PRODUCT MANUAL OPERATOR S MANUAL VEHICLE SPEED CONTROL SYSTEM TOYOTA SPECIAL DESIGN

Transcription

1 PRODUCT MANUAL OPERATOR S MANUAL TOYOTA SPECIAL DESIGN VEHICLE SPEED CONTROL SYSTEM

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3 WARNING This manual describes how to handle the Vehicle Speed Control System. For other features, refer to Operator s Manuals separately issued for each model. Make sure these important instructions are available for the operator. Keep this manual in the pocket on the seat back. Do not start the truck unless you understand these instructions.

4 rtable of Contents Before You Begin... 1 Know Your Truck... 1 Product Information... 2 Vehicle Speed Control... 2 Product Compatibility... 2 Description... 2 Key Components... 2 Speed Controller... 3 Operation Instructions... 3 Basic Operations... 3 Troubleshooting... 4 Basic Troubleshooting... 4 Error Codes... 4 Viewing Error Codes... 4 List of Symptoms... 6 Troubleshooting Steps... 8 Parts Layout Drawing Schematic Pin Diagram (Controller Connectors) Parts & Service Toyota Genuine Parts Your Best Overall Value Ensuring You Get What You Need Value of Toyota Genuine Parts Service Parts Catalog General Information Illustration & Part Name Code Text Page Composition Data Plate & Serial Numbers

5 Before You Begin Know Your Truck Read this entire operator s manual along with your truck s operator s manual, especially the safety information, before operating. This manual is an important part of your truck. Keep all manuals in a convenient location, such as the pocket on the back of the operator s seat, so they can be accessed easily. Use the safety and operating information in the product operator s manual, along with the truck operator s manual, to operate and service the product safely and correctly. If you have any questions or concerns with the operation and service of this product, contact your local Toyota dealer. Safety Understanding the Safety Labels If your truck has any additional safety labels other than the standard safety labels found on the truck, they would be found in this section. Safety Labels are placed in important areas on your truck to draw attention to potential safety hazards. On the safety labels, the words DANGER, WARNING, and CAUTION are used on this safety alert symbol. DANGER identifies the most serious hazards. The operator s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word, CAUTION, and the safety-alert symbol. Operate Truck Safely Read, understand and follow all instructions in this product manual, the truck operator s manual and safety signs on equipment before starting. Do not let anyone ride on the truck other than the operator unless truck is equipped with an authorized passenger seat. Additional riders are subject to injury such as being struck by foreign objects or being thrown off. Riders may also obstruct the operator s view and cause a collision. Read the general safety operating precautions in your product operator s manual and your truck operator s manual for additional safety information. 2

6 Product Information Vehicle Speed Control Product Compatibility The Vehicle Speed Control System is available as a Toyota Special (TS) option for Toyota s 2TDU25 diesel tow tractors. Description The Vehicle Speed Control System limits the top speed an operator can travel to a value of 10 mph. This allows operators to always stay within the confines of the facility s speed limits without having to look down at a speedometer. The speed control is accomplished by converting the throttle control to a drive by wire setup. Instead of the operator directly controlling the throttle to the engine an electric signal is read from a sensor mounted to the accelerator pedal. This is called the Accelerator Pedal Position Sensor (APPS). This signal is then read by a central controller and converted to drive a motor that actuates the throttle cable. The speed is also fed to the central controller by means of a sensor mounted to the transmission. When the top speed is reached then the motor will not pull on the cable any further thus limiting the speed. Note that with this method of electronically limiting the speed your acceleration and torque will not be affected. There are other safety features that can be incorporated into the system since we now have an electronically controlled throttle. If an operator leaves the seat the throttle will go back to idle. Also, if an operator presses the brake pedal then the throttle will go back to idle. This will keep operators from power braking or applying both the brake and accelerator at the same time. Key Components Below is a diagram and description of the overall input-output of the speed control system and its key components. Accelerator Pedal Position Sensor (APPS) converts the pedal position to a voltage that is fed to the controller. Vehicle Speed Sensor (VSS) converts the speed of travel to a series of pulses which pulses are fed to the controller where it interprets them into actual speed of travel. Speed Controller is the central controller that reads all of the inputs and sends out to the motor to accelerator or decelerator. Error Indicator (red LED) flashes if there is an error in the system and further diagnosis will have to be made. It also the System Reset Switch. System Reset Switch upon pressing usually after an error is indicated, the system will recalibrate the APPS and motor. Mainly meant to be used when components may be replaced or for diagnostics/troubleshooting. Stepper Motor actuates the throttle cable, and is controlled by the Speed Controller. Zero Position Switch allows the motor to always know where zero throttle (idle) is located. 3

