Stand-Up Lift Truck Service 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

© 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.

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

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

How To Use This Manual Toyota Stand-Up End Control Service Manual
iv 00700-CL1SM-3 Issued: 6/1/04
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

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 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

How To Use This Manual Toyota Stand-Up End Control Service Manual
vi 00700-CL1SM-3 Issued: 6/1/04
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Toyota Stand-Up End Control Service Manual How to Use This Manual
00700-CL1SM-3 Issued: 6/1/04 1-1
How to Use This Manual1:

How to Use This Manual Toyota Stand-Up End Control Service Manual
Map of the Manual
1-2 00700-CL1SM-3 Issued: 6/1/04
Map of the Manual
Abbreviations &
Symbols
Manual Design
Map of the Manual
Component Location
Photos
Alphabetical List of
Component
Procedures
Table of Contents
Vehicle Specifications
How To Use This
Manual
Safety
Systems
Overview
Planned
Maintenance
Troubleshooting
Messages, Codes
And Tests
Go to Chart
MAP2
Component
Procedures

Map of the Manual
00700-CL1SM-3 Issued: 6/1/04 1-3
MAP2: Map of the Manual (Continued)
Appendix
Index
Lubrication
Equivalency Chart
Torque Charts
Decimal Equivalent
Chart
Standard/Metric
Conversions
Theory of
Operation
Electrical and
Hydraulic
Schematics

Manual Design
1-4 00700-CL1SM-3 Issued: 6/1/04
Manual Design
This 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:
• Name of the manual
(Toyota Stand-Up End Control Service
Manual)
• Current Chapter Title
(for example; How to Use This Manual)
• Current topic
(for example; 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 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.
• Component Procedures gives step-by-step
procedures for testing, removal,
installation, and adjustment of individual
truck components. Components are
grouped by truck system.
To find a component procedure, you may
use one of three methods:
• Look up the component name in the
List of Component Procedures.
• Find the component in the Component
Locator Photos.
• Look up the component name in the
Index.
• Theory of Operation explains signal flow
within the hydraulic and electrical
schematics for various conditions of lift
truck operation.
• Appendix contains reference information
such as torque values, lubricants,
standard/metric conversions, and electrical
and hydraulic schematics.
• Index lists subjects alphabetically.

Abbreviations & Symbols
00700-CL1SM-3 Issued: 6/1/04 1-5
These abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A ampere
approx approximately
amp ampere or amplifier
aux auxiliary
AWG American Wire Gauge
BDI Battery Discharge Indicator
BSOC battery state-of-charge
BWI Brush Wear Indicator
CAN Controller Area Network
cm centimeter
COP Computer Operating
Program
dia. diameter
DGND Digital Ground
DVM Digital Volt Meter
EE UL Electric Truck Type
Certification Rating where
electrical equipment is
completely enclosed
EPO Emergency Power Off
ESD Electrostatic Discharge
ft. foot
gal. gallon or gallons
gm gram
Gnd ground
HD hours on deadman
Ht. height
in. inch, inches
kg kilogram(s)
km/h kilometers per hour
kPa kilo Pascal
lb. pound, pounds
LED Light Emitting Diode
LPC Lift Power Control
mA milliampere
max maximum
min minute or minimum
mm millimeter
mph miles per hour
NV non-volatile
Nm newton meter
OACH Overall Collapsed Height
ODI Operator Display Interface
OSHA Occupational Safety and
Health Association
oz. ounce
PC personal computer
psi pounds per square inch
PWM pulse width modulation
P/N part number
RAM random access memory
ROM read only memory
Regen regenerative braking
SAE Society of Automotive
Engineers
SG Specific Gravity
SOL solenoid
spec specification
STR Steer Contactor
TPC Traction Power Control
UL Underwriter’s Laboratories

1-6 00700-CL1SM-3 Issued: 6/1/04
Term/Symbol Definition
V volt
VDC volts direct current
wrt with respect to
w/ with
w/o without
@ at
™ trademark
© copyright
® registered
+ plus or positive
– minus or negative
± plus or minus
° degrees
°F degrees Fahrenheit
°C degrees Celsius
< less than
> greater than
% percent
= equals

Toyota Stand-Up End Control Service Manual Safety
00700-CL1SM-3 Issued: 6/1/04 2-1
Safety2:

Safety Toyota Stand-Up End Control Service Manual
Definitions
2-2 00700-CL1SM-3 Issued: 6/1/04
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
WARNING!
Warning means a potentially hazardous
situation exists which, if not avoided,
could result in death or serious injury.
CAUTION!
Caution means a potentially hazardous
situation exists which, if not avoided,
could result in minor or moderate injury
or in damage to the truck or nearby
objects.

General Safety
00700-CL1SM-3 Issued: 6/1/04 2-3
General Safety
Do not operate or work on this truck unless you
have reviewed the Operator’s Manual
(Publication No. 00700-AUCL1-2) and are
trained, qualified, and authorized to do so.
Know the truck’s controls and what they do.
Do not operate this truck if it is in need of repair
or if it is in any way unsafe.
Operate this truck only from the operator’s
compartment.
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General Safety
2-4 00700-CL1SM-3 Issued: 6/1/04
Before working on this truck, always turn the
key switch to OFF and disconnect the truck’s
battery connector (unless this manual tells you
otherwise).
Do not wear watches, rings, or jewelry when
working on the truck.
Follow the scheduled lubrication, maintenance,
and inspection steps.
Follow exactly the safety and repair instructions
in this manual. Do not take “shortcuts.”
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General Safety
00700-CL1SM-3 Issued: 6/1/04 2-5
Do not use an open flame near the truck.
Do not use gasoline or other flammable liquids
for cleaning parts.
Clean up any hydraulic fluid, oil, or grease that
has leaked or spilled on the floor.
.
Use and park this truck indoors. Do not operate
outdoors (except for dock or ramp operation, if
permitted).
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General Safety
2-6 00700-CL1SM-3 Issued: 6/1/04
Do not wash this truck with a hose. Do not
steam clean inside compartments.
Do not add to or modify this truck without
written approval from Toyota. Refer to the
Standards Compliance section of the Operator’s
Manual (Publication No. 00700-AUCL1-2).
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Battery Safety
00700-CL1SM-3 Issued: 6/1/04 2-7
Battery Safety
Before working on or near a battery, review the
general safety rules. Always follow these safety
rules.
See the battery manufacturer’s instruction
manual for specific instructions on battery
maintenance. The instructions found there take
precedence over the instructions found in this
truck manual.
Size and Type
When you install a battery in this truck, make
sure that it is the correct size and voltage.
WARNING!
Do not install a battery that weighs less
than the recommended minimum
weight. This could affect the truck’s
stability.
The truck’s specification plate gives you
important information about the battery used
in this truck. See Figure 2-1.
The following list explains the numbered items
in the figure:
1. Truck weight without battery
(pounds/kilograms)
2. Truck voltage
3. Minimum/maximum allowable weight of
battery (pounds/kilograms)
4. Maximum rating of battery (amp-hours)
412-645.eps
Figure 2-1: Truck Specification Plate
31 42

