
Install using
Loctite 242 *
m

Shim mast bearings

so that lateral
movement is between
0.030" and 0.045"
(0.76 - 1.14 mm)
between the
mainframe and the
telescopic.

Remaining Section Views are on following pages.

Figure 7-34: Elevating Section

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Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

Install using
Loctite 242

Flat on
bearing
stud to be
Adjust gap with camage fully tight
lowered with no load to against
approximately: shoulder.
0 . 2 5 (6.4 mm) Trucks with
OALH of less than 95" (241 cm). shim mast bearings so
0.38" (9.7)for all others. that lateral movement is
between 0.030" and 0.045"
(0.76 - 1.14 mm) between
the mainframe and the
telescopic.

--TI- I Y d
P-

-
' I
I I ;,
I 1 ,
i
i
i -
L
--'L
r-
-L
I
I

Install using
A
/ Loctite 242
/!3',
\ \,yJ,
1.
L

'
,
c
\

View C-C View C-C

Outer Telescopic Lower Bearing Mainframe Upper Bearing
(Typical, Both Sides) (Typical, Both Sides)

Figure 7-35: Elevating Section (cont.)

0070-CL221 Issued: 9/10/98

Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

- View E-E
Thread anchor
-\, until even
\ with bottom
of block.
Loosen 1/2
, I turn or less
I to align with
1
chain.
I

l l Torque jam
I n u t to 100
I
ft. lbs. (140
-
17
-
5 - .
Nm).

View .I
Figure 7-36: Elevating Section (cont.)

0070-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

Figure 7-37: Elevating Section (cont.)

3-Stage Elevating System Service Notes

The service information for the 3-stage elevating
section includes all 2-stage elevating section
service notes shown on the previous pages,
PLUS those shown in Figure 7-38.

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Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

-p\G

L
i
I
Lift RAM
mounting screws
to 170 ftlbs
(238 Nm).
-
-/-'l

Figure 7-38: Three Stage Elevating Section

End Cap Pulley Assembly

If a chain needs to be removed on the side of the
end cap that h a s the cable pulleys, note the

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Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

following. This only applies to three-stage

masts.
1. If the chain sheave on the pulley side needs
to be removed, the cable pulleys must be
taken off first.
2. After the cable pulleys are off, remove Rod
Extension (p/n 00590-03311-71) using a
pipe wrench. Removal of this part will
cause it to be ruined. YOU MUST INSTALL
A NEW ROD EXTENSION.
3. The chain sheave can now be removed.
4. Reverse disassembly. Special assembly
requirements are shown in Figure 7-39.

Apply Loctite 242 to threads of Rod

Torque to 125 Extension. Tighten Using Hand Pressure
ft. lbs. (175 Only. If you use a wrench to tighten Rod
Nm). Extension, it will ruin the surface finish.

Apply
Loctite 242.
, Torque to
55 ft. lbs.
(72 Nm).

Apply
Loctite 242
then Loctite
Retaining
compound. 00590-03311-71
(Rod Extension).

Figure 7-39: End Cap Pulley Assembly (3 Stage mast only)

Mast Shimming
Over time, the mast and carriage may require
shimming to reduce rattles which may occur as
the truck travels over floor irregularities.
Experience has shown that shimming just the
upper bearings will reduce rattles to an
acceptable level. However, because of the time
and tools necessary for this procedure, the
lower bearings should also be checked and
shimmed.

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Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

Be sure that any rattles are in fact coming from

the mast. In some instances, the forks and fork
bars have worn and are causing the noise.

Items Required
p/n 00590-05259-71 shim (as required)
p / n 00590-05260-71 shim (as required)
1 1/8" socket
1 /2" allen socket
torque wrench capable of 300 ft lbs
hoist or reach truck
feeler gauge

Procedure
NOTE: The lower bearings should be shimmed
before shimming the upper bearings.

Shimming the Lower Bearings

1. Elevate the camage approximately seven (7)
feet (2.lm). The mast sections should
appear as shown in Figure 7-40.

Countersunk, alien Inner Telescopic

head screw,

Operator's
Platform

Hex Head Cap Outer Telescopic

screw, M20 x 40

- Main Frame

Figure 7-40: Staging of Mast Prior to Shimming Bearings

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Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

2. Attach a chain hoist to the overhead guard

and to the platform near the forks. The
chain attached near the forks prevents the
carriage from tipping when the carriage
upper bearings are above the inner
telescopic.
A reach truck may also be used to
support the carriage. If a reach truck is
used, the forks on the orderpicker must
be removed along with the light/fan
package (if installed). Ensure that the
carriage on the orderpicker is chained to
the fork carriage of the reach truck.
3. 3-stage masts only. To be able to lift the
bearings of the carriage out the top of the
inner telescopic, the end cap assembly on
the top of the center cylinder must be
removed. This will allow the carriage to be
hoisted without interference.
a. Hoist the carriage just enough to allow
the hoses, cables, and lift chains to be
removed from the end cap assembly.
b. With the hoses, cables, and chains
removed, lift the end cap assembly from
the top of the center cylinder.

End Cap Assembly

W p:
I

Figure 7-41 : End C a p Assembly, 3 Stage Mast

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Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

4. Hoist the caniage until it comes completely

out of the top of the inner telescopic.
5. The bearings on the carriage simply slide
off the bosses.
6. Shims. There are two (2)thickness shims
available:
.015"(0.381mm) p / n 00590-05259-71
.062"(1.58mm) p / n 00590-05260-71
7. Install the required shims between the
bearing and the boss. The carriage
bearings should be shimmed so that there
is no side play between the bearings and
the inner telescopic. The shimming should
not cause the bearing to gall the inner
telescopic. Shim both sides equally.

Shimming the Upper Bearings

8. Use a feeler gauge to check the amount of
wear on the lower bearings. Normal lateral
movement is in the range of .030"- .045"
(0.762mm - 1.143 mm).
9. The bearings on the carriage simply slide
off the bosses.
10. Shims. There are two (2)thickness shims
available:
.015"(0.381mm) p / n 00590-05259-71
.062"(1.58 mm) p / n 00590-05260-71
11. Install the required shims between the
bearing and the boss. The carriage
bearings should be shimmed so that there
is no side play between the bearings and
the inner telescopic. The shimming should
not cause the bearing to gall the inner
telescopic. Shim both sides equally.
12. Using the hoist, lower the carriage into the
inner telescopic.
13. 3-stage masts only. Install the end cap
assembly. Assemble the lift chains, hoses
and cables onto their respective pulleys/
sheaves.
14. Finish lowering the carriage.
15. Outer telescopic. Using the 1 /2"allen
socket, loosen (DO NOT REMOVE) the
bearing retaining screw on the outer
telescopic.

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Toyota Orderpicker Service Manual Component Procedures

Elevating System Service Notes

16. hevent the bearing from dropping when

the screw is removed. Remove screw.
17. Add the required shims on either side so
that total lateral movement between the
inner and outer telescopics is .030n- .045"
(0.762 mm - 1.143 mm). Shim both sides
equally.
18. Install and torque the countersunk screw to
250 ft lbs. (350 Nm).
19. Mast main frame. Using the 1 1 /8" socket,
loosen (DO NOT REMOVE) the screw
holding the bearing retaining screw in the
main frame.
20. Prevent the bearing from dropping when
the screw is removed. Remove screw.
21. Add the required shims on either side so
that total lateral movement between the
outer telescopic and the main frame is
.03OW - .045" (0.762 mm - 1.143 mm). Shim
both sides equally.
22. Install and torque screws to 300 ft lbs.
(420 Nm).
23. Remove the hoist.
End of procedure.