7 Speed Controller The heart of the Vehicle Speed Control system is the Speed Controller. Toyota has chosen Applied Motion s ST10-Q for its robust features such as Stand-alone Operation, Multitasking functions, Third-party HMI compatibility, and ST Configurator software for setup. For a complete detailed list of specifications please refer to Applied Motion s ST Hardware Manual. Grounding screw is a green screw (on side, not shown) Screw terminal connector for the motor & power supply DB-25 connector for digital inputs & outputs and analog inputs LED s for status & error codes (top: green, bottom: red) RJ11 connector for RS-232 port Operation Instructions Basic Operations For complete operation instructions, refer to the user s manuals for the products received with your truck. Any set up operations or adjustments should only be performed by authorized personnel. 4

8 TROUBLESHOOTING Basic Troubleshooting Listed in this section are some common troubleshooting issues that the operator may encounter. These troubleshooting steps are applicable to the Speed limiting option only. For a complete list of troubleshooting solutions, refer to the user's manual for the product. If after following the troubleshooting steps provided in this manual, there are still problems or questions, please contact Toyota's FedEx helpline at Error Codes In the event of an error, the red LED indicator on top of the stepper motor cover will flash. This is telling you that the speed controller needs your attention. Look at the speed controller, and if red and green LED's on the main board are flashing in alternating red-green patterns, then refer to the following information for the corresponding error. Viewing Error Codes To view the error codes, you must remove the metal cover in order to see the control unit for the speed control system. Follow these steps to see the error codes: 1. Locate the Control unit cover. It is located on the passenger side of the operator compartment on the right hand side of Glove Compartment. 2. Remove the two bolts holding the cover in place. 3. The control unit should now be visible including the red and green lights used to indicate an error condition. CONTROLLER COVER 5

9 TROUBLESHOOTING = Red = Green Code Error solid green no alarm, motor disabled Contact Service rapid flashing green no alarm, motor enabled Normal operation 1 red, 1 green motor stall (optional encoder only) N/A 1 red, 2 green move attempted while drive disabled See T4 (page 7) 1 red, 3 green subroutine stack overflow (Si only) N/A 2 red, 1 green ccw limit N/A 2 red, 2 green cw limit N/A 2 red, 3 green subroutine stack underflow (Si only) N/A 3 red, 1 green drive overheating Contact Service 3 red, 2 green internal voltage out of range See T5 (page 7) 3 red, 3 green blank Q segment Contact Service 4 red, 1 green power supply overvoltage Contact Service 4 red, 2 green power supply undervoltage See T6 (page 7) 4 red, 3 green bad instruction in Si program N/A 5 red, 1 green over current / short circuit Contact Service 5 red, 2 green motor resistance out of range Contact Service 6 red, 1 green open motor winding See T7 (page 7) 6 red, 2 green bad encoder signal (optional encoder only) N/A 7 red, 1 green serial communication error N/A 7 red, 2 green flash memory error Contact Service 8 red, 1 green internal voltage out of range See T5 (page 7) 6

10 TROUBLESHOOTING List of symptoms NOTE: Evaluate the "Items to check" in the order they are listed in the following tables. T1: No throttle Inspect the speed control system controller to determine exact error condition. See page 5 for instructions on viewing lights on controller. Error condition Item to check How to check Fuse (See Page 10 for Fuse Check) No throttle, no lights DC converter (See Page 11 for DC Converter Check) Controller Replace controller Potentiometer (See Page 8 for Poteniometer Calibration) Cable (See Page 9 for Cable Check) No throttle, normal lights Brake switch (See Page 15 for Brake Switch Check) Accel pedal sensor (See Page 12 for Accelerator Pedal Sensor Check) Stepper motor (See Page 14 for Stepper Motor Check) Controller Replace controller No throttle, error lights See page 4 for details on error codes T2: No speed limitation Error condition Item to check How to check Speed sensor (See Page 13 for Speed Sensor Check) No speed limitation controller Replace controller T3: Abnormal noise Error condition Item to check How to check Cable (See Page 9 for Cable Check) Abnormal noise stepper motor (See Page 14 for Stepper Motor Check) controller Replace controller 7