Battery Safety
2-8 00700-CL1SM-3 Issued: 6/1/04
WARNING!
As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not
properly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Be sure
there are no open flames or sparks in
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
CAUTION!
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get on
your face or in your eyes, flush the area
with cold water and get medical help
immediately.
Wear personal protective equipment to protect
eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields), and a rubber apron.
Make sure a shower and eyewash station are
nearby in case of an accident.
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Battery Safety
00700-CL1SM-3 Issued: 6/1/04 2-9
A battery gives off explosive gases. Never
smoke, use an open flame, or use anything that
gives off sparks near a battery.
Keep the charging area well-ventilated to avoid
hydrogen gas concentration.
Disconnect the battery from the truck at the
battery connector, after turning the key switch
OFF. Do not break live circuits at the battery
terminals. A spark often occurs at the point
where a live circuit is broken.
Do not lay tools or metal objects on top of the
battery. A short circuit or explosion could
result.
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Battery Safety
2-10 00700-CL1SM-3 Issued: 6/1/04
Keep batteries clean. Corrosion causes shorts
to the frame.
Keep plugs, terminals, cables, and receptacles
in good condition to avoid shorts and sparks.
Keep filler plugs firmly in place at all times
except when the electrolyte level is checked,
when water is added to the cells, or when the
specific gravity is checked.
Make certain that the vent holes in the filler
plugs are open to allow the gas to escape from
the cells.
Do not allow cleaning solution, dirt, or any
foreign matter to enter the cells.
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Battery Safety
00700-CL1SM-3 Issued: 6/1/04 2-11
Make sure that the battery you are installing in
this truck is the correct size. A smaller or
lighter weight battery could seriously affect
truck stability. See the truck’s specification
plate for more information.
Never plug a battery charger into the truck’s
battery connector. Plug the battery charger only
into the battery connector from the battery.
Follow the charging procedures in the Battery
Instruction Manual and in the Battery Charger
Instruction Manual.
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Static Precautions
2-12 00700-CL1SM-3 Issued: 6/1/04
Static Precautions
Electronic circuit boards and devices used on
this Toyota lift truck can be damaged by the
discharge of static electricity, called
electrostatic discharge (ESD).
Static charges can accumulate from normal
operation of the lift truck as well as movement
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, styrofoam coffee cups).
Accumulated static can be discharged through
human skin to a circuit board or component by
touching the parts. Static discharge is also
possible through the air, when a charged object
is placed close to another surface at a different
electrical potential. Static discharge can occur
without seeing or feeling it.
Whenever working on or near static-sensitive
electronics, always use static discharge
precautions.
1. Place a static discharge wrist strap around
your wrist. Connect the ground lead to the
wrist strap connector. The wrist strap
should be equipped with a 1 megohm
resistor to protect against shock hazard.
2. Connect the ground plug to the ESD
ground jack on the lift truck. The ESD
ground jack is located on the tractor frame
near the steer tiller. If you cannot use the
ground jack, connect the ground clamp to
an unpainted, grounded surface on the lift
truck frame.
3. Handle circuit boards by edges only. Avoid
touching edge connectors.
4. If you will be removing or installing
static-sensitive components, place them on
a properly grounded static mat.
5. To transport static sensitive components,
including failed components being
returned, place the components in an
antistatic bag or box (available from your
Dealer).
The wrist strap and associated accessories
should be tested monthly to verify they are
working properly. A non-functional static
discharge wrist band will not alert you that it is
bad.
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Figure 2-2: Anti-Static Ground Jack

Static Precautions
00700-CL1SM-3 Issued: 6/1/04 2-13
Figure 2-3 shows the components of the Toyota
antistatic field service kit, Part Number (P/N)
00590-04849-71. The kit includes a wrist strap,
ground cord, and static-dissipative work
surface (mat). Follow the instructions packaged
with the kit.
Wrist straps are available in quantities of 25, as
P/N 00590-04848-71.
A wrist strap tester is available as
P/N 00590-04850-71.
Contact your local Toyota dealer for
information.
MAT2.TIF
Figure 2-3: Anti-Static Kit (P/N 00590-04849-71) with Wrist Strap and Mat

Jacking Safety
2-14 00700-CL1SM-3 Issued: 6/1/04
Jacking Safety
Sometimes you may need to jack the truck off
the floor to perform maintenance procedures.
When doing so, observe the proper safety
precautions:
1. Lower the carriage and forks completely to
the floor. Remove any load.
2. Place all controls in neutral.
3. Block the wheels to reduce the risk of
movement of the vehicle.
4. Disconnect battery connector.
5. Place the jack under the designated jacking
points. See Figures 2-4 and 2-5.
WARNING!
Use extreme care whenever the truck is
jacked up. Never block the truck
between the telescopic and the floor.
Keep hands and feet clear from vehicle
while jacking the truck. After the truck is
jacked, place solid blocks beneath it to
support it. DO NOT rely on the jack
alone to support the truck.
6. To jack the drive wheel: Place the jack in
the designated jacking position. See
Figure 2-4. Jack the truck up just high
enough to raise the drive wheel off the floor.
Place a block under the frame as shown.
7. To jack the tractor: Place the jack in the
designated jacking position near the
steerable wheel. See Figure 2-5. Jack the
truck so that the steerable wheel is off the
floor no more than 1 in. (25.4 mm). Block
under the frame as shown.
NOTE: After working on vehicle, test all controls
and functions to verify correct operation.
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Figure 2-4: Jacking Drive Wheel
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Figure 2-5: Jacking Tractor

Towing
00700-CL1SM-3 Issued: 6/1/04 2-15
Towing
To safely tow this lift truck:
1. Lower the carriage and remove any load
from the forks.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Install the brake release bolts.
4. Using a suitable towing vehicle, lift the
truck until the steer tire is no more than
1 in. (25.4 mm) off the floor.
5. Tow the truck slowly in the tractor-first
direction.
WARNING!
When towing is complete, make sure to
remove the brake release bolts. Failure
to do so could cause serious injury.

Welding Safety
2-16 00700-CL1SM-3 Issued: 6/1/04
Welding Safety
CAUTION!
Flame cutting or welding on painted
surfaces may produce potentially
harmful fumes, smoke, and vapors.
Prior to performing flame cutting or
welding operations, it is recommended
that the coating be removed in the
vicinity where the operation(s) will be
performed. Coating removal may be by
mechanical methods, chemical methods,
or a combination of methods. Perform
flame cutting and/or welding operations
in well ventilated areas. Use local
exhaust if necessary.
Before working on this truck, make sure that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
CAUTION!
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
• Check for shorts to frame as described on
page 5-15. If any shorts are detected,
remove them before you proceed with the
welding operation.
• Clean the area to be welded.
• Remove Interface Card, Translator Card,
and power amplifiers from the lift truck.
• Protect all truck components from heat,
weld spatter, and debris.
• Attach the ground cable as close to the weld
area as possible.
• Do not perform any welding operations
near the electrical components.
• Remove battery from truck if welding must
be done near the battery compartment.
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Toyota Stand-Up End Control Service Manual Systems Overview
00700-CL1SM-3 Issued: 6/1/04 3-1
Systems Overview3:

Systems Overview Toyota Stand-Up End Control Service Manual
Lift Truck Dimensions and Specifications
3-2 00700-CL1SM-3 Issued: 6/1/04
This lift truck is rated for performance by load
center and load weight.
Review the specification plate located in the
battery compartment for detailed load capacity
and load center information.
For basic dimensions, see Table 3-1, Lift Truck
Dimensions and Specifications on page 3-3.
412-645.wmf
Figure 3-1: Lift Truck Specification Plate
Nominal battery
voltage Serial Number
Approximate
weight of lift
truck minus
battery, load,
and operator
Toyota model
designation
Battery weight must be between the minimum and maximum weight
Maximum load
capacity for this
lift truck
Maximum
battery weight
for this lift
truck
Minimum
battery weight
for this lift
truck

00700-CL1SM-3 Issued: 6/1/04 3-3
Table 3-1: Lift Truck Dimensions and Specifications
Category Model
7BNCU15 7BNCU18 7BNCU20 7BNCU25
Max Load @ 24 in.
(610 mm) Load
Center
3000 lb.
(1361 kg)
3500 lb.
(1588 kg)
4000 lb.
(1814 kg)
5000 lb.
(2268 kg)
Overall Collapsed
Height* (OACH)
83 - 107 in.
(2108 - 2716 mm)
Elevated Height* 127 to 258 in.
(3226 to 6553 mm)
123 to 251 in.
(3124 to 6375 mm)
Extended Height
w/Load Backrest*
175 to 306 in.
(4445 to 7772 mm)
175 to 299 in.
(4445 to 7594 mm)
Truck Wheelbase 50.3 in.
(1280 mm)
53.1 in.
(1349 mm)
55.6 in.
(1412 mm)
Truck Head Length
w/o Sideshift*
68.5 in.
(1740 mm)
71.2 in.
(1808 mm)
73.7 in.
(1872 mm)
Truck Head Length
w/Sideshift
70.9 in.
(1801 mm)
73.6 in.
(1869 mm)
76.1 in.
(1933 mm)
Battery Compartment 39.6 x 18.5 x 32.3 in.
(1007 x 470 x 820 mm)
39.6 x 21.25 x 32.3 in.
(1007 x 540 x 820 mm)
39.6 x 23.75 x 32.3 in.
(1007 x 603 x 820 mm)
Battery Voltage 36V
Minimum Battery
Weight
2300 lb.
(1044 kg)
2600 lb.
(1180 kg)
2700 lb.
(1226 kg)
*Specifications will vary according to mast type

