Toyota 7BNCU15 User manual

Stand-Up End-Control Lift Truck
Models: 7BNCU15
7BNCU18
7BNCU20
7BNCU25
Serial No. 50,001 and up
SERVICE MANUAL
00700-CL1SM-3 Issued: 6/1/04
epcatalogs.com

© 2004 by Toyota Industrial Equipment
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 Industrial Equipment believes the information in this manual is accurate and current as of the publication
date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any
errors that may appear in the manual.
epcatalogs.com

Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 REV: 1/31/08
1 SIB MA06-001 - 7FBCU Option Menu Changes ma06-001.pdf 69 KB 2/20/2006
2SIB CC06-001 - A5 Error Code Additional Information cc06-001.
p
df 119 KB 2/20/2006
3SIB RA06-002 - Tie Rod Chan
g
e ra06-002.
p
df 343 KB 3/7/2006
4SIB FA06-003 - Front Axle Hub Chan
g
e fa06-003.
p
df 129 KB 3/7/2006
5SIB FA06-002 - Chan
g
es to Reamer Bolt Tor
q
ue S
p
ecification fa06-002.
p
df 44 KB 3/7/2006
6SIB RA04-001 - New Tie Rod End Desi
g
n ra04-001.
p
df 963 KB 6/7/2006
7SIB MA05-009 7FBEU O
p
tion Set Menu Chan
g
es ma05-009.
p
df 124 KB 6/7/2006
8SIB MA05-008 Re
p
air Manual Correction
(
Front Axle Bearin
g
Preload
)
ma05-008.
p
df 742 KB 6/7/2006
9SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion ce02-002r.
p
df 52 KB 6/8/2006
10 SIB CY04-001 - New V & FSV Lift C
y
l. Sealsfor 1~3 Ton 7 Series Trucks c
y
04-001.
p
df 83 KB 6/8/2006
11 SIB BF04-003 - Batter
y
Com
p
artment Reinforcement Plate & Batter
y
Sto
pp
er Ad
j
ust bf04-003.
p
df 271 KB 6/8/2006
12 SIB DU05-004 - Reduction Gear Chan
g
e du05-004.
p
df 222 KB 6/8/2006
13 SIB ST99-001R - Recommended S
p
ecial Service Tools st99-001r.
p
df 59 KB 6/8/2006
14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshootin
g
st03-001.
p
df 93 KB 6/8/2006
15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshootin
g
st00-001.
p
df 57 KB 6/8/2006
16 SIB CC05-002 - Inchin
g
While Brakin
g
O
p
tion
(
7FBC
(
H
)
U15-32
)
cc05-002.
p
df 50 KB 6/8/2006
17 SIB CC05-008 - TMPU Ins
p
ection Standards
(
7FBCU15-55
)
cc05-008.
p
df 89 KB 6/8/2006
18 SIB CC05-006 - MB Contactor Cover
(
7FBCU15-32
)
cc05-006.
p
df 191 KB 6/8/2006
19 SIB FA05-001 - Gear Case Chan
g
e
(
7FBCU35-55
)
fa05-001.
p
df 107 KB 6/8/2006
20 SIB HS05-003 Mini Lever Pressure Relief
(
7FBEU15-20
)
hs05-003.
p
df 929 KB 6/8/2006
21 SIB MS03-001 Introduction of O
p
tional Quad Mast for 7FBEU15~20 ms03-001.
p
df 1810 KB 6/8/2006
22 SIB CE05-001 Ke
y
Switch Chan
g
e
(
All Models
)
ce05-001.
p
df 103 KB 6/8/2006
23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20) cc05-003.pdf 98 KB 6/8/2006