11 TROUBLESHOOTING List of symptoms NOTE: Evaluate the "Items to check" in the order they are listed in the following tables. T4: "Move attempted while drive disabled" Error condition Item to check How to check 1 red, 2 green Controller Replace controller T5: "Internal voltage out of range" Error condition Item to check How to check Fuse (See Page 10 for Fuse Check) 3 red, 2 green DC converter (See Page 11 for DC Converter Check) Controller Replace controller T6: "Power supply undervoltage" Error condition Item to check How to check Fuse (See Page 10 for Fuse Check) 4 red, 2 green DC converter (See Page 11 for DC Converter Check) Controller Replace controller T7: "Open motor winding" Error condition Item to check How to check Stepper motor (See Page 14 for Stepper Motor Check) 6 red, 1 green Controller Replace controller 8

12 TROUBLESHOOTING < Potentiometer Calibration > If problems occur with the tractor or if a new controller has been installed, it may be necessary to re-calibrate the throttle potentiometer. Please note that the process to calibrate the potentiometer will require two people. To start the calibration process, locate the red calibration button located on top of the stepper motor bracket. See figure below. 1. Have one person press and hold this button while the second person starts the engine. Continue holding the button for at least 2 seconds after the headlights turn on. 2. Release the button. The engine should remain running. 3. After the button is released, the person in the cab should press down on the accelerator pedal until it reaches the floor, then release. Repeat this process with the accelerator pedal at least 3 times. NOTE: There will not be any engine acceleration for approximately 20 seconds during this calibration. The engine should start reacting to the accelerator pedal once the controller programming is complete. Once this occurs, the calibration is complete. If after completing this process, the problem still persists, return to pages 6-7 for next component to check. 9

13 TROUBLESHOOTING < Check Cable > 1. It is important to check the tension on the cable between the dc motor and the injection pump throttle lever. Locate the cable and check for excessive slack. If slack is found, continue. OK NG No slack found, return to pages 6-7 for next component to check. 2. Locate each end of the cable (as shown below). Inspect for loose/damaged connections. OK NG Tighten/Replace as needed. 3. Locate cable mounting points as shown in illustrations below. Bolt may be obscured by the position of the cable. Inspect to determine if bolt is loose or missing. Center Mounting bolt on bottom of this band. If no problem found, return to pages 6-7 for next component to check. NG Tighten/Replace as needed. 10

14 TROUBLESHOOTING < Check Fuse > 1. Locate 15A fuse in engine compartment. 2. Check for blown fuse. 3. Replace if necessary. If no problem is found, return to pages 6-7 for next component to check. 11

15 TROUBLESHOOTING < Check DC Converter > 1. When checking the DC converter, have the engine running. Check input voltage to DC converter: 12 Vdc between Red and Black NOTE: After disconnecting the wires to check voltage, inspect for dirt, corrosion etc. Clean wire connections before re-attaching. OK 2. When checking the DC converter, have the engine running. Check output voltage of DC converter: 24 Vdc between Yellow and Black NOTE: After disconnecting the wires to check voltage, inspect for dirt, corrosion etc. Clean wire connections before re-attaching. OK NG NG Make sure all connections are secure between the battery and DC converter. Replace DC converter 3. Check input voltage at the controller 24V Between black and yellow wires (Furthest from 25 pin connector) OK NG Issue with wire harness 4. Check to make sure wires are connected properly and that the screws are tight. OK If no problem found, return to pages 6-7 for next component to check. NG Tighten screws or change wire positions if incorrect. If all is correct, replace controller. 12