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Component Procedures Toyota Orderpicker Service Manual

Elevating System Service Notes

Service Notes
Figure 7-42 shows a sectional view of the
steering control and the applicable service
notes.
/
If bearing is removed, apply
Loctite to outer race of
/
/ - bearing.

, , --

,
4
, :
8

i
- ---
-.:-.-
- --
-
:,4,T- *5 - ~ dL
YT3
:<:
.
i/.
,
/

,
?d
/
z-=&
-
"
-L.

SE5
,x,-
,
,
,
.
-
-.

+.:. -s
/-.-- Apply Loctite
./ (990-536) to
6 threads.
'
7

/
--
I
If the steering wheel should
Apply h c t i t e to threads
..squealt.. as it is turned,
and torque to 120 in lbs
apply a very small amount of
(13.56 Nm).
grease to this surface.

Figure 7-42: Steering Control Assembly

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Toyota Orderpicker Service Manual Theory of Operation

Theory of Operation

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Theory of Operation Toyota Orderpicker Service Manual

Electrical Functions

Electrical Functions

The braking, steering, and travel control

systems on the Toyota lift truck are completely
electrically controlled and monitored. The lift/
lower system is electrically controlled and
hydraulically activated.

Operating Description Overview

The Carriage Interface Card monitors the state
of switches, sensors, operator control handle,
and other input devices. It then sends outputs
to the Display Card. The Display Card contains
a microprocessor. The microprocessor makes
decisions based on the information received
from the Tractor Interface Card, power
amplifiers, operator display, and Carriage
Interface Card inputs. Output devices that are
controlled through the Tractor Interface Card
are: solenoids, the brake, the MM contactor,
and optional equipment to customize the truck.
The display card's microprocessor can be
customized for each application. Two of the
parameters that can be customized are the
clock and calendar. The microprocessor is
connected to a battery with a ten year life span
that can store the customized parameters in
memory when the truck's battery is
disconnected.
The microprocessor performs a diagnostic test
at start up and during truck operation. The
diagnostic test assists in repair by identifying
problems and minimizing truck downtime. ~ b r
any identified problems, the operator is alerted
by a visible tool bar icon displaying error code
numbers and a n audible alarm. A history log
records error codes by hour meter reading.

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Toyota Orderpicker Service Manual Theory of Operation

Lift/Lower System

Lift/Lower System

Overview
All inputs and outputs related to the lift/lower
system are controlled by the Display Card. The
Display Card determines what actions are
required based on inputs from the operator and
from system feedback.
The Camage Interface Card sends voltage
through lift/lower potentiometer VR2. As VR2 is
moved by the operator, a voltage, proportional
to the position of the control, is sent back to the
Display Card.
When the lift/lower control is moved to lift,
voltage from VR2 increases; when it is moved to
lower, the voltage from VR2 decreases. As the
lift/lower control is moved, VR2 voltage is
sensed by the Display Card which determines
whether to lift or lower. This is accomplished by
the Display Card comparing the present voltage
to the Learned voltage values.
The Display Card then sends a request to the
lift power amplifier by way of the BUS +/-
communication lines to turn the lift motor on, if
lift has been requested.

Unique System Features

The lift/lower system uses 24-volt coils.
The Display Card monitors the lift pump motor
by way of the lift power amplifier. If the control
is moved from lift to lower, the Display Card will
not allow the carriage to lower until the lift
pump motor has stopped. This allows smooth,
controlled lowering of the carriage without a
"bump." The length of the delay will depend on
the oil viscosity, pump/motor tightness,
'
temperature, and the load on the camage.
The lift pump will start to rotate when the lift/
lower pot (VR2) is rotated to the lift position.
The farther the pot is rotated to lift, the faster
the pump will rotate. The proportional lower
solenoid (SOLl) is only used during lower, not
during lift.

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Theory of Operation Toyota Orderpicker Service Manual

Lift

Lift
With the key switch on and deadman pedal
depressed, moving the lift/lower control on the
multi-function control handle to lift causes:

Variable Lift
1. VR2 to output a voltage higher than when
in the neutral position.
2. The Display Card senses this increase in
voltage a t JPC2-3. The Display Card
energizes the MM contactor coil. This closes
the MM contactor tips and starts the lift
pump motor.
3. Lift motor voltage is monitored by way of
BUS +/-. The further VR2 is moved from
neutral during lift, the faster the lift motor
will turn. This is accomplished by the
Display Card sending a signal to the lift
power amplifier by way of BUS +/- which in
turn starts the lift motor.
4. The weight of the load on the forks is
determined by inputs to the Steer Manager
from the optional pressure sensor a t JP2-
13.

Lower
1. With the key switch ON and the deadman
depressed, rotating the lift/lower control
VR2 to the lower position will send a signal
to the Display Card which will be a
decreasing voltage.
2. The Display Card, due to its Learned
values, will sense the request for lower and
a t which rate lower is requested.
3. The Display Card will send a message to the
Tractor Interface Card. The Tractor
Interface Card will signal the load holding
solenoid (SOL2)a t JPR- 17 to energize its .
coil.
4. At the same time, the proportional lower
solenoid (SOL1)will be opened by a signal
from the Tractor interface Card a t JPR1-12
to allow fluid to flow back to the tank. The
solenoid will be opened proportional to the
amount that VR2 is moved from neutral
during lower.

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Toyota Orderpicker Service Manual Theory of Operation
Lower

5. The resistance during lower remains

constant and the Display Card converts the
signal into an average current that varies
with the pulse width (position of VR2).
6. Voltage across the proportional lower
solenoid will vary depending on the position
of the lift/lower control (VR2).
elow voltage = slow lowering
.high voltage = fast lowering
7. The plunger in the coil moves a s the field
strength varies in relation to the average
Direct Current level. The plunger is
mechanically coupled to the spool valve, so
a varying DC current level will control the
hydraulic flow.

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Theory of Operation Toyota Orderpicker Service Manual

Steering System

Steering System
The steering system is electrically controlled. If
a fault is sensed in the steer controller, output
to the Carriage Interface Card will change
causing the brake solenoid coil to drop out, no
travel will be allowed. An error code will appear
on the Operator Display indicating a steer
controller problem.
Turning the steering wheel clockwise directs B+
current to the steer motor.

Braking System
The bralung system on the Toyota lift truck is
hydraulically controlled. It is dependent upon
inputs from the Display Card and the deadman
switch (S3).
NOTE: The brake is not dependent on the
deadman switch: it is dependent on the
brake pedal and the brake dump
solenoid.
With the deadman pedal in its normal UP
position, the master cylinder is deactivated; the
slave cylinder is depressurized allowing the
brake spring to keep the brake applied.
Stepping on the deadman pedal strokes the
master cylinder which increases the pressure in
the slave cylinder, pushing against the brake
spring and releasing the brake.

