Toyota 7BNCU15 7BNCU18 7BNCU20 7BNCU25 Lift Truck Service Manual PDF

How to Use This Manual1-1
Map of the Manual 1-2
Manual Design 1-4
Abbreviations & Symbols 1-5
Safety 2-1
Definitions2-2
General Safety 2-3
Battery Safety 2-7
Static Precautions 2-12
Jacking Safety2-14
Towing 2-15
Welding Safety2-16
Systems Overview3-1
Lift Truck Dimensions and Specifications 3-2
General System Data3-4
Configure Mode 3-6
Maintenance Mode 3-11
Software Configuration/PC Loader Program 3-15
Planned Maintenance 4-1
Maintenance Guidelines 4-2
Battery Maintenance4-11

Troubleshooting 5-1
How to Use This Chapter 5-2
Start-up 5-3
Power Amplifier Fault Codes 5-5
Electrical Troubleshooting Guidelines 5-9
Troubleshooting Wiring Problems 5-19
Hydraulic Troubleshooting Guidelines 5-26
Messages, Codes, and Tests6-1
List of Codes and Tests 6-2
Message and Code Summary Tables6-5
Messages and Codes 6-11
Analog Tests 6-83
Input Tests 6-89
Output Tests6-121
Component Procedures 7-1
Component Locator Photos 7-5
Covers and Accessories 7-13
Steering and Controls 7-23
Drive and Brake 7-45
Electrical Components 7-81
Hydraulic Components7-125
Mast, Chain, Hose, Cable 7-147
Theory of Operation 8-1
Traction System8-2
Travel Functions 8-9
Hydraulic Functions 8-20
Sideshift8-30
Steering 8-34
Sense Wires 8-36
Toyota Stand-Up End Control Service Manual How To Use This Manual
00700-CL1SM-3 Issued: 6/1/04 v
Appendix A-1
Lubrication Equivalency ChartA-2
Torque Chart – Standard (Ferrous) A-4
Torque Chart – Metric A-5
Torque Chart – Standard (Brass) A-6
Decimal Equivalent ChartA-7
Standard/Metric Conversions A-9
Schematics A-11
Index I-1

We suggest you get in the habit of turning to the START page first when you use this manual.

The START page asks a few simple questions to guide you to the proper chapter.

• How to Use This Manual explains the format and design of the manual as well as abbreviations and symbols used within the manual.
• Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.
• Systems Overview includes lift truck specifications and theory of operation information.
• Planned Maintenance outlines the recommended schedule of preventive services to keep your lift truck working  most efficiently.
• Troubleshooting is designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.
• Messages, Codes, and Tests lists the electrical fault codes and procedures for running firmware electrical tests.