16 TROUBLESHOOTING < Check Accelerator Pedal Sensor> Locate connectors 16 and 17 (See Part Layout Drawing page 16) for additional information. These connectors will be useful for troubleshooting potential problems related to the accelerator pedal sensor. After locating the connectors, disconnect them and proceed with the following steps. 1) Measure the following on connector 16: +5V between M1 and M3 or M4 Check continuity between #M1 on OK NG connector 16 and %AF on connector 1. If problem is found, replace wire harness. 2) Re-connect 16 and 17 and measure the following on connector 14: +5V between %F5 and %FE Check continuity between %M1 on OK NG connector 17 and %F5 on connector 14. If problem is found, replace wire harness. 3) Disconnect connector 16 and 17 and check the following on connector 17: > While pressing and releasing the accelerator pedal, you should notice a change in the resistance measured between %M2 and %M3 Continuity between %M2 on connector OK NG 17 and %FP on connector 14. If problem is found, replace wire harness. 4) Re-connect 16 and 17 and measure the following on connector 14: While pressing and releasing the accelerator pedal, you should notice a change in the resistance measured between %A1 and GND on connector 1. Continuity between %FP on connector 14 OK NG and %A1 on connector 1. If problem is found, replace wire harness. If no problem is found, return to pages 6-7 for next component to check Connector 16 #M1 - +5V #M2 - Signal #M3 - GND #M4 - GND Connector 17 %M1 - +5V %M2 - Signal %M3 - GND %M4 - GND Connector 1 %A1 - Signal %AF - +5V %AB - GND Connector 14 %FP - Signal %F5 - +5V %FE - GND 13

17 TROUBLESHOOTING < Check Speed Sensor > 1) Check for 12V between V1 and V2 on connector 12 (Speed sensor) Note: Wire harness connector located on bottom of engine. Please use care when accessing the bottom of the the tow tractor. %V1-12V %V2 - GND %V3 - Signal output OK NG Issue not related to speed control system. 2) Check for continuity between V3 on wire harness connector 12 (speed sensor) and AA on connector 1 (controller) Connector 12: Wire harness/speed control Connector 1: Wire harness controller connection %V3 - Signal output %AA- Speed sensor signal OK NG Wire harness issue If all checks out OK, replace the speed sensor. If problem still persists after replacing sensor, return to page 6-7 for next component to check. 14

18 TROUBLESHOOTING 1. Check resistance of stepper motor at motor connector. Should measure a resistance of about.2 ohms between the following pins on the stepper motor connector: Pins %M1 and %M2 Pins %M3 and %M4 An error condition would most likely be indicated by a reading a very large resistance value or 0 ohms. OK NG Replace stepper motor. 2. Check resistance of motor at controller end of wire harness. Should measure a resistance of about.2 ohms between the following pins on the stepper motor connector: %C1 and %C2 (Red and Yellow wires) %C3 and %C4 (Black and Orange wires) An error condition would most likely be indicated by a reading a very large resistance value or 0 ohms. Orange OK NG Replace stepper motor wire harness. 3. Check wire connections at the controller. Make sure screws are tight and wires are in the correct place. Red Yellow Orange Black OK If no problem found, return to pages 6-7 for next component to check. NG Tighten screws or change wire positions if incorrect. If all is correct, replace controller. 15

19 TROUBLESHOOTING < Check Brake Switch > 1. Measure voltage between pin %A4 of connector 1 (controller) and GND. Should measure 12V when brake pedal is engaged, 0V when not. OK Return to pages 6-7 for next component to check. NG 1. Check continuity between connector 13 (brake switch) and pin %A4 of connector 1 (controller). OK NG Wire harness issue 3. If the appropriate voltage is not measured at the controller and the wire harness checks out as good, the problem is with the brake switch itself. Connector 1: Wire harness controller connection A4 - Brake Switch 16

20 TROUBLESHOOTING < Parts Layout Drawing > For additional clarity, some engine components not shown Connector 16 and 17 Fuse Stepper motor Brake switch connector DC Converter Throttle cable - Speed. sensor -Viewed Accel sensor shown in yellow from underside of engine 17

21 TROUBLESHOOTING < Parts Locations > 18

22 TROUBLESHOOTING < Controller Connectors > Pin Signal Wire Connected to %A1 Accelerator Sensor Signal Yellow 24V - DC converter %A2 Reset Switch Black GND - DC converter %A3 Limit Switch Red %A4 Brake Switch Yellow Stepper motor wire %A5 OPS Relay Orange harness %A6 GND Black %A7 GND %A8 (AF) Accelerator Sensor +5V NOTE: Identification starts with wire on the left (furthest %A9 GND from 25 pin connector) %AA Speed Sensor Signal %AB GND %AC T/M Interlock %AD LP warning %AE GND %AF Accelerator Sensor +5V %AG GND All others No connect 19