Proportional Plugging
When the truck is traveling in one direction and
the control handle is moved through neutral to
the opposite direction to stop the truck and/or
change directions, the process of plugging
occurs. "Proportional Plugging" means the
farther the control handle is moved, the quicker
the truck stops and changes direction. In this
example, plugging occurs from forward to
reverse.
1. The Traction Power Amplifier senses that
the truck is still moving forward because of
the input from the traction power
amplifiers.
2. The Display Card senses the voltage from
VR1 and recognizes this is a request for
forks first travel.

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Toyota Orderpicker Service Manual Theory of Operation

Proportional Plugging

3. The Traction Power Amplifier will not

change the polarity of the fields during
plugging.
4. As the armature continues to rotate it will
be turned into a generator. The generated
voltage will be routed back to the battery
which has now become the load.
5. This process will continue until the truck is
almost stopped. After the truck has slowed
almost to a stop, proportional plugging will
stop and the traction system will be in drive
mode.

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Theory of Operation Toyota Orderpicker Service Manual

lndicators and Switches

Indicators and Switches

Traction Motor Brush Wear lndicator

The traction motor on this lift truck contains a
pair of brush wear indicator switches. When the
brushes need replacing, an icon will light on the
operator display. This is accomplished by metal
bars, attached to the north and south poles of
the brush housing, coming in contact with the
brush housing a s the brush wears down. This
completes a circuit allowing B+ battery voltage
on the Tractor Interface Card (depending on
whether the north or south pole brushes are
worn). The Tractor Interface Card sends a
signal through the CAN Bus to the Display
Card. The Display Card processes the input and
signals the brush wear indicator, on the
Operator Display, to light.
Travel is not disabled when the brush wear
warning icon is lit. Brushes should be inspected
or replaced when the icon becomes illuminated.

Lift Motor Brush Wear Indicator

The lift motor on this lift truck contains a pair
of brush wear indicator switches. When the
brushes need replacing, an icon will light on the
operator display. This is accomplished by metal
bars, attached to the north and south poles of
the brush housing, coming in contact with the
brush housing a s the brush wears down. This
completes a circuit.allowing B+ battery voltage
on the Tractor Interface Card (depending on
whether the north or south pole brushes are
worn). The Tractor Interface Card sends a
signal through the CAN Bus to the display card.
The display card processes the input and
signals the brush wear indicator, on the
Operator Display, to light.
Lift is not disabled when the brush wear
warning icon is lit. Brushes should be inspected
or replaced when the icon becomes illuminated.

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Toyota Orderpicker Service Manual Theory of Operation

Electric Steering

Electric Steering
Electric steering is standard for this vehicle.
The electric steering system performs two
functions:
Manages the overall operation of the
steering system.
Positions the drive unit based on
commands from:
Inputs from the steering encoder
(turned a s the steering wheel is moved).

Steering Components
Major components which make u p the electric
steer system include:
Steering Command Encoder (located
behind steering wheel on operator's
carriage)
Carriage Interface Card
Steer Controller (SC)
Permanent Magnet Steering Motor
Gear Reducer
Home Proximity Sensor
Steer Position Encoder (located near the
steer gear reducer)
Steer Indicator Lights
Display Controller Card

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Theory of Operation Toyota Orderpicker Service Manual

Electric Steering

Steering Encoder
The Steering Encoder is located on the
operator's carriage, behind the steering wheel.
The steering encoder sends a quadrature-phase
signal to the Display Controller Card when the
steering wheel is turned.

Steering Communications

CAN
CAN stands for Controller Area Network. A CAN
is a communication protocol. A CAN uses two
digital signal lines referred to as Bus+ and
Bus-.

BUS+/BUS- serves a s the communication link

between the Display Card and the Steer
Controller. These devices use BUS+/BUS- to
communicate with each other.

Steer Controller (SC)

The "brains" of the electric steering system is
the Steer Controller. All inputs/outputs related
to steering are controlled by the SC.
The Steer Controller has a "heartbeat" LED
located on the card. A slow, steady blink
indicates a normal condition. No blinking
indicates an error condition on the Steer
Controller.
The Steer Controller also contains transistors
that are used to power the steer motor. It also
sends steering position information to the
Display Controller Card.

Permanent Magnet Steer Motor

This motor receives power from the SC. The
motor is connected to a gear reducer. The steer
motor provides the mechanical force to steer the
drive unit.

Gear Reducer
The Gear Reducer is powered by the permanent
magnet steer motor. The output shaft turns a
gear that powers a gear on the drive unit.

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Toyota Orderpicker Service Manual Theory of Operation

Electric Steering

Home Proximity Switch

The Home Proximity Switch is located near the
Gear Reducer Assembly. The switch opens or
closes depending upon its proximity to a metal
surface. The signal from the switch is sent to
the Steer Controller.

Steer Position Encoder

The Steer Position Encoder is located near the
steering gear reducer. As the drive unit steers, a
corresponding quadrature-phase signal is sent
to the Steer Controller (SC).The signal from this
encoder allows the SC to determine the
direction the drive unit is steered and also how
far the drive unit has been steered.
Quadrature-phase modulation is a method for
determining which way the steering wheel has
been turned and how far it has been turned.
As the steering wheel is turned, two individual
square wave signals are produced. The
relationship between these two signals is a n
indication of which way the steering wheel is
being turned. The number of pulses generated
is an indication of how far the steering wheel
has been turned.
Determining which way the steering wheel is
turned is based on the phase between the two
signals. This is because one of the two square
wave signals ahead of the other. The signal that
is ahead tells which way the wheel is being
turned.
These square wave signals are sent to the
Display Card (Channel B/Channel A) at HD-5.
The Display Card interprets the inputs from the
steering encoder and sends steering command
signals out over BUS+/BUS-.

Steering Indicator Lights

The Steering Indicator Lights are located on the
operator's control console. The steer indicator
lights show the operator the approximate
position of the steerable drive unit.

Theory of Operation Electric-

Steering
Theory of operation will look at the electric
steering system for three conditions:

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Theory of Operation Toyota Orderpicker Service Manual

Electric Steering

At power up
Normal driving
Calibrate mode

At Power Up
When the truck is turned on, the drive unit is
positioned to the straight-ahead position
automatically after the deadman pedal is
depressed.
The Steer Controller (SC) uses an input from
the Home Sensor Proximity Switch a t JP2-9.
The Home Sensor Proximity Switch can be over
metal or it can be away from metal a t power up.
A metal ring located on the left half of the
steering arc lets the SC determine if the drive
unit needs to be steered left or right a t power
UP.
When the truck is initially turned on, the Steer
Controller will steer the drive unit toward the
straight-ahead position until the Home
Proximity Sensor changes state. The sensor
changes state when a metal surface passes
beneath it (drive unit in straight-ahead
position).
During power up, the signal from the Steer
Position Encoder is ignored until the drive unit
is centered and the steering indicator LEDs are
all off until the Deadman is activated, and the
drive unit has been centered.

Channel " A leads

Channel "B" by

CHANNEL " A ~il-rL-r

Figure 8-1: Steering Encoder Output - Left Turn

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Toyota Orderpicker Service Manual Theory of Operation

Electric Steering

+++
1 I Channel "A" lags
Channel "B" by

CHANNEL " A 2 rfir

- - -
angle 0.