General System Data
3-4 00700-CL1SM-3 Issued: 6/1/04
General System Data
Modes of Operation
There are four different modes of operation for
this lift truck:
• Performance Selection Mode
• Configure Mode
• Maintenance Mode
• Learn Mode
To select a mode, enter the correct password
(see page 3-5 for instructions on entering a
password).
Performance Selection Mode
Entering Performance Selection Mode will allow
the operator or supervisor to choose between
four different performance modes. Each
performance mode can be configured and
stored for use in different types of applications.
Use the MODE button on the operator display
to view the mode being used. Pressing the
MODE button will cycle through all four
performance modes.
Configurable settings in Performance Selection
Mode include maximum forward and reverse
speeds, acceleration strength and coast
distances. To configure each mode individually,
use the operator display to enter Configure
Mode and select Mode #1, Mode #2, Mode #3, or
Mode #4.
Configure Mode
Entering the Configuration Password lets you
access the lift truck’s Configure Mode.
This mode lets you enter the lift truck’s software
and change the lift truck’s performance limits.
Use the Configure Mode Chart on page 3-6 to
see which items you can change and the
selections that are available.
Maintenance Mode
This mode lets you test a circuit in the lift truck
while the lift truck is stationary.
You cannot operate the lift truck while it is in
Maintenance Mode.
WARNING!
Before placing the lift truck in
Maintenance Mode:
1. Jack the lift truck so that the drive
tires are off the floor.
2. Make sure the controls are in neutral.
3. Make sure the lift truck is blocked
to keep it from moving.
4. Lower the forks all the way
to the floor.
See Maintenance Mode on page 3-11.
Learn Mode
You can select Learn Mode after entering
Maintenance Mode.
Learn Mode lets you re-calibrate the lift truck’s
control handle. You would enter Learn Mode
and perform the instructions that are shown on
the operator display if you replace any of these
components:
• Interface Card
• Control Handle
• Firmware
NOTE: The lift truck automatically asks the
technician to perform Learn on initial
power-up. It does not need to be run
again.

General System Data
00700-CL1SM-3 Issued: 6/1/04 3-5
Passwords
There are two levels of passwords that you
might use on this lift truck.
The Configuration Password allows you to enter
most of the items in Configure Mode.
The Maintenance Password lets you enter
Maintenance Mode.
Entering a Password
1. The operator display will show 7BNCU15 or
similar message depending on the truck
model.
NOTE: If you are trying to access Maintenance
Mode or Configure Mode after the lift
truck has shown an error code on its
operator display, simply press the
ENTER button.
2. Press the ENTER button.
3. The operator display will show 8 blank
spaces.
4. Enter the password as follows:
NOTE: The default Maintenance Password is
“TOY2----”. The default Configuration
Password is “TOY1----”.
5. To illustrate this procedure, assume you
will be entering the default Maintenance
Password (“TOY2----").
6. Look at the operator display. The blinking
space is the active space.
7. To move the active space to the right, press
the ENTER button.
To move the active space to the left, hold
down the ENTER button and press the
DOWN button.
8. When the space you want to change is
active, stop pressing the button.
9. Press the UP button. You will scroll up
through the numbers (0, 1, 2, 3 — 7, 8, 9)
and letters (a, b, c, — x, y, z).
If you press the DOWN button, you will
scroll down through the letters (z, y, x, — c,
b, a) and numbers (9, 8, 7 — 2, 1, 0).
NOTE: If you push and hold the button, you will
scroll very quickly.
10. Stop pressing the button when the letter or
number you want appears in the space.
11. Move to the next space you want to change
by:
• pressing the ENTER button to move the
active space to the right.
• holding down the ENTER button and
pressing the DOWN button to move the
active space to the left.
12. Repeat steps 8, 9, and 10 to change the
letter or number in this space. Repeat steps
7, 8, 9, and 10 to enter the rest of the
password.
13. When the operator display shows the
correct password, press the ENTER button.
14. If the password was correct, you are now in
the lift truck’s Maintenance Mode.

Configure Mode
3-6 00700-CL1SM-3 Issued: 6/1/04
Configure Mode
Configuration Mode Menu
NOTE: @ Indicates Factory Default; *
Indicates Optional Item
Item Values Description
Quit
Save? Yes
Save? No
Exit Configuration Mode
Save changes and leave Configuration Mode
Abandon changes and leave Configuration Mode
Default
Yes
No
Restore Factory Defaults
Restore to Factory Defaults
Do not restore Factory Defaults
Modes
@ Operator
Super.
Select Mode Access
Mode Selection Accessible by Operator
Mode Selection Accessible Only by Supervisor
Mode #1 Configure Performance Mode #1.
See Mode #1 Menu on page 3-9.
BDI 20%) @ 20% Set BDI Lift Cutout Point
0% to 50% (1% increments)
TOY2_____ Enter new Maintenance Password
Default Maintenance Password = "TOY2----"
TOY1_____ Enter New Configuration Password
Default Configure Password = “TOY1----“
English
Quit
@ English
French
Spanish
Select Language for Messages
Quit Language Selection Menu
Select English
Select French
Select Spanish
English
Quit
@ English
Metric
Units of Measurement (For Display Messages)
Quit Selection Menu
English
Metric

Configure Mode
00700-CL1SM-3 Issued: 6/1/04 3-7
Clock Set Date and Time
Quit Quit
24 Hour? Y
24 Hour? N
Select 12 or 24 Hour Clock
DayLtS? Y
DayLtS? N
Daylight Savings Time?
Set Time Set Time: 10:41PM = 10:41 PM or
2241 = 10:41 PM (24 Hour Clock)
08/20/98 Set Date: Month/Day/Year
SchMaint
Quit
Reset
@ Brake
Drive
200 Hours FS
MSG Only
L Cutout
Enable
Disable
Select Hourmeter for Scheduled Maintenance
Quit Scheduled Maintenance Menu
Reset Clock
Select Deadman Brake Hourmeter
Select Drive System Hourmeter
Select Interval For Service Reminder
20 to 500 Hours in 20 Hour Increments
Defaults (hours) =
Hourmeter E Label EE Label
Brake 200 200
Drive 350 150
Message reminder only
Lift cutout with reminder
Turn ON maintenance reminder feature
Turn OFF maintenance reminder feature
BWI-Trac
Half Speed
@ Icon
Brush Wear Indicator Action Mode
Half Top Travel Speed After 200 Additional Traction Miles
or
Illuminated Icon ONLY
BWI-Lift
No Lift
@ Icon
Brush Wear Indicator Action Mode
Lift Motor Inoperative After 10 Additional Lift Hours
or
Illuminated Icon ONLY
Sideshift*
On
Off
Select Sideshift (Low Speed Attachment)
Turn Sideshift On
Turn Sideshift Off
NOTE: @ Indicates Factory Default; * Indicates Optional Item

Configure Mode
3-8 00700-CL1SM-3 Issued: 6/1/04
Travel Alarm*
Forks
Tractor
@ Both
None
Select Alarm To Sound For Travel
Forks-First Direction Of Travel
Tractor-First Direction Of Travel
Both Directions Of Travel
Neither Direction of Travel
SpdLimit*
@ 3.0 MPH
2.0 to 6.0 MPH
3.0 to 10.0 KPH
Set the Height Limit Switch Speed
0.2 MPH Increments
0.2 KPH Increments (metric)
LftLimit*
@ On
Off
Set the Lift Limit with Bypass Switch
Turn On Switch Function
Turn Off Switch Function
Weight*
On
Off
Learn
Select Weight Sensor
Turn On Weight Sensor
Turn Off Weight Sensor
Learn Weight Sensor
Attch#1*
Type?
Clamp
Other
None
Quit
Select Optional Hydraulic Attachment #1
Select Attachment Type
Clamp Attachment
Another Type of Attachment
No Attachment
Quit
Attch#2*
On
Off
Select Optional Hydraulic Attachment #2
Turn Attachment #2 On
Turn Attachment #2 Off

