Toyota Reach Service Manual Appendix

Appendix A:

00700-CL220-01 Issued: 6/1/04 A-1

Appendix Toyota Reach Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart

Approved Toyota Lubricants

Toyota Part
Where Used Type Approved Manufacturer
Number

Drive Unit Gear Gear Forsythe Ltd. 00590-04834-71

Case above Lubricant Shell Spirax HD (1 qt./0.9 liter)
30qF (-1qC) 00590-04838-71
(5 gal./18.9 liters)

Drive Unit Gear Oil Chevron Delco 400 15W-40 API Service 00590-04835-71
Case below SE (1 qt./0.9 liter)
30qF (-1qC) Citgo C-6 10W-30 Motor Oil 00590-04837-71
Lift Chains MIL-H-46152 (5 gal./18.9 liters)
Exxon Extra Motor Oil 10W-30 API
Service SE
Gulflube Motor Oil X.H.D. 10W-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 10W-30 MIL-L-46152
API Service SE
Texaco URSATEX 10W-30 2166

Hydraulic Hydraulic Chevron AW ISO 46 005900-04934-71

Reservoir Fluid Citgo 46 (2 gal./7.6 liters)
(non-cold Exxon Nuto H 46 00590-04840-71
storage Forsythe AWTH215 ISO46 (5 gal./18.9 liters)
trucks) Mobil DTE-1B
NOCO NOCOLUBE AW46
Texaco Cygnus 46 or HD 46
Ultramar Ultra Hydraulik AW46
Hydraulic Hydraulic Exxon Univis J13 (similar to 00590-04841-71
Reservoir Fluid MIL-H-5606A) (1 gal./3.785 liters)
(cold storage Mobil Aero HFA
trucks) (+40 Texaco Aircraft Hydraulic Fluid 15
to -20qF) (4qto
-29qC)
Figure 1-1: Lubrication Equivalency Chart

A-2 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Lubrication Equivalency Chart

Approved Toyota Lubricants

Toyota Part
Where Used Type Approved Manufacturer
Number

Hydraulic Hydraulic NOCO NOC 1866 00590-04842-71

Reservoir Fluid Shell Tellus T Oil 32 (1 gal./3.785 liters)
(cold storage Texaco HD AZ 32 1627 Rando or 00590-04843-71
trucks) (20to Cygnus 32 (5 gal./18.9 liters)
70qF) (-6 to
21qC)

Hydraulic Hydraulic Chevron AW-MV 00590-04842-71

Reservoir (for Fluid Mobil 423 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 30qF only) cartridges per case)
Exxon RONEX MP or UNIREX N2 00590-04845-71
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 1-1: Lubrication Equivalency Chart

00700-CL220-01 Issued: 6/1/04 A-3

Appendix Toyota Reach Service Manual

Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous)

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
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
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
Figure 1-2: Torque Chart - Standard
* NOTE: Use ”oiled” values for bolts with thread locking compound

A-4 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Torque Chart - Standard (Ferrous)

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
Figure 1-2: Torque Chart - Standard
* NOTE: Use ”oiled” values for bolts with thread locking compound

00700-CL220-01 Issued: 6/1/04 A-5

Appendix Toyota Reach Service Manual

Torque Chart - Standard (Brass)

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 1-3: Torque Chart - Standard Brass
* NOTE: Use ”oiled” values for bolts with thread locking compound

A-6 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

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 1-4: Torque Chart - Ferrous Metric
* NOTE: Use ”oiled” values for bolts with thread locking compound

Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (with bolts oiled*)

(in millimeters) Newton-meters Inch-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10
5 2.2 19
6 3.9 34
8 9 79
10 17 150
Figure 1-5: Torque Chart - Brass Metric
* NOTE: Use ”oiled” values for bolts with thread locking compound

00700-CL220-01 Issued: 6/1/04 A-7

Appendix Toyota Reach Service Manual

Decimal Equivalent Chart

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
Figure 1-6: Decimal Equivalent Chart

A-8 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400
Figure 1-6: Decimal Equivalent Chart

00700-CL220-01 Issued: 6/1/04 A-9

Appendix Toyota Reach Service Manual

Standard/Metric Conversions

Standard/Metric Conversions

To Convert... Multiply...
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621

