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

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

2 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.

3 rtable of Contents Before You Begin... 1 Know Your Truck... 1 Safety... 1 Understanding the Safety Labels... 1 Operate Truck Safely... 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 Alarm Codes... 4 DB-25 Connector Diagram... 4 Parts & Service... 5 Toyota Genuine Parts... 5 Your Best Overall Value... 5 Ensuring You Get What You Need... 5 Value of Toyota Genuine Parts... 5 Service Parts Catalog... 5 General Information... 5 Illustration & Part Name Code Text Page Composition... 6 Data Plate & Serial Numbers... 6

4 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. 1

5 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. 2

6 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. 3

Alarm 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.

7 Troubleshooting Basic Troubleshooting Listed in this section are some common troubleshooting issues that the operator my encounter. For a complete list troubleshooting solutions, refer to the user s manuals for the products received with your truck, or contact your local Toyota dealer. Alarm 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 diagram below for the corresponding error. The pattern will repeat until the alarm is cleared by an authorized person. DB-25 Connector Diagram The DB-25 Connector encodes the digital inputs and outputs as well as the analog inputs. To determine proper connections, ensure that all the connections are connected to the correct destinations. The diagram below shows the In/Out destinations of the DB-25 connector. 4

8 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. 5

9 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. 6

10 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. 7

11 1001 ACCELERATOR PEDAL SUB-ASSEMBLY CODE PART NUMBER PRODUCT PERIOD ACCELERATOR PEDAL SUB-ASSEMBLY 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 8

12 1001 ACCELERATOR PEDAL SUB-ASSEMBLY (CONT.) CODE PART NUMBER PRODUCT PERIOD ACCELERATOR PEDAL SUB-ASSEMBLY (CONT.) 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 9

13 1002 STEPPER MOTOR SUB-ASSEMBLY A CODE PART NUMBER PRODUCT PERIOD STEPPER MOTOR SUB-ASSEMBLY 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 10

14 1003 STEPPER MOTOR W/ RAIN GUARD SUB-ASSEMBLY CODE PART NUMBER STEPPER MOTOR W/ RAIN GUARD SUB-ASSEMBLY PRODUCT PERIOD UMT GUARD, RAIN BOLT, FLANGE W/ WASHER UMT SWITCH ASSY, WARNING/RESET 1 QTY 11

15 1004 DC-DC CONVERTER SUB-ASSEMBLY CODE PART NUMBER PRODUCT PERIOD DC-DC CONVERTER SUB-ASSEMBLY 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 12

16 1005 SPEED CONTROLLER SUB-ASSEMBLY CODE PART NUMBER PRODUCT PERIOD SPEED CONTROLLER SUB-ASSEMBLY UMT CONTROLLER COVER BOLT, FLANGE W/ WASHER 2 QTY 13

17 1005 SPEED CONTROLLER SUB-ASSEMBLY (CONT.) CODE PART NUMBER PRODUCT PERIOD SPEED CONTROLLER SUB-ASSEMBLY (CONT.) UMT CONTROLLER SUB-ASSY, SPEED UMT PLATE, SPEED CONTROLLER SCREW, W/ WASHER BAND, CLAMP BOLT, FLANGE 1 QTY 14

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

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

PRODUCT MANUAL OPERATOR S MANUAL TOYOTA SPECIAL DESIGN VEHICLE SPEED CONTROL SYSTEM WARNING This manual describes how to handle the Vehicle Speed Control System. For other features, refer to Operator