24 SIB CE05-008 7FBEU Voltage Conversion ce05-008.pdf 51 KB 6/8/2006
25 SIB CC05-011 Low Battery Voltage / Performance Reduction cc05-011.pdf 63 KB 6/8/2006
26 SIB CC05-007 MB Contactor Cover (7FBEU15-20) cc05-007.pdf 184 KB 6/8/2006
27 SIB ST06-001 - Recommended Special Service Tools st06-001.pdf 90 KB 6/13/2006
28 SIB CE05-006 Pump Motor Cooling Fan ce05-006.pdf 229 KB 6/16/2006
29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit ce05-002.pdf 5801 KB 9/6/2006
30 SIB MA07-005 - Maintenance Indicator Changes ma07-005.pdf 102 KB 5/10/2007
31 SIB RA07-001 Rear Axle Flange Change ra07-001.pdf 100 KB 5/10/2007
32 SIB HS07-001 Addition of Back-Tilt Lock Valve hs07-001.pdf 1246 KB 5/10/2007
33 SIB CE06-005R - Display Battery Replacement ce06-005-r1.pdf 876 KB 7/12/2007
34 SIB CE06-005R Display Battery Replacement ce06-005-r1.pdf 876 KB 7/12/2007
35 SIB FA07-001R Front Axle Shaft Change fa07-001r.pdf 281 KB 9/25/2007
36 SIB CC07-004 - Tuning No. 14 Information cc07-004.pdf 190 KB 10/26/2007
37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section dm07-001.pdf 557 KB 10/26/2007
Technical New Briefs affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 REV: 1/31/08
1TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal O
p
tion, Over Heatin
g
Dia
g
nosis, and 7FBCU Volta
g
e S
p
ecs tnb-2001-01.
p
df 113 KB 11/29/2005
2TNB - 2004-07 - H
y
draulic oil chan
g
e tnb-2004-07.
p
df 79 KB 11/29/2005
3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange tnb-2006-02.pdf 375 KB 2/20/2006
4TNB - 2006-04 - Cast Iron Bod
y
H
y
draulic Pum
p
tnb-2006-04.
p
df 125 KB 4/25/2006
5TNB - 2006-05 - Plate to Prevent Chain Rollback tnb-2006-05.
p
df 86 KB 4/25/2006
6TNB - 2006-10 - 7FBCU15-32 Steer Motor O
p
erates After Auto Shutdown Activates tnb-2006-10.
p
df 140 KB 9/6/2006
7TNB - 2006-12 - 7FBCU15-18 Excessive H
y
draulic Return Circuit Back Pressure tnb-2006-12.
p
df 82 KB 11/1/2006
8TNB - 2006-13 - H
y
draulic Fluid for Cold Stora
g
e tnb-2006-13.
p
df 159 KB 12/22/2006
9TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Dis
p
la
y
tnb-2006-01r.
p
df 517 KB 4/9/2007
10 TNB - 2006-09 - 7-Series Electric ROM Write tnb-2006-09.
p
df 339 KB 4/9/2007
11 TNB-2003-07 - Allowable Variance on Mast Shimmin
g
, 7FBEU Counterwei
g
ht Retention tnb-2003-07.
p
df 118 KB 1/31/2008
12 TNB-2006-03 - 7FBEU Counterwei
g
ht S
q
ueakin
g
tnb-2006-03.
p
df 805 KB 1/31/2008
13 TNB-2003-04 - 7FBEU Steer S
y
stem – Air Pur
g
in
g
Procedure tnb-2003-04.
p
df 110 KB 1/31/2008
epcatalogs.com