Square Inches to Square Centimeters Square Inches x 6.452

Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196

Pints to Liters Pints x 0.473

Liters to Pints Liters x 2.113
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

Ounces to grams Ounces x 28.35

Grams to ounces Ounces x 0.035
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

A-10 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Standard/Metric Conversions

To Convert... Multiply...
Pounds per Square Inch (psi) to Kilo pascals Pounds per Square Inch x 6.894
(kPa)
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. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) 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 0.6214

Fahrenheit to Celsius (°F - 32) x 0.555

Celsius to Fahrenheit (°C x 1.8) + 32

00700-CL220-01 Issued: 6/1/04 A-11

Appendix Toyota Reach Service Manual

Standard/Metric Conversions

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A-12 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Electrical Schematics
A: Appendix

Electrical Schematics

00700-CL220-01 Issued: 6/1/04 A-13

Appendix Toyota Reach Service Manual

Electrical Schematics

OHG
JP9 CONN.
51 3 51 F11 103
-4
A -11
32 8 1/4A
98 1
-15
79 4
-16
31 7 31 F10 104
-3
1/4A 104 79 98 32 103 1
103 BROWN
4 8 5 2 1
31 B+ MAST SW 1 LIFT INHIB. AGND +12V 32 2 WHITE
ENCODER

6 3 ( OPTIONAL WITH
PROGRAMMING BLACK 101 100 GREEN
HEIGHT INDICATOR )
9 - LIFT CUTOUT SET ENCODER CH. A - 6
CONNECTORS
WHITE 5 102 99 4 YELLOW
10 - END OF FREELIFT SET ENCODER CH. B - 7

OPTIONAL HEIGHT INDICATOR MODULE

B
DISPLAY CARD
TRACTOR INTERFACE HD2
JP12
-1 -1
13 DGND
B+ PCF POWER SUPPLY -2
-2 CHANNEL 0 -3
13 CHANNEL 1
B+ PCF -4
-4 CHANNEL 2
B+KEY

22 -5
+12V

B+ FUSED
GND
DGND
+5V

22 -5 -6
B+ FUSED LED OUT -7
40 -3 JPD2 JPS2 LED OUT
PWR GND -1 -1 -8
40 -6 RED RED LED OUT
PWR GND MISO MISO -9
-2 BLK BLK -2 LED OUT
MOSI MOSI -10
LED OUT
JP10 -3 GRN GRN -3 -11
SCLK SCLK DGND -12
-9 -4 CLR CLR -4 LED OUT

OVERLAY CONNECTIONS
+5VP2 SS2 SS2 -13
C VR1
-14
-11
TRAVEL IN DGND
-5
-6
SHD LED
LED
LED
OUT
OUT
OUT
-14
-15
POT RTRN -7 -16
-15 LED OUT -17
-8 LED OUT
CONTROL HANDLE INPUTS

-13
VR2 LIFT/LOWER IN -9 HD6
CONTROL HANDLE

-1 -1
+5V P2 LED OUT
-2
JPD3 JPS3 LED OUT
-3
-2 LED OUT
HORN IN -1 BLK BLK -1 -4
CHANNEL 3(L/L) CHANNEL 3(L/L) LED OUT
-8 -2 WHT WHT -2 -5
REACH IN CHANNEL 4(TRAVEL) CHANNEL 4(TRAVEL) LED OUT
-6
-7 -3 RED RED -3 DIG IN
RETRACT PC OFF SS3 -7
-4 GRN GRN -4 LED OUT
-6 +12V PWR +12V PWR -8
SSHIFT RIGHT LED OUT
-5 ORN ORN -5 -9
-5 CHANNEL 5(MUX) CHANNEL 5(MUX) LED OUT
-6 -6 -10
SSHIFT LEFT MOTOR TEMP BLU BLU MOTOR TEMP
LED OUT
-11
-4 -7 BRN BRN -7 LED OUT
TILT UP +5V P1 +5V P1 -12
-8 -8 DGND
-3 YEL YEL
TILT DOWN PWR GND PWR GND

D -10
-12
AGND JP5
-1 22
SHD SPEED
FEEDBACK SFB
-1 RED
HD5
-1
SHIELD AGND B+ FUSED 5V ENC
-2 + -2 BLK -2
B+ FIL PROX. ENC GND
X14 JP9 H2 -3 GRN -3 HD1
MAST SWITCH

