Toyota Stand-Up End-Control Lift Truck 7BNCU15 7BNCU18 7BNCU20 7BNCU25 Workshop Repair Service Manual PDF - MTOIN7BNCUCL1SM.zip

Full service and repair documentation, complete with Electrical Wiring Diagrams, covering the Toyota Stand-Up End-Control Lift Truck 7BNCU15, 7BNCU18, 7BNCU20 and 7BNCU25 series — everything needed to service, troubleshoot, fix and rebuild these machines the way trained technicians do.

The workshop service and repair manual for Toyota Stand-Up End-Control Lift Truck models 7BNCU15, 7BNCU18, 7BNCU20 and 7BNCU25 contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 814 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

7BNCU15-18-20-25 Electrical Wiring Diagram-020.pdf

00700-CL1SM-3 - Toyota Stand-Up End-Control Lift Truck 7BNCU15, 7BNCU18, 7BNCU20, 7BNCU25 Service Manual (Serial No. 50,001 and up).pdf

00715-00085-09 - Toyota Stand-Up End-Control Lift Truck 7BNCU15, 7BNCU18, 7BNCU20, 7BNCU25 Parts Manual (Serial No. 50,001 and up).pdf

MAIN SECTIONS

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

00700-CL1SM-3 Issued: 6/1/04

iiiHow To Use This Manual

Toyota Stand-Up End Control Service Manual

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 Tests. . .. . .. . .. . ... . . 6-1

List of Codes and Tests. . .. . .. . .. . .. . .. . .. . . . . 6-2

Message and Code Summary Tables.. . .. . .. . .. . .. . . . . 6-5

Messages and Codes. . .. . .. . .. . .. . .. . ... . . 6-11

Analog Tests. . .. . .. . .. . .. . .. . .. . ... . . . 6-83

Input Tests. . .. . .. . .. . .. . .. . .. . .. . .. . . 6-89

Output Tests. . .. . .. . .. . .. . .. . .. . ... . . .6-121

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 Components.. . .. . .. . .. . .. . .. . .. . . .7-125

Mast, Chain, Hose, Cable. . .. . .. . .. . .. . .. . .. . .7-147

Theory of Operation. . .. . .. . .. . .. . ... . . . 8-1

Traction System. . .. . .. . .. . .. . .. . .. . ... . . 8-2

Travel Functions. . .. . .. . .. . .. . .. . .. . .. . . . . 8-9

Hydraulic Functions. . .. . .. . .. . .. . .. . ... . . 8-20

Sideshift. . .. . .. . .. . .. . .. . .. . .. . .. . . . . 8-30

Steering. . .. . .. . .. . .. . .. . .. . .. . ... . . 8-34

Sense Wires. . .. . .. . .. . .. . .. . .. . .. . .. . . 8-36

iv

00700-CL1SM-3 Issued: 6/1/04Toyota Stand-Up End Control Service Manual

How To Use This Manual

Appendix. . .. . .. . .. . .. . .. . .. . .. . . . .A-1

Lubrication Equivalency Chart. . .. . .. . .. . .. . .. . . . . A-2

Torque Chart - Standard (Ferrous). . .. . .. . .. . ... . . . A-4

Torque Chart - Metric. . .. . .. . .. . .. . .. . ... . . . A-5

Torque Chart - Standard (Brass). . .. . .. . .. . .. . .. . . . A-6

Decimal Equivalent Chart. . .. . .. . .. . .. . .. . .. . . . A-7

Standard/Metric Conversions. . .. . .. . .. . .. . ... . . A-9

Schematics. . .. . .. . .. . .. . .. . .. . .. . .. . . . A-11

Index. . .. . .. . .. . .. . .. . .. . .. . .. . . I-1