CHANNEL "B" U U L
Figure 8-2: Steering Encoder Output - Right Turn

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Theory of Operation Toyota Orderpicker Service Manual

Electric Steering

Normal Driving
To properly steer the truck the Steer Controller
(SC) needs inputs from other areas of the truck.
These other inputs include:
Steer request from Display Controller Card
Truck speed
Travel direction (Wire Guidance only)
Deadman status
The SC has access to this information through
the network communications bus (BUS+/
BUS-). The network allows the truck computers
to work together a s one unit. This permits
displaying steering information directly on the
display from the SC. The SC will provide other
devices connected to BUS+/BUS- steering
information which includes: drive unit position,
steering status, error conditions, and
maintenance mode information. The SC retains
direct and exclusive control over the permanent
magnet steer motor.

Drive Unit Positioning

Drive Unit positioning is accomplished by the
Steer Controller (SC).
Calculating the actual drive unit position
via input from the steering position
encoder.
Calculating the desired position of the drive
unit via input from the Display Controller
Card.
Steering the drive unit to the desired
position
If the SC attempts to steer the drive unit
(current to the steer motor is sensed), but no
movement is detected after approximately 2
seconds, the SC will time-out and display a
fault. Steer motor current is measured at the
shunt of the Steer Controller. During normal
operation current will be 40-50 amps, with a
current limit of 80 amps.
As the drive unit is steered, the Home Proximity
Sensor changes from one state to another as
metal/no metal passes underneath it. If the
Home Proximity Sensor doesn't sense a
transition from one state to another, the drive
unit will continue to steer until it reaches its
mechanical limits. After approximately 2

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Toyota Orderpicker Service Manual Theory of Operation

Electric Steering

seconds after reaching the steering mechanical

limits, the system will time-out and display a
fault.

Calibrate Mode For Steering

Calibrate mode allows the Steer Controller to
calibrate the steering system. Calibrate mode
for the steering system should be run when any
of the following items are replaced:
Steer Motor
Gear Reducer
Steer Controller
Electric Steer Firmware
AnDme the steering system is not
responding correctly.

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Theory of Operation Toyota Orderpicker Service Manual

Wire Guidance (Optional)

Wire Guidance (Optional)

The optional wire guidance system (Figure 8-3
on page 8-18) is designed to provide precise
electronically controlled steering for narrow
aisle applications.

Systems Concept
The system consists of two subsystems:
The Warehouse Installed Equipment (WIE)
produces a tuned signal and transmits this
signal through a guide wire from which the
signal is radiated.
The Truck Installed Equipment (TIE)senses
the radiated signal, combines it with other
input signals. then develops a command
signal which provides the necessary
steering control. It also provides the safety
and warning controls necessary for proper
system operation.

Warehouse Installed Equipment (WIE)

The Warehouse Installed Equipment (WE)
consists of:
Line Driver
Guide Wires

Line Driver: The Line Driver is a wall mounted

assembly which develops and transmits the
guidance signal for the system.

Guide Wire: The Guide Wire is imbedded in the

floor and functions a s an antenna, transmitting
the signal from the line driver to the truck.

Truck Installed Equipment (TIE)

In addition to electric steering components, the
following items are required for wire guidance:
Antenna Assembly (one a t tractor end, one
a t load end)
Filter Card
Wire Guidance Auto/Manual Switch (S45)

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Toyota Orderpicker Service Manual Theory of Operation

Wire Guidance (Optional)

Antennas
There are two sets of antennas on the truck.
One set is located on the front bumper of the
tractor (Tractor Sensor). The second set is
located under the operator's camage (Load
Sensor). Each set is comprised of two
independent "coil pairs" which are used
together to determine the position of the truck
in relation to the guide wire. See Figure 8-3.

Home Proximity Sensor (HP)

The Home Proximity Sensor is located on the
drive unit next to the Steer Position Encoder.
The Home Proximity Sensor is used in
conjunction with the SPE to provide a starting
reference to the steer controller. The sensor
output depends on its proximity to a metal
surface. The signal from the sensor is sent to
the Steer Controller.
When the truck is initially turned on, the Steer
Controller will steer the drive unit toward the
straight-ahead position until the Home
Proximity Sensor changes state. The sensor
changes state when a metal surface passes
beneath it (drive unit in straight-ahead
position).

Speed Prox 1 and Speed Prox 2 Sensors

They are used in conjunction with the holes in
the brake drum to produce a quadrature signal
that is sent to the steer controller. The
characteristic pulses of the quadrature signal
are produced a s the proximity sensors read
either the metal or void of the rotating brake
drum. The steer controller can then calculate
vehicle direction and speed.

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Theory of Operation Toyota Orderpicker Service Manual

Wire Guidance (Optional)

Stee
A Electric Steer Controller Moi

Right
Tractor Sensor

Guide Wire

Left

Figure 8-3: Wire Guidance Functional Block

Diagram

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Toyota Orderpicker Service Manual Theory of Operation

Wire Guidance (Optional)

Tractor Left Tractor Near Wire Tractor Right

Figure 8-4: Location of Wire Guidance Coils and

Related Tests

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Theory of Operation Toyota Orderpicker Service Manual

Filter Card
The Filter Card mounts on and mates with the
Steer Controller (SC).The Filter Card processes
signals from the antennas and removes .
unwanted signals/noise from sources other
than the guidewire. The signals from the
guidewire are AC and are converted by the
Filter Card into DC which is sent to the Steer
Controller.

Wire Guidance Auto/Manual Switch: This

switch is located near the directional speed
control. Its purpose is to allow the operator to
select between manual electric steering or
automatic wire guided steering.
When the truck has locked onto a guide wire,
the operator has no control over the steering
system.

Wire Guidance LED's

The wire guidance LED's are located on the
Operator's Console (Figure 8-5).The LED's
consist of two green triangles and three
yellow rectangles. The LED's indicate when
the wire guidance system is turned On and
when locked on the guide wire.

0070-CL221 Issued: 9/10/98

Toyota Orderpicker Service Manual Theory of Operation

Figure 8-5: Wire Guidance LEDs on the Operator's Display

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Theory of Operation Toyota Orderpicker Service Manual

Sequence of Operation (Wire Guidance)

At Power Up
At power up, the wire guidance is generally not
turned ON.

Normal Driving
Drive the truck using manual electric steering
to where the guidewire is located.
NOTE: The truck is designed to acquire the wire
in the tractor-first direction.

Wire Guidance Acquisition

When the auto/manual switch (S45) is
positioned to Auto:
1. The guidance system goes into a seeking
mode and is looking for a guidewire.
2. The two green triangles on the wire
guidance display.
3. An audible alarm sounds to let the operator
know that the guidance system is seeking
the guidewire.
, 4. When the system senses a guidewire of the
proper frequency and amplitude, the
display changes to "Aligning". The audible
alarm will stop. Steering is now done
automatically by the Steer Controller.
5. When the truck has acquired the guidewire,
the three yellow LED'S on the guidance
display will light; the two green lights will
remain on. Any speed limitation is now
removed. The Operator's Display will now
show the selected default setting.
To properly steer the truck automatically, the
following process occurs:
1. As the truck is driven towards the
guidewire in manual. the antenna on the
tractor- end of the truck is looking for a
guidewire signal. This signal must be of the
proper frequency and amplitude for the
system to use it.
2. The signal from the guidewire is AC. The
coils in each antenna assembly pick up the
guidewire signal. Each coil pair in the
antenna assembly sends the wire guidance
signal to the Filter Card.