BRN -6 31 -1 -3 - B ENC CHB

B+KEY 53 -4 -1
S6 BACKUP ENC CHA +12V
-4 BACKUP -5 -2 97
PWR GND ALARM ENC BUS-
BLK -9 79 -16 MAST 1 JP6
SFA
-1 RED -6 -3 C3-SHD
DGND PWR GND CAN
BLU -10 32 -9 AGND -2 31 -2 BLK -4 C3-RED
B+KEY BUS+
PROX. -3 -5 C3-BLK
-1 37 WHT BUS-
B+KEY B+RELAY A
-6
-5 TERM RES
K1 RELAY CNTL 28
OPTIONAL LIFT -4 26 HD3
B+ PCF
LIMIT PROX. AGND -7 2 Y12 1 -1 RED
DIRA SOL. 90
BRN -3
MAST SWITCH

31 B+KEY DIRA -2 BLK

S4 31 K1
-6 91 2 Y13 1
DIRB SOL. 1
BLK 98 -15 DIRB
E BLU 32 -11
LIFT INHBT
AGND
B+ KEY
-3 31
2
-10 89
LIFT SOL. LIFT 1
-9 88 3 0 4 2 8 6
+12V PROP. LOWER PROP. 15
23 -14
RT FOOTSWITCH -8 83 LOWER 28
S7 NEG DIR LIMIT 14
32 -12 Y10 37
AGND
-7 22
BLK -3 57 180˚SWITCH
180˚ BLUE -2 32 -13
SWITCH AGND JP15
BRN -1 51 -5
+12V -1 BRN
-6 B+KEY S8 STEER CONTROLLER
X14 SK2
JP7 -5 SK1
-2 106 BLU BLK
31 -8 STAGING IN 37 -1 -1 25
B+ KEY -3 32 -7 BLK/WHT BLU START/STOP
S1 22 -5 AGND
B+ FUSED -4 82 -13
-10 POS DIR LIMIT +24V OUT
31 B+ KEY
S2A 24 -6 JP7 X14 82 -3 60
ESTOP -11 POS DIRECTION (+)
F S3
49
32
-14
-13
DEADMAN
AGND
B+ RELAY
B+ PCF
-9
-2
37
13
-8 BLK

83 -5
LIMIT
NEG DIRECTION DMS
-1 RED -1 -20 94 -3 RED Y17
+5V_P3 TILT SOL. TILT LIMIT
-4 -4 61
VR3 -3 BLK BRAKE POT IN (-)
-19 95 -4 GRN Y16 -2 40
-17 SS SOL. S/S 63 -4
-2 WHT + TACHOMETER
AGND
SHD -21 92 -1 ORG Y14
JPM-2 JPM-1 REACH 1 SOL. REACH 1 REVERSE
38 -24 TACH STEERING
DT˚ TRACT RTRN -3 -2 WHT Y15 OPTION
39 -23 REACH 2 SOL. 93 REACH 2
TRACT. TEMP 62 -6
41 -16 -18 TACHOMETER
TB-1 BRUSH WEAR TRACTION 2 PWR GND 44 52
-15 -8
TB-2 42 ON CARRIAGE SAFETY RELAY
BRUSH WEAR TRACTION 1 HORN
JPZ-2 JPZ-1 50 -11 -22 54 OUTPUT
LT˚ LIFT RTRN HORN OUT S
34 -12 -7
LIFT TEMP B+ FUSED 16 + H1
JP16 37
JP8 40 -
77 -1 FAN 1
LB-1 BRUSH WEAR LIFT 1 -1 37
B+ RELAY
G 78 -2
LB-2 BRUSH WEAR LIFT 2 -3 37
B+ RELAY
JP13 -11 36
BRN -1 51 -2 PC TRACT
+12V -2 24
STEER BLK -3 80 -1 ESTOP
STOP PROX A -6 85 X
PC CONTROL
A BLUE -2 32 -3
AGND MM
137 37
JP11 Y
-1 -2 -8 12
BRN 51 +12V PC SENSE
STEER -3 -1 -12 64 2 1 37
BLK 81 PROX B BRAKE OUT BR
STOP -7 83
B -3 NEG DIR LIM FB
BLUE -2 32 -5 52
AGND STEER BRAKE IN
JP14 -9 82
POS DIR LIM FB
C1-BLK -1 -10 75
AGND PC LIFT
B -2 -4 37
AGND B+ RELAY
C C1-CLR -3
PRESS PRESSURE
-4
H A C1-RED
-5
+12V