Hotline Tech Tips affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 REV: 1/31/08
1HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU
g
radeabilit
y
; 7BNCU tilt s
p
eed; Side
p
anels 7FBCU hotline tech ti
p
s-2004-11.
p
df 114 KB 2/6/2006
2HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU
g
radeabilit
y
; 7FBCU CB1 and CB2 hotline tech ti
p
s-2004-12.
p
df 130 KB 2/6/2006
3HTT-2005-01 - 7FBEU Motor Bearin
g
/RPM Sensor; E3 Dis
p
la
y
on 7FBEU; Hour Meter on 7FBEU and 7FBCU hotline tech ti
p
s-2005-01.
p
df 119 KB 7/5/2006
4HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Com
p
ounds; 7FBCU35-55 Differential Oil Level hotline tech ti
p
s-2005-03.
p
df 121 KB 2/6/2006
5HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testin
g
hotline tech ti
p
s-2005-05.
p
df 168 KB 7/5/2006
6HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Batter
y
Correction hotline tech tips-2005-06.pdf 326 KB 2/6/2006
7HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Com
p
uter Board Re
p
lacement hotline tech ti
p
s-2005-07.
p
df 118 KB 3/13/2006
8HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2 hotline tech ti
p
s-2005-08.
p
df 112 KB 3/13/2006
9HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers hotline tech ti
p
s-2005-09.
p
df 323 KB 2/6/2006
10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon hotline tech ti
p
s-2005-10.
p
df 97 KB 2/2/2006
11 HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Ti
p
Re
p
lacement, Slow Travel hotline tech ti
p
s-2005-11.
p
df 74 KB 2/6/2006
12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures; 7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse
R
hotline tech tips-2005-12.pdf 278 KB 4/9/2007
13 HTT-2006-01 - 7 Series Electric Lift Truck Erratic Dis
p
la
y
; 7FBE Drive Unit Part Numbers hotline tech ti
p
s-2006-01.
p
df 71 KB 2/2/2006
14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes hotline tech ti
p
s-2006-02.
p
df 185 KB 3/2/2006
15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3 hotline tech ti
p
s-2006-03.
p
df 249 KB 4/3/2006
16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Re
p
lacement hotline tech ti
p
s-2006-04.
p
df 84 KB 4/27/2006
17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm hotline tech ti
p
s-2006-05.
p
df 279 KB 6/20/2006
18 HTT-2006-06 - 7FBCU & 7FBEU Batter
y
Consum
p
tion hotline tech ti
p
s-2006-06.
p
df 344 KB 7/11/2006
19 HTT-2006-07 - 7FBEU Slow Motor S
p
eed hotline tech ti
p
s-2006-07.
p
df 131 KB 4/9/2007
20 HTT-2006-08 - 7FBEU E2-1 Error Code hotline tech ti
p
s-2006-08.
p
df 268 KB 9/6/2006
21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N hotline tech ti
p
s-2006-09.
p
df 134 KB 10/3/2006
22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes hotline tech ti
p
s-2006-10.
p
df 257 KB 4/9/2007
23 HTT-2006-11 - 7FBCU Drive Transistors hotline tech ti
p
s-2006-11.
p
df 99 KB 11/27/2006
24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor hotline tech ti
p
s-2006-12.
p
df 308 KB 4/9/2007
25 HTT-2007-01 - H
y
draulic Oil for Cold Stora
g
e; 7FBEU Motor Bearin
g
Seal Install hotline tech ti
p
s-2007-01.
p
df 136 KB 4/9/2007
26 HTT-2007-02 - 7FB Strin
g
Cutters, OPSS Tilt Back Lock Valve added hotline tech ti
p
s-2007-02.
p
df 519 KB 4/9/2007
27 HTT-2007-03 - CU322 u
p
date; Re
p
lacin
g
Interface Card on 7BNCU hotline tech ti
p
s-2007-03.
p
df 154 KB 4/9/2007
28 HTT-2007-04 - Class 1
g
ear case oil hotline tech ti
p
s-2007-04.
p
df 381 KB 5/10/2007
29 HTT-2007-05 - 7FBCU Gear Case Sealin
g
hotline tech ti
p
s-2007-05.
p
df 216 KB 9/24/2007
30 HTT-2007-06 - Steer C
y
linder chan
g
e hotline tech ti
p
s-2007-06.
p
df 162 KB 9/24/2007
31 HTT-2007-07 - Jerk
y
Cree
p
S
p
eed, New H
y
draulic Oil hotline tech ti
p
s-2007-07.
p
df 600 KB 9/24/2007
32 HTT-2007-08 - O
p
tional 12V Power Su
pp
l
y
, DC/MD Card troubleshootin
g
hotline tech ti
p
s-2007-08.
p
df 148 KB 9/24/2007
33 HTT-2007-09 - Re
p
air Manual 322 hotline tech ti
p
s-2007-09.
p
df 502 KB 9/24/2007
34 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors hotline tech tips-2007-10.pdf 303 KB 10/30/2007
35 HTT-2007-11 - CU322 Re
p
air manual clarification, 7FBEU 31-1, 31-2, 31-3 hotline tech ti
p
s-2007-11.
p
df 155 KB 11/19/2007
36 HTT-2007-12 - Class 1 Alarm with OPSS hotline tech ti
p
s-2007-12.
p
df 479 KB 12/12/2007
37 HTT-2008-01 - Class I Gear Noise hotline tech tips-2008-01.pdf 363 KB 1/28/2008
epcatalogs.com

Toyota Stand-Up End Control Service Manual How To Use This Manual
00700-CL1SM-3 Issued: 6/1/04 iii
i: How To Use This Manual Table of Contents
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Abbreviations & Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Jacking Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lift Truck Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Configure Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Software Configuration/PC Loader Program . . . . . . . . . . . . . . . . . . . . . 3-15
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
epcatalogs.com

Buy now
Toyota Stand-Up End-Control Lift Truck 7BNCU15, 18/20/25 Service
Manual PDF
With Instant Download