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Toyota Orderpicker Service Manual Theory of Operation

Sequence of Operation (Wire Guidance)

3. The amplitude out of each coil depends on

several factors:
How far the coil is from the wire
The amplitude of the current in the wire
The frequency of the signal in the wire
The angle between the wire and the coil
The center coil pair (near wire) on each antenna
is used to determine wire signal strength.
4. The signals from the antennas are filtered
by the Filter Card. The Filter Card converts
these AC signals into 6 DC signals. These
signals are amplified and sent to the Steer
Controller a s a steering request to
determine the distance from the guidewire
and the heading angle. Steering requests
are updated and sent to the Steer
Controller every 10 ms.
5. A steering request from the Filter Card is
processed and executed in the same
manner as a normal steering request.

Calibrate Mode For Wire Guidance

The purpose for calibrating wire guidance is to
program the Steer Controller, tune the Filter
Card, and adjust the gain on the antenna
assemblies. This allows these components to
"learn" the wire frequency and amplitude.

Learn Wire Guidance Offset

Learning the wire guidance offset allows the
Steer Controller to determine the location of the
truck in relation to the guidewire.

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Theory of Operation Toyota Orderpicker Service Manual

Sequence of Operation (Wire Guidance)

0070-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Appendix

Appendix

00700-CL221 Issued: 9/10/98

Appendix Toyota Orderpicker Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart

Approved Toyota Lubricants

Toyota Part
Where Used 'IPPe Approved Manufacturer
Number
Drive Unit Gear Gear Forsythe Ltd. 00590-04834-7 1
Case (above Lubricant (1 quart/0.9 liter)
30" F) Shell Spirax HD
00590-04838-7 1
(5 gal./ 18.9 liters)
Drive Unit Gear Oil Chevron Delco 400 15W-40 API Service 00590-04835-7 1
Case (below SE (1 quart/0.9 liter)
30" F) (below - Citgo C-6 10W-30 Motor Oil MIL-H- 00590-04837-71
lo C) 46152 (5 gal./18.9 liters)
Lift Chains Exxon Extra Motor Oil 10W-30 API
Service S E
Gulflube Motor Oil X.H.D. 1OW-30
Mobil Delvac Special 10W-30 API
Service SE
Phillips Trop-Arctic All Season Motor Oil
10W-40 MIL-L-46152
Shell Rotella T 15W-40 API Service SE,
CC and CD
Sohio Multron LOW-30 MIL-L-46152
API Service SE
Texaco URSATEX 10W-30 2 166
Hydraulic Hydraulic Chevron AW IS0 4 6 005900-04934-71 (2
Reservoir Fluid Citgo 4 6 gal./7.6 liters)
(non-cold Exxon Nuto H 46 00590-04840-71
storage Forsythe AWTH21 5 IS046 (5 gal./18.9 liters)
trucks) Mobil DTE-1 B
NOCO NOCOLUBE AW46
Texaco Cygnus 46 or HD 46
Ultrarnar Ultra Hydraulik AW46
1 Hydraulic Hydraulic Exxon Univis 5 1 3 (similar to MIL-H- 00590-0484 1-71
Reservoir Fluid 5606A) (1 gal. /3.785 liters)
(cold storage Mobil Aero HFA
trucks) (+40° Texaco Aircraft Hydraulic Fluid 1 5
F to -20" F) (4"
C to -29" C)
Figure 9-1: Lubrication Equivalency Chari

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Toyota Orderpicker Service Manual Appendix

Lubrication Equivalency Chart

Approved Toyota Lubricants

Toyota Part
Where Used I'ype Approved Manufacturer
Number
Hydraulic Hydraulic NOCO NOC 1866 00590-04842-7 1
Reservoir Fluid Shell Tellus T Oil 32 (1 gal./3.785 liters)
(cold storage Texaco HD AZ 32 1627 Rando or 00590-04843-7 1
trucks) (20"F Cygnus 32 (5 gal./ 18.9 liters)
to 70" F) (-6"C
to 21" C)
Hydraulic Hydraulic Chevron AW-MV 00590-04842-7 1
Reservoir (for Muid Mobil423 or 424 (1 gal. /3.785 liters)
extreme NOCO Torque TDH
heating
conditions)
Bearings Grease Chevron Avi-Motive Grease 00590-04844-71 (10
Citgo HEP2 (above 30" F only) cartridges per case)
Exxon RONEX MP or UNIREX N2 00590-04845-7 1
Gulf Gulfcrown Grease No. 2 (5 gal. / 18.9 liters)
Mobil Grease 77
Phillips Philube 1B and RB Grease
Shell Alvania Grease EP2
Sohio Bearing Guard "LT"
Texaco Regal AFB 2 Grease MIL-G-
18709A
Figure 9-1 : Lubrication Equivalency Chart

00700-CL221 Issued: 9/10/98

Appendix Toyota Orderpicker Service Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)
Grade I
Identification None
\I/
/ \ 'I\
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
I Size
Dry Oiled* Dry Oiled* DT Oiled*
in. lbs. in. lbs. in. lbs. in. lbs. in. lbs. in. lbs.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 I 10 I 8 I 16 I 12 I 23 I 17 I

ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
5/16-18 11 8 17 13 25 18
5/ 16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35

Figure 9-2: Torque Chart - Standard

* NOTE: Use ''oiled" values for bolts with thread locking compound

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Toyota Orderpicker Service Manual Appendix

Torque Chart - Standard (Brass)

Grade I \I/
Identification None / \
Marking 'I'
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size Oiled*
Dry Oiled* Dry Oiled* Dr~r
in. lbs. in. lbs. in. Ibs. in. lbs. in. lbs. in. lbs.
1 1/2-6 740 560 1940 1460 3160 2360
I
1 1/2-12 840 620 2200 1640 3560 2660
Figure 9-2: Torque Chart- Standard
" NOTE: Use "oiled" values for bolts with thread locking compound

Torque Chart - Standard

(Brass)

Brass MS63 Standard Bolts, Coarse Thread

Torque (with bolts oiled*)
Size
Newton-meters Inch-pounds
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/ 16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147
Figure 9-3: Torque Chart - Standard Brass
* NOTE: Use "oiled" values for bolts with thread locking compound

00700-CL22 1 Issued: 9/10/98

Appendix Toyota Orderpicker Service Manual

Torque Chart - Metric

Torque Chart Metric -
Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.6 6 12 9
8 21 15 29 21
10 42 30 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Figure 9-4: Torque Chart - Ferrous Metric
* NOTE: Use "oiled" values for bolts with thread locking compound

1I Brass MS63 Metric Bolts, Coarse Thread

I/
I/ Diameter
Torque (with bolts oiled*)
II
I (in millimeters)
1 Newton-meters 1 Inch-pounds 1

10 17 150
Figure 9-5: Torque Chart - Brass Metric
* NOTE: Use ''oiled values for bolts with thread locking compound

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Toyota Orderpicker Service Manual Appendix