1 2 3 4 5 6
1356_001.eps

Figure 1-1: Electrical Schematic (180° Steering) - Part 1 of 2

A-14 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Electrical Schematics

HEATSINK
27 THERMOSTAT

ELEC. COMP.
27 TEMP. SW. 111 A
111 K3 127 K2
1 1

OPTIONAL COLD STORE/FREEZER

PACKAGE COMPONENTS
0 8 6 0 8 6 4 3
40 27 66 40 27 110 37 137

AMBIENT
27 THERMOSTAT 55

55 55 55 66
100 WATT
HEATSINK
B
HEATER
11 WATT 11 WATT 11 WATT 300 WATT 40
OVERLAY RIGHT FOOT LEFT FOOT HANDLE ELEC. COMP.
SW. HEATER SW. HEATER HEATER HEATER
40 40 40 40
DGND
INPUT SW1 S2B F9
INPUT SW2 27 33 33 11
INPUT SW3 22
ESTOP 20A
DGND
BRUSHWEAR 15A
22 11
BSOC LED10
BSOC LED9 F4
BSOC LED8
BSOC LED7
DGND 15 15 15
BSOC LED1
S96 S99 S97

STEER LED2
C
45 46 47
STEER LED3
STEER LED4 LIGHT OHG
WORK WORK
FAN OHG LIGHT
LIGHT
BSOC LED2
BSOC LED3 40 40 40 40
BSOC LED4
BSOC LED5
BSOC LED6
1 3
INPUT SW4
STEER LED1 14 40
STEER LED8
STEER LED7 TS1
STEER LED6
STEER LED5 F7
DGND 14 11

15A

25
F1
11
D
30A SB
F5
13 12

15A
TRACTION POWER AMP MM
F2
JT1
-2 250A B+
INTERLOCK PWR 2
37 -1 B+
B+ RELAY
-9 F1
COIL RETURN A1
TRACTION MOTOR

4 E1 F3
36 -17
PC CONTROL 425A - 24V 3500# CAP.
DMD 355A - 36V 3500# CAP. B+
JT2 500A - 36V 4500# CAP.
-1
-2
+15V
F2
5 E2
A2
E
GND B-
C3-RED -3 M-
BUS+
C4-BLK -4 3
BUS-
-5
TERM
C3-BLK -6
BUS-
C4-RED

JB- 15
B-
B- WARNING
LIGHT
40

LIFT POWER AMP

JL1
F
B+
-2 10 A1
INTERLOCK PWR
37 -1
B+ RELAY
-9 DMP
COIL RETURN
75
LIFT MOTOR

-17
PC CONTROL
JB-
JL2
-1
+15V
-2
GND B- 9 D1
C4-RED -3 M-
BUS+
-4
BUS- B-
96 -5 B-
TERM B-
-6 40
C4-BLK 40
BUS-
40
40
G
40

40 15A

16 11
40 F6
40

7 8 9 10 11 12
1356_002.eps

Electrical Schematic (180° Steering) - Part 2 of 2

00700-CL220-01 Issued: 6/1/04 A-15

Appendix Toyota Reach Service Manual

Electrical Schematics

OHG
JP9 CONN.
F11
A 51 3 51 103
-4
32 8 1/4A
-11
98 1
-15
79 4
-16
31 7 31 F10 104
-3
1/4A 104 79 98 32 103 1
103 BROWN
4 8 5 2 1
31 B+ MAST SW 1 LIFT INHIB. AGND +12V 32 2 WHITE
ENCODER

6 3 ( OPTIONAL WITH
PROGRAMMING BLACK 101 100 GREEN
HEIGHT INDICATOR )
9 - LIFT CUTOUT SET ENCODER CH. A - 6
CONNECTORS
WHITE 5 102 99 4 YELLOW
10 - END OF FREELIFT SET ENCODER CH. B - 7

OPTIONAL HEIGHT INDICATOR MODULE

B
DISPLAY CARD
TRACTOR INTERFACE HD2
JP12
-1 -1
13 DGND
B+ PCF POWER SUPPLY -2
-2 CHANNEL 0 -3
13 CHANNEL 1
B+ PCF -4
-4 CHANNEL 2
B+KEY