Configure Mode
00700-CL1SM-3 Issued: 6/1/04 3-9
Configuring Modes 1-4
Mode #1 Menu
Quit Quit Mode #1
@ 7.0 MPH
2.0 to 7.0
3.0 to 11.0
Set Maximum Forward Speed
0.2 MPH Increments
@ 7.0 MPH
2.0 to 7.0
3.0 to 11.0
Set Maximum Reverse Speed
0.2 MPH Increments
Medium
Soft
Medium
@ Hard
Set Acceleration Strength
Long
Short
@ Medium
Long
Set Coast Distance
Mode #2 Menu
Quit Quit Mode #2
@ 7.0 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
@ 7.0 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
Medium
Soft
@ Medium
Hard
Long
Short
Medium
@ Long
Set Coast Distance

Configure Mode
3-10 00700-CL1SM-3 Issued: 6/1/04
Mode #3 Menu
Quit Quit Mode #3
@ 6.5 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
@ 6.5 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
Medium
Soft
@ Medium
Hard
Long
Short
Medium
@ Long
Set Coast Distance
Mode #4 Menu
Quit Quit Mode #4
@ 6.0 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
@ 6.0 MPH
2.0 to 7.0
3.0 to 11.0
0.2 MPH Increments
Medium
@ Soft
Medium
Hard
Long
Short
Medium
@ Long
Set Coast Distance

Maintenance Mode
00700-CL1SM-3 Issued: 6/1/04 3-11
Maintenance Mode
Maintenance Mode Menu
Quit Exit Maintenance Mode
Learn
Quit
Controls
Weight
Learn the Control Handle
Quit Learn Mode
Learn Controls: Return Control to Neutral, Press Enter
Learn the Weight Sensor
D Input Digital Inputs
Quit DI Quit Digital Inputs
I00 Deadman Switch
I01 EPO Switch
I02* High Speed Limit Switch
I03 Tilt Up Switch
I04 Tilt Down Switch
I05 Sideshift Right Switch
I06 Sideshift Left Switch
I07* Lift Limit Mast Switch
I08 Steer Position Sensor
I09* Attachment Spool Valve Switch
I10 Horn Switch
I11 FU1 Steering Fuse
I12 FU3 Lift Fuse
I13 Traction Motor #1 (Left) Brush Wear Indicator (Both)
I14 Traction Motor #2 (Right) Brush Wear Indicator (upper)
I15 Traction Motor #2 (Right) Brush Wear Indicator (lower)
I16 Lift Motor Brush Wear Indicator (upper)
I17 Lift Motor Brush Wear Indicator (lower)
I18 Traction Motor #1 (left) Speed Sensor

Maintenance Mode
3-12 00700-CL1SM-3 Issued: 6/1/04
I19 Traction Motor #2 (right) Speed Sensor
I20 Traction Motor #1 (left) Thermostat
I21 Traction Motor #2 (right) Thermostat
I22 Lift Motor Thermostat
I23 Lift Switch
I24 Lower Switch
I25* Tilt Limit Switch
I26* Tilt Limit Switch
I27 TPC_L Signal
I28 TPC_R Signal
I29 Left Power Amp Switch Inputs
I30 Right Power Amp Switch Inputs

Maintenance Mode
00700-CL1SM-3 Issued: 6/1/04 3-13
Output Digital Outputs
Ready? Jack Drive Wheels Off Floor
Quit DO Quit Digital Outputs
O01 Toggle the Load Hold (SOL1) Solenoid
O02* Toggle the Sideshift (SOL2) Solenoid
O04 Toggle the Tilt (SOL4) Solenoid
O05* Toggle the Aux PSI Select (SOL 5) Solenoid
O06 Toggle the Auxiliary Direction A (SOL 6) Solenoid
O07 Toggle the Equalization (SOL 7) Solenoid
O08 Toggle the Auxiliary Direction B (SOL 8) Solenoid
O09* Toggle the High Flow Auxiliary (SOL 9) Solenoid
O10* Toggle the High Flow Attachment 1 (SOL 10) Solenoid
O11* Toggle the High Flow Attachment 2 (SOL 11) Solenoid
O12 Toggle the TPC Contactor
O13 Toggle the LPC Contactor
O14 Toggle the STR Contactor
O15 Toggle the AUX Contactor
O16 Ramp Command to Traction Power Amplifier #1 (left)
O17 Ramp Command to Traction Power Amplifier #2 (right)
O18 Toggle Traction Motor Brake #1 (left)
O19 Toggle Traction Motor Brake #2 (right)
O20 Ramp the Frequency to the Operator Display Alarm
O21 Toggle the Horn
O22* Toggle the Travel Alarm

Maintenance Mode
3-14 00700-CL1SM-3 Issued: 6/1/04
A Input Analog Inputs
Quit AI Quit Analog Inputs
A05 Throttle Potentiometer Voltage
A06 Battery Discharge Indicator Voltage
A07 Power Supply +12VDC
A08 FU3 Lift Fuse Voltage
A09* Weight Sensor Voltage
# of Errors
Logged 0-16
Quit
Enter
Clear
Error Codes Logged
System Will Store Up To 16 Error Codes
Exit Error Log Menu
Press to Scroll Through Logged Error Codes
TT:Versn TT:XX.X Firmware Version Number

Software Configuration/PC Loader Program
00700-CL1SM-3 Issued: 6/1/04 3-15
Software
Configuration/PC Loader
Program
Overview
The PC Loader Program allows you to update
software, set factory defaults, and configure
options on your Toyota lift truck.
• Flash Memory Program
• Blank Primary Memory
• Set Factory Defaults
• Options
Requirements
PC Loader can be installed on an
IBM-compatible PC. The PC communicates with
the truck through a 9-pin serial cable
(P/N 00590-43591-71).
WARNING!
We recommend using the surge
protector (P/N 00590-43592-71) to
protect your PC from possible
electrostatic discharge or voltage surges.
Install PC Loader
NOTE: This program can be installed and
accessed using either DOS or Windows
application.
To Install from DOS:
1. Place the disk in your floppy drive.
2. Type a:install at the DOS prompt. If your
3.5 in. disk drive has not been designated
as “a”, you will need to substitute the
proper drive letter in its place.
3. The program will automatically install onto
your PC’s hard drive.
To Install from Windows95:
1. Use your mouse to click on the START
button located in the lower left corner of
your screen. Then, use your arrow to click
on RUN.
2. At the prompt, type a:install and use your
mouse to click on the OK button. If your 3.5
in. disk drive has not been designated as
“a”, you will need to substitute the proper
drive letter in its place.
To Install from Windows version 3.1:
1. Locate the Program Manager icon on the
main desktop screen and open it by
double-clicking on it with your mouse.
2. Locate the menu bar at the top of the
screen. Click on FILE.
3. From the FILE menu screen, select RUN by
double-clicking on it with your mouse
button.
4. At the prompt, type a:install and use your
mouse to click on the OK button. If your
3.5 in. disk drive has not been designated
as “a”, you will need to substitute the
proper drive letter in its place.

3-16 00700-CL1SM-3 Issued: 6/1/04
Connect PC To Lift Truck
1. Turn truck key switch OFF.
2. Connect the surge protector to the COMM 1
or COMM 2 port of your computer.
NOTE: On most PC’s and laptop PC’s, the
COMM 1 or COMM 2 port is located on
the rear of the unit and is a 9-pin “male”
connection.
3. Connect the 9-pin serial cable to the surge
protector.
4. Connect the cable to JC1 on the Interface
Card mounted on the left side of the tractor
frame.
Starting PC Loader
NOTE: PC Loader can be started from either
DOS or a Windows application.
To Start PC Loader from DOS:
1. Make sure you are in the main directory on
your hard drive. Your DOS prompt should
be C:>
If you are not in the main directory, type
cd at the prompt and press ENTER. This
should return you to the main directory.
2. Type C:toyotaloadliteloadlite.bat at
the DOS prompt.
3. The Main Menu screen should appear on
your PC’s screen. Select the feature you
want to use from the Main Menu. See
Figure 3-2.
To Start PC Loader from Windows95:
1. After starting Windows, use your mouse to
click on the START button located in the
lower left corner of your screen. Then, use
your arrow to click on RUN.
2. At the prompt, type
C:toyotaloadliteloadlite.bat and use
your mouse to click on the OK button.
3. The main menu screen should appear on
your PC screen. See Figure 3-2.
To Start PC Loader from Windows
version 3.1:
1. Locate the Program Manager icon on the
main desktop screen and open it by
double-clicking on it with your mouse.
2. Locate the menu bar at the top of the
screen. Click on FILE.
3. From the FILE menu screen, select RUN by
double-clicking on it with your mouse
button.
4. At the prompt, type
C:toyotaloadliteloadlite.bat and use
your mouse to click on the OK button.
5. The Main Menu screen should appear on
your PC screen. See Figure 3-2.

