Toyota Forklift 7BPUE15 Service Manual SN 80001 and up – PDF DOWNLOAD

Description

Toyota Forklift 7BPUE15 Service Manual SN 80001 and up – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 7BPUE15 Service Manual SN 80001 and up – PDF DOWNLOAD

Language : English
Pages : 373
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 7BPUE15 Service Manual SN 80001 and up – PDF DOWNLOAD

Manual Design:

The Toyota Model 7HBW23 Service Manual is designed with the following objectives in mind:

• Provide technical coverage for expected levels of user expertise
• Anticipate your needs and reduce your decisions regarding maintenance
• Reduce page flipping through a “one-stop shopping” approach

The two-line running page header at the top of each page tells you the following:
• Name of the manual
(Toyota Model 7HBW23 Service Manual)
• Current chapter title
(example: this page How to Use This
Manual)
• Current topic
(example: this page Manual Design)

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 correct chapter.

• How to Use This Manual explains the manual format and design and contains the START page.
• Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.
• Systems Overview includes truck specifications and theory of operation information.
• Planned Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently.
• Troubleshooting is a set of “decision-tree” charts and symptom tables designed to take you from a symptom to a specific sequence of tests in order to isolate a bad component.

TABLE OF CONTENTS:

Toyota Forklift 7BPUE15 Service Manual SN 80001 and up – PDF DOWNLOAD

R/M: 7BPUE15 SN: 80,001 and up.......................  2
	Table of Contents................................  4
	How To Use This Manual...........................  8
		Map of the Manual............................  9
		Manual Design................................ 11
		Page Revision Page........................... 12
		START Page................................... 14
	Safety........................................... 16
		Definitions.................................. 17
		General Safety............................... 18
		Battery Safety............................... 21
		Static Safety................................ 24
		Jacking Safety............................... 26
		Tie-Down for Transport....................... 28
		Towing a Disabled Unit....................... 29
		Welding Safety............................... 30
	Systems Overview................................. 32
		Vehicle Specification........................ 33
		General System Data.......................... 36
		Installation Instructions.................... 38
		Wire Guidance................................ 39
		Cold Storage................................. 40
		UL Label "EE"................................ 42
		Special Tools................................ 43
	Planned Maintenance.............................. 44
		Maintenance Guidelines....................... 45
			Interval 1............................... 46
			Interval 2............................... 47
			Interval 3............................... 51
	Troubleshooting.................................. 52
		How to Use This Chapter...................... 53
		Electrical Troubleshooting Guidelines........ 54
		Shorts to Frame Test......................... 55
		Troubleshooting Wiring Problems.............. 59
		Switches (General)........................... 61
		Electric Motor Tests......................... 62
		Battery Discharge Indicator (BDI)............ 64
		Contractors.................................. 66
		Fuses........................................ 66
		Hydraulic Troubleshooting Guidelines......... 67
		Definitions.................................. 68
		Electrical Connector Locator Chart........... 69
		Programmable Maintenance Tool................ 71
		Drive Unit Troubleshooting Guide............. 76
		Troubleshooting Flowcharts................... 78
		Symptom Tables: Hydraulic Functions.......... 82
		Symptom Tables: Travel Functions............. 84
		Symptom Tables: Electrical Symptoms.......... 85
	Codes and Tests.................................. 86
		Operator Display Messages.................... 87
		Maintenance Mode............................. 89
		Traction Power Amplifier Fault Codes......... 91
		Operator Display Fault Codes.................100
	Component Procedures.............................136
		List of Component Procedures.................137
		Component Locator Photos.....................140
		Covers and Finish............................146
			Tractor Covers...........................146
			Operator Console Cover...................147
			Mast Guard...............................148
			Decals...................................149
		Steering and Controls........................150
			Operator Display.........................151
			Control Handle...........................152
		Drive and Brake..............................158
			Drive Unit...............................159
			Drive Wheel..............................160
			Brake....................................162
		Electrical Components........................166
			Battery Procedures.......................167
			Motors (General).........................170
			Drive Motor..............................174
			Lift Motor...............................176
			Steer Motor..............................177
			Traction Power Amplifier.................180
			Contactors...............................181
			Contactor Tip Replacement................183
			Fuses....................................185
			Circuit Cards (General)..................187
			Switches (General).......................188
			Warning Light............................190
		Hydraulic Components.........................192
			Hydraulic Manifold.......................193
			Hydraulic Reservoir......................194
			Hydraulic Fluid..........................195
			Solenoid Valves..........................196
			Lift Pump and Motor......................197
			Lift Pressure Relief Valve Adjustment....198
			Bleeding the Hydraulic System............199
			Side Cylinder............................200
			Center Cylinder..........................204
			Flow Control Valve.......................206
		Mast Section.................................208
			Three-Stage Carriage.....................209
			Inner Mast...............................213
			Outer Mast...............................216
			Two-Stage Carriage.......................217
			Two-Stage Mast...........................219
			Mast Bearings............................220
			Mast Disassembly and Shimming............222
			Lift Chains, Three-Stage.................226
			Lift Chains, Two-Stage...................228
			Forks....................................229
			Pallet Clamp.............................230
			Load Wheels..............................231
			Skid Pads................................232
		Wire Guidance................................234
			System Overview..........................235
			Install Kit Components...................236
			Set-Up Procedure.........................242
			Codes and Tests..........................245
			Tests....................................268
			General Troubleshooting..................270
			Troubleshooting in FlashWare.............271
			Theory of Operation......................273
		Theory of Operation..........................276
			Battery Plugged In.......................279
			Key Switch (S1) On.......................285
			Closing Deadman Switches.................291
			Travel...................................297
			Steering.................................303
			Lift/Lower...............................309
			Primary Memory...........................325
			Pinout Matrix............................326
	Firmware Configuration...........................344
		FlashWare Program............................345
	Appendix.........................................346
		Lubrication Specification Chart..............347
		Torque Chart - Standard (Ferrous)............348
		Torque Chart - Standard (Brass)..............349
		Torque Chart - Metric........................350
		Decimal Equivalent Chart.....................351
		Standard/Metric Conversions..................353
		Electrical Schematics........................356
		Hydraulic Schematic..........................363
	Index............................................364

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• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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