Decimal Equivalent Chart

Decimal Equivalent Chart

Figure 9-6: Decimal Equivalent Chart

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Appendix Toyota Orderpicker Service Manual

Decimal Equivalent Chart

Figure 9-6: Decimal Equivalent Chart

00700-CL22 1 Issued: 9/10/98

Toyota Orderpicker Service Manual Appendix

StandardlMetric Conversions

Standard/Metric Conversions

To Convert... ...
Multiply I
Inches to Millimeters Inches x 25.4
Millimeters to Inches
Inches to Centimeters
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
Miles to Kilometers
Kilometers to Miles

Square Inches to Square Centimeters 1 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 I

Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

1 Ounces to grams Ounces x 28.35 1

Grams to ounces Ounces x 0.035

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Appendix Toyota Orderpicker Service Manual
-- - -

StandardlMetric Conversions

To Convert... ..
Multiply.
Ounces to kilograms Ounces x 0.028
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 Pounds per Square Inch x 6.894
(Wa)
Kilopascals to Pounds per Square Inch Kilopascals x 0.145
Pounds per Square Inch (PSI) to Kilograms per Pounds per Square Inch (PSI)x 0.0704
square centimeter (kg/cm2)

Kilograms per square centimeter (kg/cm2) to Kilograms per square centimeter (kg/cm2)x
Pounds per Square Inch (PSI) 14.2

Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
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 Kilometers per hour x 1.609
Kilometers per hour to miles per hour Miles per hour x 0.62 14

Fahrenheit to Celsius (OF - 32) x 0.555

Celsius to Fahrenheit ("C x 1.8) + 32

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Toyota Orderpicker Service Manual Appendix

Electrical Schematic

Electrical Schematic

(Startson following page.)

00700-CL22 1 Revised: 2/15/00

Appendix Toyota Orderpicker Service Manual

Electrical Schematic

- lppl HDS
-JPS3 K
I
STEERING
ENCODER
// .3 << rl2W

-9 5
LIFTAMR >> I

<< UDREi
I
//
-I /
(
, +5VENC UmRY >)
J
d
-10 /
\< umRv
DGND )) , , 'I' (( CGND

WRES
OMR
MAST

A I B 1 C I D @
Figure 9-7: Electrical Schematic (sheet 1 of 3)

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Appendix
-

Electrical Schematic

1 p c ? r------------- 1
CARRLAGE I/F
CONlROL I
WVlN >> -0 HANDLE
I
m O N N
I
I
I I W/POWER HOOKUP
V REF

Urn IN OPERATORS
UGHl h FAN
UFT RETURN
I I
HORN.
I I
I I
HORN. I

I
1 7512.3
UtHl h FAN
I

JK3

& W EDUMP
BRAKE C ~ L\\
4
,
r-------------1
OPTIONAL
II W/O POWER HOOKUP II

OPERATORS
UGHlh FAN
I JX-2 I
I I
I I
I I

OPERATORS
UGH1h FAN

I OPTIONAL
I TRACTOR COMPARTMENT HEATERS

WIRES
OVER
MAS1

I
$. E I F I G I H
Electrical Schematic (sheet 1 of 3 Cont.)
9

00700-CL22 1 Revised: 2/15/00

Appendix Toyota Orderpicker Service Manual

Electrical Schematic

W E S OVER MAST

........................
WIRE GUIDANCE (OFTON)

7
// STEER
\\ '2 MOTOR
/

A 1 B I C I D
Figure 9-8: Electrical Schematic (2 of 3)

9-1 4 00700-CL22 1 Revised: 2/15/00

Toyota Orderpicker Service Manual Appendix

Electrical Schematic

WRES OVER MAST

TRACTOR I
I/F

BUS

+l+ E I F
Electrical Schematic (2 ot 3 Cont.)

00700-CL22 1 Revised: 2/15/00

 Appendix Toyota Orderpicker Service Manual

Electrical Schematic
-
- IDEM.
D M
SHER
2
DESCRlPllON
TRACTION DPNE MOTOR
D M 2 u n MOTOR
DMS 2 STEER MOTOR
DT 2 DRNE MOTOR TEhVERANRE SENSOR

ENC l 1 STEERIM ENCODER

ENCZ 2 DUNE W I T POSITION ENCODER

F1 2 POWER FUSE FO# STEER CCNTROUBI. 70A

F2 2 POWER FUSE FO# TRACTION POWER AMP. 350A
F3 2 POWER FUSE m u n POWER AMP, ASDA
F4 2 CONTROL KlSE FOR TRACTOR W. &F, ISA
FS 2 CONTROL FUSE F OR TRACTORIff.&PC. ISA
8 F6 2 G R W N D FUSE K>R TRACTOR I/F, BF,DGND. 1SA
n 2 COMROi FUSE FOR TRACTOR I/F, M1&. 6A
1
i FB 2 G R W N D FUSE FOR TRACTOR I/F, EXl b. 6A
w 2 STROBE FUSE
F2D I CONTRM FUSEHEATERIN TRACTOR COMPARTMEM-ISA(0PT)

H1 HORN
HZ SONALERT
H3 BACKUP ALARM

HDI CAN BUS CONNKTOR O N DISPLAY CARD

HD2 OVERLAY CONNECTOR ON DISGY CARD
HD3 SONALERT CON.(ECTOR O N DISPLAY CARD
HDS STEERII*G ENCODER O N DISPLAY CARD
HW OVERLAY CONNECTOR O N DISPLAY CARD

HTRI CONTROL HANDLE HEATER IOPTJ

HTRZ TRACTOR COMPARTMEM nEATERIOPll
m 3 TRACTOR COMPARTMEM HEATERIOPTI

JLI LIFT POWER AMP CONNKTOR

JU UFI POWER AMP CAN CONNECTOR

JPI STEER CONTROLLER CARD CONNKTOR

JPZ STEER CONTROLLER CARD CONNECTOR
JP3 PRESSURE TRANSDUCER GROUND
JP4 STEER CONTROLLER CARD CONNKTOR
JPS STEER CONTROLLER OVERMST CONNECTOR
JP6 ENCZ CONNECTOR
JP7 SI S RAll SWITCH CONNECTOR
JPB HOME SWITCH CONNECTOR
JW SPI CONNECTOR
DID SP2 CONNECTOR

JPC l CARRIAGE I/FDISPLAY CONNKTOR

JPC2 CARRIAGE I/F COMROL hANDLE CONhlEClOR
JPCJ CARRIAGE l/F CONNECTOR
JPCA CARRIAGE I/F OVERWST CONNECTOR
JPCS CARRIAGE IVF EX? EATERY CONNECTOR
JPC7 CARRIAGE I/F 51 1. S12. SdS CONNECTOR
JPC8 CARRIAGE I/F M 1 CONNECTOR
JPCP CARRIAGE I/F 560 CONNKTOR

JRl 2
m 3 2
JRA 2
JPRS 2
JPR6 2 TRACTOR In 526 CONNECTOR
JPR7 2 TRACTOR l/r SI D CONNECTOR
JPRB 2 TRACTOR I/F 524 CONNECTOR
JPR9 2 TRACTOR 527 CONNECTOR
JPRlO 2 TRACTOR I/F UFT L T R A M POWER AMP CONNECTOR
JPRll 2 TRACTOR I/f CONNECTOl ,