22 -5
+12V

B+ FUSED
GND

DGND
+5V

22 -5 -6
B+ FUSED LED OUT -7
40 -3 JPD2 JPS2 LED OUT
PWR GND -1 -1 -8
40 -6 RED RED LED OUT
PWR GND MISO MISO -9
-2 BLK BLK -2 LED OUT
MOSI MOSI -10
LED OUT
JP10 -3 GRN GRN -3 -11
SCLK SCLK DGND -12
-9 -4 CLR CLR -4 LED OUT

OVERLAY CONNECTIONS
C VR1
-14
+5VP2
TRAVEL IN
SS2
DGND
-5
-6
SHD
SS2
LED
LED
OUT
OUT
-13
-14
-15
-11 LED OUT
POT RTRN -7 -16
-15 LED OUT -17
-8 LED OUT
CONTROL HANDLE INPUTS

-13
VR2 LIFT/LOWER IN -9 HD6
CONTROL HANDLE

-1 -1
+5V P2 LED OUT
-2
JPD3 JPS3 LED OUT
-3
-2 LED OUT
HORN IN -1 BLK BLK -1 -4
CHANNEL 3(L/L) CHANNEL 3(L/L) LED OUT
-8 -2 WHT WHT -2 -5
REACH IN CHANNEL 4(TRAVEL) CHANNEL 4(TRAVEL) LED OUT
-6
-7 -3 RED RED -3 DIG IN
RETRACT PC OFF SS3 -7
-4 GRN GRN -4 LED OUT
-6 +12V PWR +12V PWR -8
SSHIFT RIGHT LED OUT
-5 ORN ORN -5 -9
-5 CHANNEL 5(MUX) CHANNEL 5(MUX) LED OUT
-6 -6 -10
SSHIFT LEFT MOTOR TEMP BLU BLU MOTOR TEMP
LED OUT
-11
-4 -7 BRN BRN -7 LED OUT
TILT UP +5V P1 +5V P1 -12
-8 -8 DGND
-3 YEL YEL
D TILT DOWN PWR GND PWR GND
-10 SHD SPEED
AGND JP5 HD5
FEEDBACK SFB
-12 -1 22 -1 RED -1
SHIELD AGND B+ FUSED 5V ENC
-2 + -2 BLK -2
B+ FIL PROX. ENC GND
X14 JP9 H2 -3 GRN -3 HD1
MAST SWITCH

BRN -6 31 -1 -3 - B ENC CHB

B+KEY 53 -4 -1
S6 BACKUP ENC CHA +12V
-4 BACKUP -5 -2 97
PWR GND ALARM ENC BUS-
BLK -9 79 -16 MAST 1 JP6
SFA
-1 RED -6 -3 C3-SHD
DGND PWR GND CAN
BLU -10 32 -9 AGND -2 31 -2 BLK -4 C3-RED
B+KEY BUS+
PROX. -3 -5 C3-BLK
-1 37 WHT BUS-
B+KEY B+RELAY A
-6
-5 TERM RES
K1 RELAY CNTL 28
OPTIONAL LIFT -4 26 HD3
B+ PCF
LIMIT PROX. AGND -7 2 Y12 1 -1 RED
DIRA SOL. 90
BRN -3
MAST SWITCH

31 B+KEY DIRA -2 BLK

S4 31 K1
-6 91 2 Y13 1
E BLK
BLU
98 -15
32 -11
LIFT INHBT
DIRB SOL.

