TOYOTA Electric POWERED Forklift 7FBCU15-55 & 7FBCHU25 Service Repair Manual

FOREWORD This Manual contains specifications, maintenance, repaiir, diagnostic and service procedures for the chassis, bod5 electrical coniroliier, and material handling system of the TOYOTA ELECTRBG POWERED FORKLIFT 7FBCU15 40 55 series. Please ease this massuaii for providing quick, correct servicing 0% the coras- sponding forklift models. This manual deals with the above models as of July 2001. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. TOYOTA Material Handling Company A Division of TOYOTA INDUSTRIES CORPORATION

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 2 SIB CC06-001 - A5 Error Code Additional Information cc06-001.pdf 119 KB 2/20/2006 3 SIB RA06-002 - Tie Rod Change ra06-002.pdf 343 KB 3/7/2006 4 SIB FA06-003 - Front Axle Hub Change fa06-003.pdf 129 KB 3/7/2006 5 SIB FA06-002 - Changes to Reamer Bolt Torque Specification fa06-002.pdf 44 KB 3/7/2006 6 SIB RA04-001 - New Tie Rod End Design ra04-001.pdf 963 KB 6/7/2006 7 SIB MA05-009 7FBEU Option Set Menu Changes ma05-009.pdf 124 KB 6/7/2006 8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload) ma05-008.pdf 742 KB 6/7/2006 9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion ce02-002r.pdf 52 KB 6/8/2006 10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks cy04-001.pdf 83 KB 6/8/2006 11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust bf04-003.pdf 271 KB 6/8/2006 12 SIB DU05-004 - Reduction Gear Change du05-004.pdf 222 KB 6/8/2006 13 SIB ST99-001R - Recommended Special Service Tools st99-001r.pdf 59 KB 6/8/2006 14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting st03-001.pdf 93 KB 6/8/2006 15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting st00-001.pdf 57 KB 6/8/2006 16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32) cc05-002.pdf 50 KB 6/8/2006 17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55) cc05-008.pdf 89 KB 6/8/2006 18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32) cc05-006.pdf 191 KB 6/8/2006 19 SIB FA05-001 - Gear Case Change (7FBCU35-55) fa05-001.pdf 107 KB 6/8/2006 20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20) hs05-003.pdf 929 KB 6/8/2006 21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20 ms03-001.pdf 1810 KB 6/8/2006 22 SIB CE05-001 Key Switch Change (All Models) ce05-001.pdf 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 1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal Option, Over Heating Diagnosis, and 7FBCU Voltage Specs tnb-2001-01.pdf 113 KB 11/29/2005 2 TNB - 2004-07 - Hydraulic oil change tnb-2004-07.pdf 79 KB 11/29/2005 3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange tnb-2006-02.pdf 375 KB 2/20/2006 4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump tnb-2006-04.pdf 125 KB 4/25/2006 5 TNB - 2006-05 - Plate to Prevent Chain Rollback tnb-2006-05.pdf 86 KB 4/25/2006 6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates tnb-2006-10.pdf 140 KB 9/6/2006 7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure tnb-2006-12.pdf 82 KB 11/1/2006 8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage tnb-2006-13.pdf 159 KB 12/22/2006 9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display tnb-2006-01r.pdf 517 KB 4/9/2007 10 TNB - 2006-09 - 7-Series Electric ROM Write tnb-2006-09.pdf 339 KB 4/9/2007 11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention tnb-2003-07.pdf 118 KB 1/31/2008 12 TNB-2006-03 - 7FBEU Counterweight Squeaking tnb-2006-03.pdf 805 KB 1/31/2008 13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure tnb-2003-04.pdf 110 KB 1/31/2008