23 Parts & Service Toyota Genuine Parts Your Best Overall Value Toyota's quality control system makes certain that every Toyota component is constructed to the same exacting tolerances and strict quality control standards as the part it replaces. In order to ascertain optimum performance and maximum trade-in value for your investment it is best to maintain your lift truck with Toyota Genuine Parts. Ensuring You Get What You Need Repeat business has stemmed from Toyota Industrial Equipment's reputation for product quality and parts availability. In order to offer you instant service, each dealer carries a full inventory of Toyota Genuine Parts, and they will help you get the parts you need for special option needs as well. Value of Toyota Genuine Parts All Toyota lift trucks are constructed with Toyota Genuine Parts and Accessories. To maintain the highest levels of safety and quality, any replacement part used on a Toyota lift truck should be a Toyota Genuine Part. Toyota parts have built a reputation for their high level of quality and durability. Remember, the best way to receive the highest level of performance out of your lift truck is to use the best parts. So don't be fooled by imitators. The only place to source Toyota Genuine Parts is an authorized Toyota Industrial Equipment dealer. Service Parts Catalog General Information This section includes the service parts specific to this Toyota Special (TS) option and has been prepared for the customers of Toyota Industrial Vehicles. Only the part name codes are shown instead of the part numbers. When ordering parts from your local Toyota dealer, please specify the complete model of the truck including the serial number, or specify the frame number (see Data Plate & Serial Numbers of this section). Also it is essential that you specify the part name codes described in the pages of illustrations and text. For the industrial vehicles with optional equipment, which is described in the lower part of the DESCRIPTION, it is imperative for you to specify optional equipment when ordering parts. Your Toyota dealer is furnished with enough information to decode the correct part numbers based on your information of model number, engine number or frame number as well as part name codes. 20

24 Illustration & Part Name Code Text Page Composition This section has been prepared similar to the user s Industrial Equipment Parts Catalog that is included with your truck. For a detailed explanation of the Illustration and part Name Code Text page Composition please refer to the Industrial Equipment Parts Catalog. Data Plate & Serial Numbers For retrieving the correct part numbers, it is crucial to know the complete model of the truck including the serial number, or know the frame number (see note below). This information can be found on the data plate on the truck or in the user s Industrial Equipment Parts catalog. If you do not know where to locate the data plate or frame number plate, refer to the user s Industrial Equipment Parts Catalog in the Data & Serial Numbers section. Note: The frame number is a combination of the truck model plus the 5-digit serial number. i.e. 8FGU Both the truck model and the serial number are found on the data plate. 21

25 Service Parts Catalog General Information This section includes the service parts specific to this Toyota Special (TS) option and has been prepared for the customers of Toyota Industrial Vehicles. Only the part name codes are shown instead of the part numbers. When ordering parts from your local Toyota dealer, please specify the complete model of the truck including the serial number, or specify the frame number (see Data Plate & Serial Numbers of this section). Also it is essential that you specify the part name codes described in the pages of illustrations and text. For the industrial vehicles with optional equipment, which is described in the lower part of the DESCRIPTION, it is imperative for you to specify optional equipment when ordering parts. Your Toyota dealer is furnished with enough information to decode the correct part numbers based on your information of model number, engine number or frame number as well as part name codes. Illustration & Part Name Code Text Page Composition This section has been prepared similarly as the user s Industrial Equipment Parts Catalog that is included with your truck. For a detailed explanation of the Illustration and part Name Code Text page Composition please refer to the Industrial Equipment Parts Catalog. Data Plate & Serial Numbers For retrieving the correct part numbers, it is crucial to know the complete model of the truck including the serial number, or know the frame number (see note below). This information can be found on the data plate on the truck or in the user s Industrial Equipment Parts catalog. If you do not know where to locate the data plate or frame number plate, refer to the user s Industrial Equipment Parts Catalog in the Data & Serial Numbers section. Note: The frame number is a combination of the truck model plus the 5-digit serial number. i.e. 8FGU Both the truck model and the serial number are found on the data plate. 22