B+ KEY
-3 31
DIRB
1

AGND
-10 89 2
LIFT SOL. LIFT 1
-9 88 3 0 4 2 8 6
+12V PROP. LOWER PROP. 15
23 -14
RT FOOTSWITCH -8 LOWER 28
S7 NEG DIR LIMIT 14
32 -12 Y10 37
AGND
-7 22
BLK -3 57 180˚SWITCH
180˚ BLUE -2 32 -13
SWITCH AGND JP15
BRN -1 51 -5
+12V -1 BRN
-6 B+KEY S8 STEER CONTROLLER
X14 SK2
JP7 -5 SK1
-2 106 BLU BLK
31 -8 STAGING IN 37 -1 -1 25
B+ KEY -3 32 -7 BLK/WHT BLU START/STOP
S1 22 -5 AGND
B+ FUSED -4 82 -13
-10 POS DIR LIMIT +24V OUT
31 B+ KEY
S2A -6 JP7 -3 60
F
24 ESTOP X14 -11 (+)
-14 -9 37 -8 BLK POS DIRECTION
49 DEADMAN B+ RELAY
S3 LIMIT
32 -13 -2 13
AGND B+ PCF -5 DMS
-20 -3 NEG DIRECTION
-1 RED -1 94 RED Y17
+5V_P3 TILT SOL. TILT LIMIT
-4 -4 61
VR3 -3 BLK BRAKE POT IN (-)
-19 95 -4 GRN Y16 -2 40
SS SOL. S/S 63 -4
-2 WHT -17 AGND + TACHOMETER
SHD -21 92 -1 ORG Y14
JPM-2 JPM-1 REACH 1 SOL. REACH 1 REVERSE
38 -24 TACH STEERING
DT˚ TRACT RTRN -3 -2 WHT Y15 OPTION
39 -23 REACH 2 SOL. 93 REACH 2
TRACT. TEMP 62 -6
41 -16 -18 TACHOMETER
TB-1 BRUSH WEAR TRACTION 2 PWR GND 44 52
-15 -8
TB-2 42 ON CARRIAGE SAFETY RELAY
BRUSH WEAR TRACTION 1 HORN
JPZ-2 JPZ-1 50 -11 -22 54 OUTPUT
LT˚ LIFT RTRN HORN OUT S
34 -12 -7
LIFT TEMP B+ FUSED 16 + H1
JP16 37
JP8 40 -
77 -1 FAN 1
G LB-1
LB-2 78 -2
BRUSH WEAR LIFT 1
BRUSH WEAR LIFT 2
B+ RELAY
B+ RELAY
-1
-3
37
37
JP13 -11 36
BRN -1 51 -2 PC TRACT
+12V -2 24
STEER -1 ESTOP
BLK -3 80
POSITION PROX A -6 85 X
SENSE PC CONTROL
BLUE -2 32 -3
A AGND MM
137 37
JP11 Y
-1 -2 -8 12
BRN 51 +12V PC SENSE
STEER -3 -1 -12 64 2 1 37
POSITION
BLK 81 PROX B BRAKE OUT BR
-7
SENSE -3 NEG DIR LIM FB
B BLUE -2 32 -5 52
AGND STEER BRAKE IN
JP14 -9
POS DIR LIM FB
C1-BLK -1 -10 75
AGND PC LIFT
B -2 -4 37
AGND B+ RELAY
C C1-CLR -3
PRESS PRESSURE
H A C1-RED -4
-5
+12V

1 2 3 4 5 6
1356_001.eps

Figure 1-2: Electrical Schematic (360° Steering) - Part 1 of 2

A-16 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Electrical Schematics

HEATSINK
27 THERMOSTAT

ELEC. COMP.
27 TEMP. SW. 111
A
111 K3 127 K2
1 1

OPTIONAL COLD STORE/FREEZER

PACKAGE COMPONENTS
0 8 6 0 8 6 4 3
40 27 66 40 27 110 37 137

AMBIENT
27 THERMOSTAT 55

100 WATT
B
55 55 55 66 HEATSINK
HEATER
11 WATT 11 WATT 11 WATT 300 WATT 40
OVERLAY RIGHT FOOT LEFT FOOT HANDLE ELEC. COMP.
SW. HEATER SW. HEATER HEATER HEATER
40 40 40 40
DGND
INPUT SW1 S2B F9
INPUT SW2 27 33 33 11
INPUT SW3 22
ESTOP 20A
DGND
BRUSHWEAR 15A
22 11
BSOC LED10
BSOC LED9 F4
BSOC LED8
BSOC LED7
DGND 15 15 15
BSOC LED1
S96 S99 S97
C
STEER LED2 45 46 47
STEER LED3
STEER LED4 LIGHT OHG
WORK WORK
FAN OHG LIGHT
LIGHT
BSOC LED2
BSOC LED3 40 40 40 40
BSOC LED4
BSOC LED5
BSOC LED6
1 3
INPUT SW4
STEER LED1 14 40
STEER LED8
STEER LED7 TS1
STEER LED6
STEER LED5 F7
DGND 14 11