00700-CL1SM-3 Issued: 6/1/04 3-17
Troubleshooting
At Start-Up
If PC Loader cannot read the truck software
when you start PC Loader, you will see the
communication error screen in Figure 3-3.
1. Check the following:
• Cable connection between the truck and
the PC
• Correct communication port selected (1
or 2)
• Truck key switch is ON
2. Cycle key switch OFF and ON.
3. Restart PC Loader.
opening.tif
Figure 3-2: Main Menu Screen In PC Loader
comm.tif
Figure 3-3: Communication Error Screen, At Start-Up

3-18 00700-CL1SM-3 Issued: 6/1/04
During Regular Use
If you see the screen in Figure 3-4 while you are
using PC Loader, communication with the truck
software was lost.
Check the following:
• Cable connection between the truck and
the PC
• Truck key switch is ON
NOTE: If you see the message in Figure 3-5, the
truck’s firmware must be updated.
To clear the screen, perform the following:
1. Close and restart PC Loader.
2. Update the truck software. See Flash
Memory Program on page 3-19.
3. If you see the message in Figure 3-5 at any
time after you update the software, call
your authorized Toyota Dealer.
Figure 3-4: Communication Error Screen, During Regular Use
Figure 3-5: Dealer Mismatch Screen

00700-CL1SM-3 Issued: 6/1/04 3-19
Flash Memory Program
The flash memory program allows you to:
• Identify current version of software on your
truck
• Update current version of software with a
newer version
1. Type F at the main menu prompt. See
Figure 3-6.
2. Type the number of the software version
you want to load on the truck at the flash
programming prompt. See Figure 3-7.
NOTE: To exit this menu, select A to abort. This
will return you to the main menu.
3. After the Flash Memory Program has been
installed, select X to terminate PC Loader.
Turn the key switch OFF and wait 5
seconds. Then, turn the key switch back
ON to complete the software loading
process.
Opening.tif
Figure 3-6: Main Menu Screen

3-20 00700-CL1SM-3 Issued: 6/1/04
Blank Primary Memory
The Blank Primary Memory feature allows you
to clear the memory in a truck so the Operator
Display can be used in another truck.
NOTE: The primary memory of this truck is
located on the Operator Display.
1. Type B at main menu prompt. See
Figure 3-8.
Flash.tif
Figure 3-7: Flash Programming Screen

00700-CL1SM-3 Issued: 6/1/04 3-21
2. After selecting this feature, the Blank
Primary Memory screen appears. See
Figure 3-9.
3. If you type N, the action is cancelled. If you
type Y, the memory is cleared. The truck
will then automatically restart and a new
prompt appears on your screen. See
Figure 3-10.
CAUTION!
Before removing the Operator Display,
be sure you do not cycle the power
OFF/ON. Doing so will rewrite the
memory of the truck.
4. Turn the truck OFF. It is now safe to
remove the Operator Display from the lift
truck.
clearcau.tif
Figure 3-9: Clear Primary Memory Caution Screen
clear2.tif
Figure 3-10: Blank Primary Memory Screen

3-22 00700-CL1SM-3 Issued: 6/1/04
Set Factory Defaults
The “Set Factory Defaults” feature allows you to
configure the truck to the original factory
settings.
1. Type S at the Main Menu prompt. See
Figure 3-11.
2. The program will ask you to verify your
decision to restore the factory defaults.
Enter Y if you want to restore the settings.
Enter N if you want to exit to the Main
Menu screen. See Figure 3-12.
Figure 3-12: Factory Default Settings Screen

00700-CL1SM-3 Issued: 6/1/04 3-23
Options
The Options feature allows you to:
• Enable and disable options on the truck
like sideshift, attachments, electric key, etc.
• Check the software version on the truck
• Check the serial number of the truck
• Check the manufacture date of the truck
• Check the model type of the truck
1. Type O at the Main Menu prompt. See
Figure 3-13.
opening.tif

3-24 00700-CL1SM-3 Issued: 6/1/04
2. The Options Menu screen shows you the
available options which can be
enabled/disabled on the truck. See
Figure 3-14.
3. Use the UP or DOWN arrows to move
through the options items. See Figure 3-14.
4. To change an option setting:
a. Type Y or N to change the highlighted
option. See Figure 3-14.
b. When you finish changing the options,
type X to exit.
NOTE: The option settings for “EE Truck,”
“French” and “Spanish” are for
information only. They cannot be
configured and appear as grey letters.
c. The program will then ask you to verify
the settings which you have chosen. A
message, “Write This Data to the
Vehicle?”, will appear at the bottom of
your screen. Type Y to configure the
truck or N to exit.
d. After changing the option settings, the
Main Menu appears.
options.tif
Figure 3-14: Options Menu Screen

Toyota Stand-Up End Control Service Manual Planned Maintenance
00700-CL1SM-3 Issued: 6/1/04 4-1
Planned Maintenance4:

Planned Maintenance Toyota Stand-Up End Control Service Manual
Maintenance Guidelines
4-2 00700-CL1SM-3 Issued: 6/1/04
A planned maintenance program is
recommended to enable:
• Maximum truck performance
• Maximum truck life
• Reduction of costly down time
• Avoidance of unnecessary repairs
Planned maintenance includes:
• Lubrication
• Cleaning
• Inspection
• Service
The planned maintenance guidelines fall into
two categories:
• Moderate usage
• Severe usage:
• More than 1500 hours of operation per
year
• Extreme environment conditions, such
as a bumpy or abrasive floor, constant
exposure to air saturated with dirt or
metallic particles, or an “EE” label
Perform all of the scheduled checks and
maintenance during the suggested intervals.
The time intervals given in this guide are based
on normal operating conditions. When
operating under abnormal or severe conditions,
perform these services more often as required
to keep the unit in good operating condition.
See “Lubrication Equivalency Chart” on
page A-2. This provides information on
lubrication specifications. Refer to the
manufacturer’s supplements for components
not listed on the following pages.

00700-CL1SM-3 Issued: 6/1/04 4-3
Operator’s Daily Checklist
7BNCU15/18/20/25 Operator’s Daily Checklist
Visual Inspection/Key Turned OFF
Component What to Check Mark
BATTERY
Battery
Battery Gates
Fully charged/correct water level/correct voltage, no leakage,
proper installation
Proper installation
BRAKE
Deadman Pedal Pedal moves freely, no binding
Deadman brake functions properly (travel circuit disabled)
CONTROLS
Function
Controls
Emergency Power
Off
Move smoothly without binding, return to neutral when released
Emergency disconnect functions properly
GENERAL
Guards/Covers
Decals
Leakage
Guards and covers installed and secure
Replace warning decals that are illegible or damaged.
Check floor under truck for any accumulation of fluid indicating a
possible leak
LIFT/LOWER SYSTEM
Cables/Hoses
Hydraulic
Reservoir
No damage to chains or hoses
Check hydraulic fluid level in hydraulic reservoir
TIRES
Tires No gouges, chunking, or flat spots
No bond failures
Adequate tread (if applicable)

4-4 00700-CL1SM-3 Issued: 6/1/04
7BNCU15/18/20/25 Operator’s Daily Checklist
Operational Inspection/Key Turned ON
Component What to Check Mark
HORN
Sounds when button is depressed
STEERING
Smooth steering, without binding or excess play
DIRECTIONAL/SPEED CONTROL
Moves smoothly without binding
Returns to neutral when released
Controls speed and direction properly
Plugging functions properly
Speed limits function properly
LIFT/LOWER SYSTEM
Lift/lower controls move smoothly and return to neutral when
released
All controls perform their functions as indicated
OPERATOR DISPLAY
Displays correct information and is easily readable
BRAKES
Pedal moves freely without binding
Lift truck stops in specified distance
Deadman brake functions properly (travel circuits disabled)
EMERGENCY POWER OFF BUTTON
Shuts down travel and lift functions when depressed
SAFETY
All flashing and working lights (optional) are functional
All limit switches function properly
Travel alarm (optional) functions
Check condition of static straps (beneath tractor)