JPS2 1 DISPLAY CARD SP1 CONNECTOR

JPSZ 2 STEER CONTIIOLER CONNECTOR

I 1;
IPS3

JPlL
JPIT
1

83
02
DISPLAY CARD CONNECTOR

CONNECTOR O N W G LOAD END ANTENNA

CONNECTOR O N W G TRACTOR END ANTENNA

JPWl CONNECTOR O N FILTER CARD

JPWZ CONNECTOR O N FILTER CARD

JPM TRACTION MOTOR THERMISTOR CONNECTM

JPPI STEERING ENCODER (ENCII CONNECTOR
JPZ LIFT MOTOR THERMISTOR CONNECTOR

JS 1 STEER COMROLLER CWNECTOR

nl TRACTW POWER AMP CONNECTOR

JTZ TRACTDN POWER AMP CAN CONNECTOR

LB UFT BRUSH WEAR CONNECTM

LT UFT MOTOR TEMPERATLIRESENSOR (OPT)

MM POWER DISCONNECT COMACTOR

PRESS PRESSURE TRANSDUCER

PROX HOME SWlTCH PROX. SENSOR

PRESSURE TRANSDUCER CONNECTOR

00700-CL221 Revised: 2/15/00

Toyota Orderpicker Service Manual Appendix

Hydraulic Schematic

Hydraulic Schematic
(Startson following page.)

00700-CL22 1 Issued: 9/10/98

Appendix Toyota Orderpicker Service Manual

Hydraulic Schematic

FILTER

FILTER 1
-j
I I

CTR.
cn

&+; I
LIFT
PUMP

p fiiz-
-,
$'
,7-= - : -,;
L =:,:--lELZ 5c"-
,",,-,.
,J

-- --
J sj;bz5z
,F>T,,y-'?
G l ! -,
. . FI7ESSURE
3 STAGE ,
8 -, TRANSWCM I 180 PSI

Figure 9-9: Hydraulic Schematic

00700-CL22 1 Issued: 9/10/98

Toyota orderpicker Service Manual Index

lndex

Adjustment and Repair . . . . . . . . . . 7-17 Decimal Equivalent Chart . . . . . . . . . 9-7

Bleeding Side Lift Cylinders . . . 7-45 Drive Unit . . . . . . . . . . . . . . . . . . . . . . 3-17
Brake
Adjustment . . . . . . . . . . . . . . . 7-30
. Assembly Removal . . . . . . . . 7-33
Bleeding . . . . . . . . . . . . . . . . . 7-34
Inspection . . . . . . . . . . . . . . . . 7-30 Electric Motor
Master Cylinder Replacement 7-32 Tests . . . . . . . . . . . . . . . . . . . . . . . 5-12
Center Lift Cylinder (3-Stage) Grounded Motor . . . . . . . . . . 5-13
Reassembly . . . . . . . . . . . . . . 7-42 Open Circuit . . . . . . . . . . . . . 5-12
Removal . . . . . . . . . . . . . . . . . 7-40 Short Circuit Armature or Field
Service . . . . . . . . . . . . . . . . . . . 7-41 Winding . . . . . . . . . . . . . . . . 5-13
Deadman Switch Adjustment . . 7-36 '&pes . . . . . . . . . . . . . . . . . . . . . . . 5-12
Drive Electrical
Motor Removal . . . . . . . . . . . . 7-27 Codes and Tests . . . . . . . . . . . . . . 6-1
Tire Replacement . . . . . . . . . 7-26 Disabling Brush Wear Warning 6-7
High Pressure Relief Valve Starting the Hour Meter . . . . 6-8
Adjustment . . . . . . . . . . . . . . . . 7-43 Components and Systems . . . . . 3-24
Lift/Lower Manifold Service . . . 7-44 Traction Motor . . . . . . . . . . . . 3-25
Lift/Lower System . . . . . . . . . . . . 7-37 Connector Locator Chart . . . . . . . 5-4
Potentiometer Removal (VR1) . . 7-48 Functions . . . . . . . . . . . . . . . . . . . . 8-2
Power Section . . . . . . . . . . . . . . . 7-17 Schematic . . . . . . . . . . . . . . . . . . . 9-11
Skid Pad Replacement . . . . . . . . 7-28 Troubleshooting Guidelines . . . . 5-2
Electrostatic Discharge Damage . . 7-11
Electrostatic Sensitive Devices
Proper Handling . . . . . . . . . . . . . 7-12
Emergency
Battery Cleaning Procedure . . . . . . 4-15 Lowering Valve . . . . . . . . . . . . . . . 3-23
Battery Inspection and Care . . . . . . 4-15 Stop Switch . . . . . . . . . . . . . . . . . 3-10
Brake Assembly . . . . . . . . . . . . . . . . . 3-17 End Cap Pulley Assembly . . . . . . . . 7-60
Error analysis mode (AnL) . . . . . . . . 6-11

Cables . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Calibrate (Calibrte) Mode . . . . . . . . . 6-16 Fuses. Miscellaneous Circuits . . . . 3-40
Carriage/Tractor Interface Cards . 3-30
Charging Process . . . . . . . . . . . . . . . 4-16
Code Summary . . . . . . . . . . . . . . . . . 6-22
Compartment Dimensions . . . . . . . . 3-9
Component Locator Photos . . . . . . . . 7-2 Hydraulic
Conversions. Standard/Metric . . . . . 9-9 Components . . . . . . . . . . . . . . . . . 3-21

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index Toyota Orderpicker Service Manual

Problems . . . . . . . . . . . . . . . . . . . . 5-23 Planned Maintenance Schedule .4.3. 4.9

Schematic . . . . . . . . . . . . . . . . . . . 9-17
Troubleshooting Guidelines . . . 5-15 S

Safety
Battery . . . . . . . . . . . . . . . . . . . . . . 2-6
Lift Truck Error Codes . . . . . . . . . . . 6-43 General . . . . . . . . . . . . . . . . . . . . . . 2-3
Lift/Lower System . . . . . . . . . . . . . . . 3-21 Jacking . . . . . . . . . . . . . . . . . . . . . 2-13
Lubrication Chart . . . . . . . . . . . . . . . . 9-2 Static . . . . . . . . . . . . . . . . . . . . . . . 2-11
Static electricity . . . . . . . . . . . . . . 2-11
Tie-down for Transport . . . . . . . 2-14
Towing . . . . . . . . . . . . . . . . . . . . . . 2-14
Welding . . . . . . . . . . . . . . . . . . . . . 2-15
Maintenance Self-diagnosis Mode . . . . . . . . . . . . . . 6-9
General Instructions . . . . . . . . . . 7-7 Service Notes
Practices . . . . . . . . . . . . . . . . . . . . . 7-7 Elevating System . . . . . . . . . . . . . 7-55
Welding Procedures . . . . . . . . . . 7-10 Steering Control Assembly . . . . 7-66
Mast Shorts to Frame Test . . . . . . . . . . . . . 5-4
Assembly . . . . . . . . . . . . . . . . . . . 3-19 Standard to Metric Conversions . . . . 9-9
Shimming . . . . . . . . . . . . . . . . . . . 7-61 Steer Controller Guidance . . . .3.13. 3.33
Modes of Operation . . . . . . . . . . . . . . . 6-3 Codes and Tests . . . . . . . . . . . . . 6-99
Configure (Configur) . . . . . . . . . . 6-20 Steer Controller Guidance System
Operation Analog Input Tests . . . . . . . . . . 6-149
Self-diagnosis . . . . . . . . . . . . . . 6-3 Digital Input Tests . . . . . . . . . . 6-173
Overview System Specifications . . . . . . . . . . . . 3-5
Analyzer (AnL) . . . . . . . . . . . . . 6-3 Chassis Description . . . . . . . . . . . 3-6
Calibrate (Calibrte) . . . . . . . . . 6-3
Configure (Configur)Mode . . 6-3
Tuning . . . . . . . . . . . . . . . . . . . . 6-3