15A
F1
D
25 11

30A SB
F5
13 12

15A
TRACTION POWER AMP MM
F2
JT1
-2 250A B+
INTERLOCK PWR 2
37 -1 B+
B+ RELAY
-9 F1
COIL RETURN A1
TRACTION MOTOR

4 E1 F3
36 -17
PC CONTROL 425A - 24V 3500# CAP.
DMD 355A - 36V 3500# CAP. B+
JT2
-1
+15V 5 E2
500A - 36V 4500# CAP.
E
-2 A2
GND B- F2
C3-RED -3 M-
BUS+
C4-BLK -4 3
BUS-
-5
TERM
C3-BLK -6
BUS-
C4-RED

JB- 15
B-
B- WARNING
LIGHT
40

LIFT POWER AMP

F
JL1 B+
-2 10 A1
INTERLOCK PWR
37 -1
B+ RELAY
-9 DMP
COIL RETURN
75
LIFT MOTOR

-17
PC CONTROL
JB-
JL2
-1
+15V
-2
GND B- 9 D1
C4-RED -3 M-
BUS+
-4
BUS- B-
96 -5 B-
TERM B-
-6 40
C4-BLK 40
BUS-
40 G
40
40

40 15A

16 11
40 F6
40

7 8 9 10 11 12
1356_002.eps

Electrical Schematic (360° Steering) - Part 2 of 2

00700-CL220-01 Issued: 6/1/04 A-17

Appendix Toyota Reach Service Manual

Electrical Schematic Legend

Electrical Schematic Legend

KEY DESCRIPTION KEY DESCRIPTION

BR Brake Coil JPS3 Display Card Analog Input Connector

DIRA Direction A Solenoid JT1 Traction Power Amplifier Power Connector
DIRB Direction B Solenoid JT2 Traction Power Amplifier CAN Bus
DMD Drive Motor (Traction Motor) Connector
DMP Lift Motor JPM Traction Motor Thermistor Connector
DMS Steering Motor JPZ Lift Motor Thermistor Connector
DT Drive Motor Temperature Sensor K1 Key Switch Relay
LIFT Lift Solenoid LB Lift Brush Wear Connector
F1 Control Fuse for B+ Steering (30A) WORK LIGHT Work Light (Option)
F2 Power Fuse for Traction Power Amplifier LIGHT OHG Overhead Guard Light
(250A) LT Lift Motor Temperature Sensor
F3 Power Fuse for Lift Power Amplifier MM Power Disconnect Contactor
(See Note) P/L Proportional Lower
F4 Control Fuse for B+ Fused (15A) PRESS Pressure Transducer
F5 Control Fuse for B+ PFC (15A) PROXA Speed Direction Feedback Proximity Sensor
F6 Control Fuse for Power Ground (15A) PROXB Speed Direction Feedback Proximity Sensor
F7 Control Fuse for Work Lights and Fan WHEEL POS. Drive Wheel Position A Feedback Sensor
(Option) (15A) WHEEL POS. Drive Wheel Position B Feedback Sensor
F8 Control Fuse for Warning Light 180 SWITCH Drive Wheel 180 Degree Switch
FAN 1 Lift Motor Cooling Fan REACH1 Reach1 Solenoid
FAN 2 Operator Cooling Fan REACH2 Reach2 Solenoid
H1 Horn S1 Key Switch
H2 Backup Alarm (Optional) S2 EPO Switch
HD1 CAN Bus Connector on Display Card S3 Deadman Switch
HD2 Overlay Connector on Display Card S4 Lift Inhibit Switch
HD3 Sonalert Connector on Display Card S5 Mast Switch 2 (Spare)
HD5 Proximity Connector on Display Card S6 Mast Switch 1 (Speed Limiting)
HD6 Overlay Connector on Display Card S7 Right Foot Switch
JL1 Lift Power Amplifier Power Connector S8 Staging Switch
JL2 Lift Power Amplifier CAN Bus Connector S96 FAN2 Switch
JP5 Tractor Interface Backup Alarm Connector S97 Working Light Switch
JP6 Tractor Interface Solenoid Connector S99 Overhead Guard Light Switch
JP7 Tractor Interface Connector SFA PROXA Connector
JP8 Tractor Interface Connector SFB PROXB Connector
JP9 Tractor Interface Connector SK1 Steer Controller Connector
JP10 Tractor Interface Control Handle Connector SK2 Steer Controller Connector
JP11 Tractor Interface Drive Wheel Position B S/S Sideshift Solenoid
Proximity Input TACH Steering Wheel Position Tachometer
JP12 Tractor Interface Power Connector TB Traction Brush Wear Connector
JP13 Tractor Interface Drive Wheel Position A TILT Tilt Solenoid
Proximity Input TS1 Power Hook-up for On Board Terminal
JP14 Tractor Interface Pressure Transducer (Option)
Connector VR1 Travel Potentiometer
JP15 Tractor Interface Spare Solenoid Driver and VR2 Lift Potentiometer
Staging Switch Connector VR3 Brake Potentiometer
JP16 Tractor Interface Lift Brush Wear WL Warning Light (Option)
Connector
JPD2 Tractor Interface Connector for Display Note: Fuse size depends upon Model.
JPD3 Tractor Interface Connector for Display 350A = 36V Models 7BSU20 and 7BRU18
JPS2 Display Card Serial Communication 425A = 24V Models 7BSU20 and 7BRU18
Connector 500A = 36V Models 7BSU25, 7BRU23, and
7BDRU15