00700-CL1SM-3 Issued: 6/1/04 4-5
Moderate and Severe Usage: 90-Day Inspection
Component What To Do Refer to
Drive Unit Change the fluid in the drive unit.
Refer to the “Recommended Oils by Temperature Chart” to
assure the proper type of fluid for your application.
page 7-46
Mounting
Hardware
Check torque of mounting hardware for major truck
components (lift motor and pump, aux. motor and pump,
brake assembly, drive motor and drive unit, hydraulic
manifolds, and mast-to-drive unit mounting bolts). Tighten or
replace any loose, broken, or missing hardware.
Check the torque of the overhead guard mounting bolts.
page A-4

4-6 00700-CL1SM-3 Issued: 6/1/04
Moderate Usage: Every 6 Months or 500 hours;
Severe Usage: Every 3 Months or 250 Hours (whichever comes
first)
Battery Check the weight stamped on the battery in the truck against
the minimum and maximum allowable weights on the
specification tag for the truck. Report any trucks that are
running with batteries under the minimum, or over the
maximum allowable weight.
Make sure the battery has no more than 0.5 in. (13 mm) free
play in any direction.
page 3-2
page 7-91
Battery
Connector
Inspect all battery connectors and leads for damage and cuts
in protective coatings.
Check for voltage and shorts to frame.
page 7-91
page 5-15
Battery Gates Make sure the battery gates are in place and not damaged. page 7-93
Brakes/Brake
Pads
In the tractor-first direction, check brakes for proper
operation.
Visually inspect the friction disc and plates with the brakes
released. Minimum thickness of the friction disc is 0.207 in.
(5.3 mm).
The air gap between the armature disc and the brake coil
must be 0.012 to 0.018 in. (0.305 to 0.457 mm). Failure to
keep the brake shimmed will cause premature wear on the
friction disc and plates and excessive motor heat.
page 7-76
Electrical Cables Inspect all cables for nicks or cuts. Replace any cable that is
damaged or shows signs of excessive heat.
Inspect over-the-mast cables for proper tension.
Make sure over-the-mast pulleys spin freely and show no
signs or wear.
Control Handle
Functions
Operate the lift/lower function. Verify the response is smooth
and controllable.
Operate the travel function. Verify that the full range of
acceleration is smooth and responsive. Make sure that
plugging/Regen is functioning properly.
Look for any play in the center position of the lift or travel.
Operate the Tilt, Sideshift and Optional attachment switches.
Verify they operate the function smoothly and do not stick.
Enter the maintenance mode and test the travel
potentiometer, Test A05. Make sure the potentiometer
voltage is stable with no voltage fluctuations in the neutral
position. If the voltage fluctuates by more than 0.2V in 10
seconds, replace the potentiometer to avoid unscheduled
down time. Run the potentiometer all the way up and down
the scale to verify smooth voltage changes.
page 7-37

00700-CL1SM-3 Issued: 6/1/04 4-7
Deadman Pedal The Deadman Pedal must operate smoothly with no binding.
Check proper activation and deactivation of the deadman
switch under the pedal.
page 7-43
Horn Make sure the horn sounds loudly when activated. page 7-101
Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cuts, chafing and
bulges. Replace bad hoses as soon as possible.
Inspect all fittings for leaks. Repair any leaks immediately.
Inspect over-the-mast hoses for proper tension.
Make sure over-the-mast pulleys spin freely and show no
signs of wear.
Hydraulic
Reservoir
Check for proper fluid level and the proper fluid for the
working environment.
page 7-126
Optional Lights Make sure all lights function and mountings are secure.
Overhead Guard Look for any physical damage to the guard. If the overhead
guard is structurally damaged, replace the guard.
page 7-20
Switches Check mast and optional switches for proper operation (if
used).
page 7-122
Chassis and Mast Inspect the mast pivot and telescopic bearings and rollers for
damage or wear.
Inspect the outside of the main frame for wear, especially if
the truck is used in drive-in racks.
page 7-148
Contactors Inspect contact tips for burnt or pitted surfaces. Failure to
replace the tips may cause surfaces to weld together,
causing unscheduled down time.
Check the plunger for smooth operation with no binding. If
binding occurs, the truck may exhibit intermittent fault
codes.
page 7-84
Drain Holes
(beneath deadman
pedal and in battery
compartment)
Make sure the drain holes are not blocked by any debris.
Drive Unit Check for proper fluid level in the drive unit. If the fluid level
is low, investigate for leaks and determine causes.
page 7-46
Forks Inspect forks for modifications, bends, cracks or wear. Check
for welding arcs and signs of excessive heat.
NOTE: If any of the imperfections above are found, replace
the fork immediately.
Hardware
(bolts, nuts, and
screws)
Check the tightness of wire and cable connections. This can
be done by physically trying to move the connection with
your hand.
page A-4

4-8 00700-CL1SM-3 Issued: 6/1/04
Lift Chains Check for proper adjustment of the chains. Lubricate as
required.
Inspect the chains for excessive stretch or wear.
page 7-153
Motors Visually inspect brushes for excessive heat (discoloration of
the pigtails). If excessive heat is evident, inspect the
armature circuit for loose connections.
Find the shortest brush in the holder. Remove the brush and
check the overall dimension. Inspect the brush for even
wear over the full surface of the brush. If the brush is not
contacting the complete surface, replace the brushes.
Inspect the brush rigging for damage or loose brush holders.
Ensure that the connections on the brush leads are tight.
Check brush spring tension.
Blow out the inside of the motor with compressed air.
Check the cable lugs to make sure they are tight to the
terminal studs. Both the inside and outside nut should be
torqued to the values listed on page A-4. Replace any cable
that shows signs of excessive heat.
page 7-102
page 7-105
page 7-102
Wheel and Tires Inspect all wheels and tires for chunking, bond failure, and
excessive or uneven wear. Replace any tire exhibiting any of
these symptoms.
Check caster wheel bearing for binding or excessive play.
Inspect drive and caster axle for excessive play.
page 7-27
Steerable Wheel
Assembly
Inspect the caster wheel axle and bearings for excessive wear.
Inspect the steer chain for proper adjustment. Flex of the
chain should be approximately 1/8 in. (3.175 mm).
page 7-31
Lift, Side Shift
and Tilt Cylinders
Inspect the condition of the rams for leaking seals, scored
pistons and secure mounting.
Check the lift cylinders for any load drift. Use the following
specifications and observe the drift over a 10-minute period:
• 7BNCU15: 3.0 in. (76 mm) drift with 3000 lb. pressure
• 7BNCU18: 3.5 in. (89 mm) drift with 3500 lb. pressure
• 7BNCU20: 4 in. (102 mm) drift with 4000 lb. pressure
• 7BNCU25: 5 in. (127 mm) drift with 5000 lb. pressure
page 7-142

00700-CL1SM-3 Issued: 6/1/04 4-9
Shorts and
Voltage Leaks to
Frame
Using a non-flammable cleaner, clean any dirt and oil buildup
inside the tractor compartments. This will reduce the
chance of intermittent error codes caused by shorts between
maintenance intervals. It will also extend the life of cables
and harnesses.
NOTE: Do not use any cleaners or solvents inside motors.
Unplug the battery and check for voltage leaks to frame. If
voltage exists, the battery must be cleaned. If cleaning does
not remove the voltage to frame, the battery must be
serviced by an authorized battery technician.
Run the ground tests as outlined on page 5-15.
page 5-15
Sideshift Carriage Ensure the cap screws that secure the lower mounting hooks
to the carriage bar are tight.
Warning Decals Replace any warning decals that have become unreadable or
are damaged.