26 1001 ACCELERATOR PEDAL SUB-ASSEMBLY PART NAME CODE PART NUMBER PRODUCT PERIOD ACCELERATOR PEDAL SUB-ASSEMBLY PART NAME UMT ACCELERATOR PEDAL SUB-ASSEMBLY UMT BRACKET, ACCELERATOR PEDAL SENSOR ASSY, ROTARY POSITION [REFER TO: G FK] BOLT, FLANGE W/WASHER, M8x a SHIM, ACCEL PEDAL (NOT SHOWN) UMT SCREW, M4x1.00 [REFER TO: G HM] WASHER, PLATE U BOLT, FLANGE 2 QTY 23

27 1001 ACCELERATOR PEDAL SUB-ASSEMBLY (CONT.) PART NAME CODE PART NUMBER PRODUCT PERIOD ACCELERATOR PEDAL SUB-ASSEMBLY (CONT.) PART NAME UMT ARM SUB-ASSY, ACCELERATOR UMT BRACKET SUB-ASSY, ACCELERATOR ROLLER, ACCELERATOR LINK WASHER, PLATE UMT RING, E SPRING, TENSION UMT BUSH WASHER, PLATE SEAL, OIL BUSH SPRING, TORSION UMT RING, SHAFT SNAP UMT PIN, ROLL RING, O 1 QTY 24

28 1002 STEPPER MOTOR SUB-ASSEMBLY A PART NAME CODE PART NUMBER PRODUCT PERIOD STEPPER MOTOR SUB-ASSEMBLY PART NAME UMT STEPPER MOTOR SUB-ASSEMBLY UMT BRACKET, STEPPER MOTOR UMT BRACKET, THROTTLE CABLE UMT BRACKET, THROTTLE ADJUST UMT MOTOR, NEMA 34 STEPPER UMT COLLAR, 1/2" SHAFT (W/ KEY) UMT SWITCH ASSY, LIMIT SCREW, W/ WASHER UMT SCREW, SOCKET HEAD CAP a U NUT, HEXAGON UMT SCREW, 7/16 SOCKET HEAD UMT WASHER, SPRING LOCK BOLT, FLANGE UMT WASHER, SPRING LOCK U BOLT, FLANGE CLAMP, WIRING HARNESS 2 QTY 25

29 1003 STEPPER MOTOR W/ RAIN GUARD SUB-ASSEMBLY PART NAME CODE PART NUMBER STEPPER MOTOR W/ RAIN GUARD SUB-ASSEMBLY PRODUCT PERIOD PART NAME UMT GUARD, RAIN BOLT, FLANGE W/ WASHER UMT SWITCH ASSY, WARNING/RESET 1 QTY 26

30 1004 DC-DC CONVERTER SUB-ASSEMBLY PART NAME CODE PART NUMBER PRODUCT PERIOD DC-DC CONVERTER SUB-ASSEMBLY PART NAME UMT DC-DC CONVERTER SUB-ASSEMBLY UMT CONVERTER, 12-24V DC-DC UMT PLATE, DC-DC CONVERTER UMT SCREW RELAY BOLT, FLANGE a BOLT, W/ WASHER UMT TIMER, 2 SEC DELAY ON BREAK BOLT, FLANGE 1 QTY 27

31 1005 SPEED CONTROLLER SUB-ASSEMBLY PART NAME CODE PART NUMBER PRODUCT PERIOD SPEED CONTROLLER SUB-ASSEMBLY PART NAME UMT CONTROLLER COVER BOLT, FLANGE W/ WASHER 2 QTY 28

32 1005 SPEED CONTROLLER SUB-ASSEMBLY (CONT.) PART NAME CODE PART NUMBER PRODUCT PERIOD SPEED CONTROLLER SUB-ASSEMBLY (CONT.) PART NAME UMT CONTROLLER SUB-ASSY, SPEED UMT PLATE, SPEED CONTROLLER SCREW, W/ WASHER BAND, CLAMP BOLT, FLANGE 1 QTY 29

33 TOYOTA Material Handling Company A Division of TOYOTA NDUSTRIES CORPORATION U Publication No. AU PRINTED IN USA 30