Hotline Tech Tips affecting Models (30-)7FBCU15-32, 7FBEU15-20, and 7BNCU15-25 REV: 1/31/08 1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels 7FBCU hotline tech tips-2004-11.pdf 114 KB 2/6/2006 2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU gradeability; 7FBCU CB1 and CB2 hotline tech tips-2004-12.pdf 130 KB 2/6/2006 3 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on 7FBEU and 7FBCU hotline tech tips-2005-01.pdf 119 KB 7/5/2006 4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential Oil Level hotline tech tips-2005-03.pdf 121 KB 2/6/2006 5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing hotline tech tips-2005-05.pdf 168 KB 7/5/2006 6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction hotline tech tips-2005-06.pdf 326 KB 2/6/2006 7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement hotline tech tips-2005-07.pdf 118 KB 3/13/2006 8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2 hotline tech tips-2005-08.pdf 112 KB 3/13/2006 9 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers hotline tech tips-2005-09.pdf 323 KB 2/6/2006 10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon hotline tech tips-2005-10.pdf 97 KB 2/2/2006 11 HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel hotline tech tips-2005-11.pdf 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 Display; 7FBE Drive Unit Part Numbers hotline tech tips-2006-01.pdf 71 KB 2/2/2006 14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes hotline tech tips-2006-02.pdf 185 KB 3/2/2006 15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3 hotline tech tips-2006-03.pdf 249 KB 4/3/2006 16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement hotline tech tips-2006-04.pdf 84 KB 4/27/2006 17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm hotline tech tips-2006-05.pdf 279 KB 6/20/2006 18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption hotline tech tips-2006-06.pdf 344 KB 7/11/2006 19 HTT-2006-07 - 7FBEU Slow Motor Speed hotline tech tips-2006-07.pdf 131 KB 4/9/2007 20 HTT-2006-08 - 7FBEU E2-1 Error Code hotline tech tips-2006-08.pdf 268 KB 9/6/2006 21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N hotline tech tips-2006-09.pdf 134 KB 10/3/2006 22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes hotline tech tips-2006-10.pdf 257 KB 4/9/2007 23 HTT-2006-11 - 7FBCU Drive Transistors hotline tech tips-2006-11.pdf 99 KB 11/27/2006 24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor hotline tech tips-2006-12.pdf 308 KB 4/9/2007 25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install hotline tech tips-2007-01.pdf 136 KB 4/9/2007 26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added hotline tech tips-2007-02.pdf 519 KB 4/9/2007 27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU hotline tech tips-2007-03.pdf 154 KB 4/9/2007 28 HTT-2007-04 - Class 1 gear case oil hotline tech tips-2007-04.pdf 381 KB 5/10/2007 29 HTT-2007-05 - 7FBCU Gear Case Sealing hotline tech tips-2007-05.pdf 216 KB 9/24/2007 30 HTT-2007-06 - Steer Cylinder change hotline tech tips-2007-06.pdf 162 KB 9/24/2007 31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil hotline tech tips-2007-07.pdf 600 KB 9/24/2007 32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting hotline tech tips-2007-08.pdf 148 KB 9/24/2007 33 HTT-2007-09 - Repair Manual 322 hotline tech tips-2007-09.pdf 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 Repair manual clarification, 7FBEU 31-1, 31-2, 31-3 hotline tech tips-2007-11.pdf 155 KB 11/19/2007 36 HTT-2007-12 - Class 1 Alarm with OPSS hotline tech tips-2007-12.pdf 479 KB 12/12/2007 37 HTT-2008-01 - Class I Gear Noise hotline tech tips-2008-01.pdf 363 KB 1/28/2008

SECTION INDEX NAME 1 SECTION GENERAL BATTERY y MULTI-DISPLAY FUNCTIONS TROUBLESHOOTING MOTOR DRIVE UNIT FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP p 8 SAS FUNCTIONS / APPENDIX