A-18 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Hydraulic Schematic - 7BRU18/7BRU23

Hydraulic Schematic - 7BRU18/7BRU23

3
13

2 2
1 6
11 6
A Y16
3
B 5 5

Y17
4
H B A
1
Y10 Y10 Y14
Y13 1
4
4
Y15
M 14

P Y12

Figure 1-3: 7BRU18/7BRU23

KEY DESCRIPTION KEY DESCRIPTION

1, 2 Staging Cylinder M Pump Motor

3 Freelift Cylinder P Pump
4 Reach/Retract Cylinder Y10 Lift/Proportional Lower Valve
5 Tilt Cylinder Y12 Direction A Valve
6 Sideshift Cylinder Y13 Direction B Valve
11 Staging Velocity Fuse Y14 Reach Valve
13 Freelift Velocity Fuse Y15 Retract Valve
14 Relief Valve Y16 Sideshift Valve
F Filter Y17 Tilt Valve

00700-CL220-01 Issued: 6/1/04 A-19

Appendix Toyota Reach Service Manual

Hydraulic Schematic - 7BDRU15

Hydraulic Schematic - 7BDRU15

13

2
2
1 11 6 6
A Y16
3
B
5 5

Y17
4
H B A
Y10 Y10 1
Y13 Y14
1
4
4
14 Y15
M

P Y12
R

Figure 1-4: 7BDRU15

KEY DESCRIPTION KEY DESCRIPTION

1, 2 Staging Cylinder M Pump Motor

3 Freelift Cylinder P Pump
4 Reach/Retract Cylinder Y10 Lift/Proportional Lower Valve
5 Tilt Cylinder Y12 Direction A Valve
6 Sideshift Cylinder Y13 Direction B Valve
11 Staging Velocity Fuse Y14 Reach Valve
13 Freelift Velocity Fuse Y15 Retract Valve
14 Relief Valve Y16 Sideshift Valve
F Filter Y17 Tilt Valve

A-20 00700-CL220-01 Issued: 6/1/04

Toyota Reach Service Manual Appendix

Hydraulic Schematic - 7BSU20/25

Hydraulic Schematic - 7BSU20/25

3
13

1 11 2 5

H B A

Y10 Y10
Y13

14
M

P Y12
R

Figure 1-5: 7BSU20/7BSU25

KEY DESCRIPTION KEY DESCRIPTION

1, 2 Staging Cylinder M Pump Motor

3 Freelift Cylinder P Pump
5 Tilt Cylinder Y10 Lift/Proportional Lower Valve
6 Sideshift Cylinder Y12 Direction A Valve
11 Staging Velocity Fuse Y13 Direction B Valve
13 Freelift Velocity Fuse Y16 Sideshift Valve
14 Relief Valve Y17 Tilt Valve
F Filter

00700-CL220-01 Issued: 6/1/04 A-21

Appendix Toyota Reach Service Manual

Hydraulic Schematic - 7BSU20/25

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A-22 00700-CL220-01 Issued: 6/1/04