4-10 00700-CL1SM-3 Issued: 6/1/04
Moderate and Severe Usage: Annually or 1500 hours
(whichever comes first)
Hydraulic
Reservoir
Change the fluid in the main hydraulic reservoir and install a
new fluid filter. Refer to Lubrication Equivalency Chart on
page A-2 to assure proper type of fluid for your application.
page 7-126
Pump
Couplings
Remove, clean, inspect and repack.

Battery Maintenance
00700-CL1SM-3 Issued: 6/1/04 4-11
Battery Maintenance
Charging - General
This section gives you only general battery
information.
For exact battery charging and maintenance
information, read the Battery Instruction
Manual and the Battery Charger Instruction
Manual.
Inspection
Before installing the battery in the truck,
inspect the battery for:
• Cleanliness
• Missing vent caps
• Broken or damaged posts
• A cracked or damaged case
• Corrosion of metal parts
• Wetness on the top or sides of the battery
case

Battery Maintenance
4-12 00700-CL1SM-3 Issued: 6/1/04
This page intentionally left blank.

Toyota Stand-Up End Control Service Manual Troubleshooting
00700-CL1SM-3 Issued: 6/1/04 5-1
Troubleshooting5:

Troubleshooting Toyota Stand-Up End Control Service Manual
How to Use This Chapter
5-2 00700-CL1SM-3 Issued: 6/1/04
How to Use This Chapter
This chapter is designed to help you
troubleshoot possible problems that may affect
truck performance.
• When a particular component has been
identified as or suspected to be bad, it is
recommended that you troubleshoot the
wiring from that component back to the
Interface Card.
• Conduct any related tests in the truck’s
Maintenance Mode to help you make any
determinations.
• This truck features electronic devices that
can help diagnose a situation. There is a
bank of LEDs located on the Translator
Card assembly that can be used to
troubleshoot a condition.
• Always take note of any fault codes that
appear on the Operator Display. Gather as
much information as you can at the time of
the Fault Code.

Start-up
00700-CL1SM-3 Issued: 6/1/04 5-3
Start-up
Waiting For Precharge Message
What is Precharge?
Precharge is a method for powering up the
traction power amplifiers in a controlled
manner. The circuits for doing this are located
within the amplifiers themselves.
The amplifiers have large banks of capacitors to
prevent voltage spikes. When the truck key
switch is turned OFF, these capacitors are
discharged slowly to near 0V. If the contactor is
immediately closed with these capacitors
discharged, very high currents would result.
This could damage the amplifiers and/or the
traction fuse and TPC Contactor.
The precharge circuits in the amplifiers will
normally begin to charge up these capacitor
banks as soon as the truck key switch is closed,
and they are normally charged in just a few
seconds.
You may encounter a “Waiting For Precharge”
message during the start-up of this truck. If
this occurs, it means that the voltage on the
output side of the TPC contactor has not
reached at least 31V. This is necessary before
the power amplifiers can be started and the
truck’s SelfTest can be completed.
The “Waiting For Precharge” message occurs for
the following reasons:
1. The battery voltage is too low.
2. There is an internal short to ground in one
or both of the power amplifiers.
3. There is an internal short to ground in the
truck wiring.
4. The precharge circuits in one or both of the
amplifiers are bad.
5. The sense line to the TPC is bad.
6. The Translator Card is bad.
7. The Interface Card is bad.
8. The key switch has been turned OFF and
ON too frequently, resulting in overheating
of the precharge circuits and causing
precharge to be very slow.
Troubleshooting
1. Check to see if battery voltage is at least
32V when under no load.
2. Check for precharge with digital voltmeter
by measuring the voltage at the output side
of the TPC contactor with reference to TP4
(B-). When the key switch is turned ON, the
voltage must climb higher than 31V and
eventually reach within 1V of battery
positive (B+).
NOTE: When the key switch is turned OFF, this
voltage will slowly drop to 0V. Use
Analog Test A08 in Maintenance Mode to
view this voltage.
3. If the voltage at the output of the TPC
contactor does not reach 31V:
a. Verify that power is reaching the
amplifiers by checking for B+ at the
following points:
• JPF5-1 or JPF5-2 on the Contactor
Fuse Panel
• JPX1-1 on the Translator Card
• JPTL1-1 on the left power amplifier
• JPTR1-1 on the right power amplifier
4. Use the following process of elimination to
isolate the problem:
a. Turn the key switch OFF and carefully
disconnect the B+ power cable to one of
the two amplifiers. Recheck to see if
precharge will occur. If it will, the
amplifier that has been disconnected is
bad and must be replaced.
NOTE: Disconnect one of the power cables to
the amplifiers at the TPC contactor and
turn on the truck. Both amplifiers
should precharge independently. If one
does not, then that amplifier is bad.
b. Reconnect the first amplifier and
disconnect the B+ power cable to the
remaining amplifier. If precharge will
now occur, then the second amplifier is
bad and must be replaced.

Start-up
5-4 00700-CL1SM-3 Issued: 6/1/04
c. Disconnect the B+ power cable from the
TPC. Leave the sense lead connected at
TPC1. Manually depress the TPC
contactor tips. If the “Waiting For
Precharge” message goes away and a
Code 44 appears, the Interface Card is
working correctly.
If the “Waiting For Precharge” message
does not go away, check continuity of
the wires between TPC1 and JPC8-8
(FU2_Sense on the Interface Card).
d. Turn key switch OFF and disconnect
battery. Reconnect the left amplifier
power cable. Reconnect the battery and
restart the truck. If the “Waiting For
Precharge” message reappears, the left
amplifier is bad.
e. Turn key switch OFF and disconnect
battery. Reconnect the right amplifier
power cable. Reconnect the battery and
restart the truck. If the “Waiting For
Precharge” message reappears, the right
amplifier is bad.
5. If the voltage at the output of the TPC does
reach 31V:
a. Perform a continuity check from the
output side of the TPC contactor to
JPC8-8 on the Interface Card and/or
measure the voltage at JPC8-8 with
respect to B-. If there is no continuity
and/or voltage present, repair the
truck’s wiring harness.
b. Read the voltage at the output of the
TPC contactor using the Analog input
test A08 in Maintenance Mode. If the
voltage read does not correspond with
the voltage measured at JPC8-8, replace
the Interface Card.

Power Amplifier Fault Codes
00700-CL1SM-3 Issued: 6/1/04 5-5
Power Amplifier Fault
Codes
The truck will return a fault code to the
operator display when an error has been
detected in the lift truck. More specifically, the
left and right traction power amplifiers may
return error codes, 2M and HK, which could
indicate a number of possible problems. Use the
following procedures to help diagnose and
troubleshoot these particular power amplifier
codes.
What these error codes mean:
Error code “2M” means that a problem has been
detected with the Left Traction amplifier, and a
code “HK” means that a problem has been
detected with the Right Traction amplifier. The
Left Traction amplifier is always checked first,
so any error condition which affects both
amplifiers will result in the display of the “2M”
error code.
How these codes are detected:
NOTE: TPC_x is a reference to either the right or
left power amplifier. Depending on which
amplifier you are working on, substitute
“L” or “R” for the “x”.
Detection of these error codes is centered
around the TPC_x signal lines from each of the
amplifiers to the Translator Card. These lines
are used by the amplifiers to request that the
TPC contactor be de-energized. The signal line
to the left traction amplifier is named TPC_L
and connects to the Translator Card at
JPX2-13. The signal line to the right traction
amplifier is named TPC_R and connects to the
Translator Card at JPX1-13.
A fault code will be detected when any of the
following conditions occur:
1. An amplifier refuses to turn on its TPC_x
output when the amplifier is told to turn
on.
NOTE: The amplifiers are told to turn on when
both the KEY and EPO signal outputs
from the Translator Card are turned on.
2. One or both amplifiers turn off its TPC_x
output when the amplifier is supposed to be
on.
3. One or both of the TPC_x lines stay on after
the amplifiers are told to turn off.
What can cause these error
codes:
1. The amplifier has an internal failure.
2. The TPC_x signal line from the amplifier to
the Translator Card is open or shorted to
battery minus.
NOTE: KEY_ON and EPO signals are generated
by the Translator Card when the TPC
contactor is energized and are not
connected to the truck key switch or
EPO switch in any way.
3. The KEY_ON signal line from the Translator
to one or both of the amplifiers is open or
shorted to battery minus.
4. The EPO output signal line from the
Translator Card to one or both of the
amplifiers is open or shorted to battery
minus.
5. The Translator Card has failed and cannot
read these inputs properly.
6. The power cables from the TPC contactor to
one or both of the amplifiers is open.
7. JPC8-8 (FU2_Sense) is shorted to battery
positive, resulting in the truck trying to
start the amplifiers when the amplifier
capacitor banks are not properly charged.
8. Battery power is not being provided to an
amplifier at JPTL1-1 or JPTR1-1,
preventing the amplifier from turning on.