GENERAL Page Page EXTERIOR VIEWS ........................... 0-2 RECOMMENDED LUBRICANT .................. VEHICLE MODEL 0-3 QUANTITY & TYPES 0-18 rn ............................. ................. FRAME NUMBER ............................. 0-4 LUBRICATION CHART 0-19 ......... HOW TO USE THIS MANUAL ...... 0-5 PERIODIC MAINTENANCE 0-21 EXPLANATION METHOD ................ 0-5 PERIODIC REPLACEMENT OF ...... TERMINOLOGY 0-6 PARTS AND LUBRICANTS 0-26 ................................. ABBREVIATIONS .............................. 0-6 OPERATIONAL TIPS ...................... 0-7 JACK-UP POINT .............................. 0-8 .............. HOISTING THE VEHICLE 0-9 CAUTION FOR TOWING ................ 0-9 ATTENTIVE POINTS ON SAS .... 0-10 CIRCUIT TESTER .......................... 0-11 STANDARD BOLT & NUT TIGHTENING TORQUE .............. 0-13 BOLT STRENGTH TYPE .......... IDENTIFICATION METHOD 0-13 ...... TIGHTENING TORQUE TABLE 0-14 PRECOAT BOLTS .......................... 0-15 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ......................................... 0-15 WlRE ROPE SUSPENSION ANGLE LIST .................................. 0-16 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ............................................ 0-16 COMPONENTS WEIGHT ............. 0-17

0-2 EXTERIOR VIEWS

VEHICLE MODEL Model Code 15 18 20 25 30 32 35 45 55 Load Capacity 3000 Ibs 3500 Ibs 4000 Ibs 5000 Ibs 6000 Ibs 6500 Ibs 8000 Ibs 10000 Ibs 12000 Ibs Vehicle Model 7FBCU15 30-7FBCU 15 7FBCU18 30-7FBCU 18 7FBCU20 30-7FBCU20 7FBCU25 30-7FBCU25 7FBCHU25 30-7FBCHU25 7FBCU30 30-7FBCU30 7FBCU32 30-7FBCU32 7FBCU35 30-7FBCU35 7FBCU45 30-7FBCU45 7FBCU55 30-7FBCU55 Voltage 36V148V 1' t 1' t 7' 1' 'r 1' 1' 'r 1' t 1' 1' 'r 'r 'r 1' 1' Remarks Dust proof Dust proof Dust proof Dust proof High capacity (battery compartment) Dust proof High capacity (battery compartment) Dust proof Dust proof Dust proof Dust proof Dust proof

FRAME NUMBER Frame No. Punching Position Punching position *: EEC spec. Punching format 7FBCU45-60011 307FBCU45-60011 7FBCU55-60011 307FBCU55-60011 Vehicle Model 7FBCu35 7FBCU45 30-7FBCU35 30-7FBCU45 7FBCU55 30-7FBCU55 Vehicle Model 7FBCU15 7FBCU18 30-7FBCU 15 30-7FBCU 18 7FBCU20 7FBCU25 Punching format 7FBCU18-60011 * 7FBCU18@60011 307FBCU18-60011 * 307FBCU18@60011 7FBCU25-60011 * 7FBCU25@60011 30-7FBCU20 30-7FBCU25 7FBCHU25 30-7FBCHU25 7FBCU30 7FBCU32 30-7FBCU30 30-7FBCU32 307FBCU25-60011 * 307FBCU25@60011 7FBCHU25-60011 307FBCHU25-60011 7FBCU32-60011 * 7FBCU32@60011 307FBCU32-60011 * 307FBCU32@60011

HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with illustration. Pattern B:Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations. Example of description in pattern B DISASSEMBLY.INSPECTI0N.REASSEMBLY Tightening torque unit T = N-m(kgf-cm) [ft-lbfl Step Nos. are partially sometimes omitted in illustrations. When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame. T = 46.1 - 48.1 (470 - 490) (34.0 - 35.51 8 Disassembly Procedure 1 Remove the cover. [Point I] 2 Remove the bushing [Point 21 C Operation explained later 3 Remove the gear. Point Operations Explanation of key point for operation with an illustration Y [Point I] Disassembly: Put a match mark when removing the pump cover. [Point 21 Inspection: Measure the bushing inside diameter. Limit: 19.12 mm (0.7528 in)

TOYOTA Electric POWERED Forklift 7FBCU15-55 & 7FBCHU25 Service Repair Manual

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