Tests
Analog List of . . . . . . . . . . . . . . . . 6-29
Theory of Operation
Navigating this Manual . . . . . . . . . . . 1-2 Braking System . . . . . . . . . . . . . . . 8-6
BUS+/BUS- . . . . . . . . . . . . . . . . . 8-10
Electric Steering . . . . . . . . . .8.9. 8-11
Electrical Functions . . . . . . . . . . . 8-2
Indicators and Switches . . . . . . . 8-8
Operator Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Compartment Options . . . . . . . . 3-11 Lift/Lower System . . . . . . . . . . . . . 8-3
Console . . . . . . . . . . . . . . . . . . . . . . 3-9 Lower . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Display . . . . . . . . . . . . . . . . . . . . . 3-10 Operating Description Overview . 8-2
Overhead guard . . . . . . . . . . . . . . . . . . 3-9 Proportional Plugging . . . . . . . . . . 8-6
Steering Communications . . . . . 8-10
Steering System . . . . . . . . . . . . . . 8-6
Wire Guidance . . . . . . . . . . . . . . . 8-16
Passwords . . . . . . . . . . . . . . . . . . . . . . . 6-6

Issued: 9/10/98
Toyota Orderpicker Service Manual Index

Torque Chart
Metric . . . . . . . . . . . . . . . . . . . . . . . 9-6
Standard . . . . . . . . . . . . . . . . . . . . . 9-3
Troubleshooting Charts
List of . . . . . . . . . . . . . . . . . . . . . . 5-25
Truck Lubrication Points . . . . . . . . . . 4-4
Tuning Mode . . . . . . . . . . . . . . . . . . . 6-13

Wire Guidance
Calibrate Mode . . . . . . . . . . . . . . 8-23
Sequence of Operation . . . . . . . . 8-22
Truck Installed Equipment . . . . 8-16
Warehouse Installed Equipment 8-16

00700-CL221 Issued: 9/10/98

 Control Circuit
CC13-006
August 15, 2013
Software Change for Brake Pedal
Operation
SERVICE INFORMATION BULLETIN 8B(D)RU18-23, 7BNCU15-20, 6PBU15

Subject: Software Change for Brake Pedal Operation Page 1 of 1

MODEL APPLICATION:
8BRU18, 8BRU23 and 8BDRU15 Reach Trucks: Serial Number 37140 and above for 36 volt trucks
and 25222 and above for 24 volt trucks.

6BPU15 Orderpickers: Serial number 72677 and above.

7BNCU15, 7BNCU18, 7BNCU20 Stand-up Riders: Serial Number 51212 and above.

GENERAL INFORMATION:
Due to recent changes in the ANSI B56.1 Safety Standards, the new software in the forklifts no
longer allow lift/lower and auxiliary functions without depressing the deadman pedal.

REPAIR INFORMATION:
Reach trucks with the software version 1.6 and later will no longer allow lift/lower and auxiliary
functions when only the right foot pedal switch is depressed. The right foot switch, S7, is still installed
on the truck and ESY Test 27 is still active. The deadman pedal, or left foot switch must be depressed
for the lift/lower and auxiliary functions to work.

Orderpickers with software version 2.2 and later will no longer allow lift/lower without depressing the
deadman pedal.

Stand-up Riders with software version 3.2 and higher will no longer allow lift/lower and auxiliary
functions when the deadman pedal is not depressed. The feature that allows 30 seconds of
lift/lower/auxiliary and attachment option after releasing the deadman pedal has been removed. Tilt
and sideshift also require the control handle to be returned to neutral to re-enable the function after
releasing the deadman pedal.
 Control Circuit
CC16-006
September 30, 2016
Wire Guidance Tone
SERVICE INFORMATION BULLETIN 6BPU15
6BPU15
Subject: Wire Guidance Tone Page 1 of 1

MODEL APPLICATION:
6BPU15

GENERAL INFORMATION:
Software version 2.3 does not produce the same wire guidance tone that previous software versions
used. Software version 2.3 will not produce a tone when actively seeking the guidance wire. The use
of software version 2.2 can be installed in place of software version 2.3 if a tone is desired when the
lift truck is actively seeking the guidance wire.

REPAIR INFORMATION:
Remove software version 2.3 from your lift truck and replace it with software version 2.2, part number
00590-51042-71.
 Chassis Electrical
CE17-006
August 31, 2017
Switch Replacement
SERVICE INFORMATION BULLETIN 6BPU15, 7BPUE15

Subject: Switch Replacement Page 1 of 3

MODEL APPLICATION:
6BPU15 and 7BPUE15

GENERAL INFORMATION:
Switch part number 00590-02995-71 (used in multiple applications) is no longer available. If the switch
is installed in a housing as shown in Figure 1, order Kit part number 00590-56871-71 which includes a
replacement switch and the parts required for a field retrofit.

Figure 1

REPAIR INFORMATION:
Order Kit part number 00590-56871-71 and install using the following instructions.

Item Part Number Description Qty.

1 00590-56554-71 Limit Switch 1
2 00590-56872-71 *Adapter Harness 1
3 00590-00811-71 Ty-Wrap 4
4 00590-47047-71 *Shrink Tubing 3
*May not be required – see below

Identify the type of connector that is connected to the old switch. Type A connectors (on truck
harness side) require the supplied harness (item 2). Type B connectors (on the truck harness side)
plug directly into the new switch (item 1).

Type A Type B
Subject: Switch Replacement Page 2 of 3
.
Installation Instructions
1. Remove the connector from the switch assembly.
2. Remove and discard the old switch/housing assembly. See Figure 1.
3. Install new switch assembly (item 1). See Figure 2.

Figure 2

4. For connector Type A, perform Steps 4.a through 4.d. For connector Type B, proceed to
Step 5.
a. Connect adapter harness (item 2) connector PX to the connector that was originally
plugged into the old switch. See Figure 3.

Figure 3

b. Secure the truck harness to the adapter harness. Use the notches to hold the ty-wrap
(item 3) in place. See Figure 4.

Figure 4

c. Slide the shrink tubing (item 4) over the connectors. See Figure 5.

Figure 5
Subject: Switch Replacement Page 3 of 3

d. Heat the shrink tubing until it is tight over the connection. See Figure 6.

Figure 6

5. Connect the harness to the new switch. See Figure 7.

Figure 7

6. Make sure the harness is secure and does not interfere with any moving parts.
7. Test the operation of the new switch.