5-6 00700-CL1SM-3 Issued: 6/1/04
Power Amplifier Start-up
Procedure:
The following is a description of the sequence of
events which occurs regarding the power
amplifiers when the truck key switch is first
turned ON.
1. The truck must complete a series of
internal checks before any tests of the
power amplifiers are started.
2. Once the internal checks are complete, the
voltage at the output side of the TPC
contactor must reach at least 32V before
the amplifiers can be turned on. This is
referred to as “precharging” because the
amplifiers have large capacitor banks which
must be charged prior to closing the TPC
contactor, or they may be damaged. This
precharging is done by the amplifiers
themselves and starts when the truck key
switch is turned ON. If precharging does
not happen within 5 seconds, a “Waiting
For Precharge” message will be displayed.
Note that since both amplifiers are
connected in parallel, one amplifier can
precharge both amplifier's capacitor banks.
See Waiting For Precharge Message on
page 5-3.
3. Once precharge occurs, the amplifiers will
be run briefly with the TPC contactor open
in order to verify that the TPC contactor is
not welded:
a. First, the amplifiers are activated by
turning on the KEY and EPO outputs
from the Translator card to the
amplifiers. There are LED indicators on
the Translator Card which illuminate
when these lines are turned on. See
Figure 5-2. The amplifiers must respond
to this by turning on their respective
TPC_x output (TPC_L for left amplifier,
TPC_R for right amplifier).
NOTE: KEY_ON and EPO signals are generated
by the Translator Card when the TPC
contactor is energized and are not
connected to the truck key switch or
EPO switch in any way. If an amplifier
fails to turn on its TPC_x output within
1 second, an error code “2M” and/or
“HK” will be displayed on the operator
display.
b. Once both amplifiers have turned on
their TPC_x outputs, the DM (deadman)
output from the Translator Card will be
turned on next. This signal also has an
LED indicator.
c. Next, one and only one direction
command signal line will be turned on
for each amplifier. These direction
signals each have an LED indicator and
are named as follows:
• FWD_L - Forward command to the
left power amplifier
• REV_L - Reverse command to the left
power amplifier
• FWD_R - Forward command to the
right power amplifier
• REV_R - Reverse command to the
right power amplifier
The left forward direction line will
always be turned on, but the right
amplifier direction line will changed
depending on how the steerable wheel is
turned: If the wheel is close to straight,
the right amplifier will be set to drive
reverse. If the wheel is not close to
straight, the right amplifier will be set to
drive forward. This will cause the drive
wheels to always drive against each
other during SelfTest.
d. Once the direction lines have been set, a
small throttle command is sent to each
amplifier. The amplifiers must then pull
down the TPC contactor output voltage
down sufficiently to verify that the TPC
contactor is open. If this does not
happen, a fault code “44” will be
displayed on the operator display.
e. The amplifiers are shut down when the
TPC contactor output voltage drops
down sufficiently or when 0.6 seconds
elapses, whichever comes first.

00700-CL1SM-3 Issued: 6/1/04 5-7
4. Once the TPC contactor welded test is
complete, the truck must log on to each of
the amplifiers using the communication
lines TXD_L, RXD_L, TXD_R, and RXD_R.
The TXD lines are transmit lines from the
Translator Card, and the RXD lines are
receive lines to the Translator Card.
Logging on involves sending several bytes of
data to each amp on the TXD lines, followed
by having each of these bytes echoed back
to the Translator Card on the RXD lines. A
failure during this procedure will produce a
“5F” and/or “5G” error code to be displayed
on the operator display.
The procedure for restarting the amplifiers after
they have been shutdown is similar in that
many of the same steps are taken (in the
following sequence). When the Deadman pedal
is depressed:
1. Precharge must have occurred or a “Waiting
For Precharge” message will be displayed.
2. The KEY_ON and EPO outputs are turned
on.
3. The power amplifiers must turn on their
TPC_x outputs,
4. The DEADMAN output will be turned on,
5. When the control handle is moved, the
appropriate direction lines will be turned
on.
6. The throttle commands will be sent to the
amplifiers.
NOTE: This sequence of events can be observed
by viewing the LED indicators on the
Translator Card, however the mounting
bracket must be removed from under
the Interface Card assembly to
accomplish this. See Translator Card on
page 7-90.
Troubleshooting Procedure:
1. Verify that the Translator Card can read the
TPC_x inputs properly:
a. Enter Maintenance Mode and select
either Test I27 for the left amplifier or
I28 for the right amplifier TPC_x input
test.
b. Disconnect the harness to the power
amp at JPX1 for the left amplifier or
JPX2 for the right amplifier. The TPC_x
input test must indicate OFF. If not,
replace the Translator Card.
c. Carefully connect pin 13 of connector
PX1 or PX2 on the Translator Card to
battery negative using a jumper clip.
The TPC_x input test must now indicate
ON. If not, replace the Translator Card.
Remove the jumper clip.
d. Reconnect the harness to the power
amp and verify that the TPC_x input test
indicates OFF (Note that the KEY_ON
and EPO outputs from the Translator
should be off when in the TPC_x
Maintenance Mode tests). If not, there is
a problem in the harness to the
amplifier and/or the amplifier itself.
2. Verify the harness to the power amp:
a. Check for continuity of the TPC_x line to
the affected amplifier per the truck
schematic.
b. Disconnect the connector JPTL1 for the
left amplifier or JPTR1 for the right
amplifier, and verify that the TPC_x
input test indicates OFF. If not, the
harness has a short to battery minus.
3. Test the amplifier TPC_x output driver:
a. Disconnect the connector JPX1 for the
left amplifier or JPX2 for the right
amplifier. This will shut down the power
amplifier.
b. Measure the resistance from JX1-13
and/or JX2-13 to battery minus. This
resistance must be greater than 20K
ohms. If not, the amplifier has failed.
4. Monitor the operation of the TPC_x line:

5-8 00700-CL1SM-3 Issued: 6/1/04
a. Measure the voltage on the TPC_x line to
the affected amplifier using a Digital Volt
Meter (DVM) referenced to battery
minus:
• When the KEY_ON and EPO signal
lines are off, the TPC_x line must be
at least 8V with respect to battery
minus. If not, replace the amplifier.
• When the KEY_ON and EPO signal
lines are on, the TPC_x line must be
no more than 2V with respect to
battery minus. If not, replace the
amplifier.

Electrical Troubleshooting Guidelines
00700-CL1SM-3 Issued: 6/1/04 5-9
Electrical
Troubleshooting
Guidelines
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. See
Battery Exterior Cleaning on page 7-93.
WARNING!
Jack and block the lift truck so that the
drive tires are off the floor whenever a
troubleshooting procedure requires
turning key switch S1 ON.
CAUTION!
Unless otherwise directed, disconnect
the battery connector when you check
electrical circuits or components with an
ohmmeter. Electrical current can damage
the ohmmeter.
• Save time and trouble by looking for simple
causes first.
• For information on electrical connector
location and function, see Table 5-1,
Electrical Connector Locator Chart on
page 5-10.
• Use a DVM such as a Fluke meter for all
measurements. Analog meters can give
inaccurate readings and load down
sensitive electronic circuits enough to
cause failure. Make sure meter cables are
connected to the proper meter jacks and
that proper function and scale are selected.
• Printed circuit boards have been conformal
coated. You may need to clean test points in
order to obtain accurate readings.
• When measuring voltage, connect the
positive meter lead to the connector or
probe point marked (+) in the test. Connect
the negative meter lead to the connector or
probe point marked (-).
• Whenever measuring resistance, turn the
key switch OFF and disconnect the battery
connector. Battery current can damage an
ohmmeter.

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