Toyota 6HBW20 4,000LB Powered Pallet Walkie Service Manual SN 17001 - PDF DOWNLOAD

Service Manual

6HBW20 4,000LB Powered Pallet Walkie Starting with Serial Number 17001

Toyota Powered Pallet Walkie Service Manual

How to Use This Manual

How to Use This Manual

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Toyota Powered Pallet Walkie Service Manual

How To Use This Manual M a p of the Manual

Map of the Manual

1

How to Use This Manual

Map of the Manual

Y Manual Design

Table of Contents I

Vehicle Specifications

Systems Overview

tl Start Page

Planned Maintenance

I

General System

1

Theoy of Operations

Electrical & Hydraulic T.S. Guidelines

Trouble Shooting

Component Procedures

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I

Alphabetical List of Component procedures

I

1

Definitions

1

I

Fault Codes

I

Component Location Photos

Appendix

Programmable Maintenance Tool

Troubleshooting Charts

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Toyota Powered Pallet Walkie Service Manual

How To Use This Manual Manual Design

Manual Design The Toyota Powered Pallet Walkie Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise Anticipate your needs and reduce your decisions regarding maintenance Reduce page flipping through a "one-stop shopping" approach The two-line running page header a t the top of each page tells you the following: Name of the manual (Toyota Powered Pallet Walkie Senrice Manual) Current chapter title (e.g., this page How to Use This ManuaO Current topic (e.g., this page M a n u a l Design) We suggest you get in the habit of turning to the START page first when you use this manual.

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Toyota Powered Pallet Walkie Service Manual

Manual Design

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

How to Use This Manual explains the manual format and design and contains the Table of Contents and START page.

Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.

Systems Overview includes truck specifications and theory of operation information.

Planned Maintenance outlines the recommended schedule of preventive senices to keep your truck working most efficiently.

Troubleshooting is a set of "decision-tree" charts designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.

TS1: START TROUBLESHOOTING on page 5-28 will guide you to the individual troubleshooting symptom chart you need.

Once you're familiar with the symptoms listed, you may instead simply find the symptom chart from the List of Troubleshooting Charts on page 5-25.

When you complete a troubleshooting procedure, be sure to follow the steps in the END1: End of Troubleshooting Procedure on page 5-31.

Component Procedures give step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in a n order which considers: Frequency of attention Physical attachment (e.g., brake must be removed before drive motor) Functional relation (e.g., drive motor and drive unit components are grouped together)

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How To Use This Manual Manual Design

To find a component procedure, you may use one of three methods: Look up the component name. See List of Component Procedures on page 6-2 Find the component. See Component Locator Photos on page 6-5.

Look up the component name in the Index on page I- 1.

Appendix contains reference information such a s torque values, lubricants and schematics.

Index lists subjects alphabetically.

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Manual Design

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How To Use This Manual Table of Contents

Table of Contents How to Use This Manual Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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ManualDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 STARTPage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 .

Generalsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 JackingSafe ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Systems Overview Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

Planned Maintenance Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2

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Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Every Month or 200 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Annually or Every 2400 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Grease Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Troubleshooting How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 .

Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . . . . . . . .5-13

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Table of Contents

Faultcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 List of Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Component Procedures List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Tractor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 Power Cables

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Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 Switches (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 Control Handle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Main ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 Brake (Deadman) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Lift-Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Hydraulic Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-51 Motors. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 Driveunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-78 Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . . . . . 6-80 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-85 LiftMotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-89 Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-91

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How To Use This Manual Table of Contents

Appendix Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Torque Chart . Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

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Torquechart-Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Index

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Table of Contents

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H o w To Use This Manual

START Page

START Page

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How To Use This Manual START Page

START:

W h y are you here?

Go to Chapter 2 "Safe$"

Yes

To troubleshoot

b

Go to Chapter 3 "Systems Overview"

Ye

Go to Chapter 4 "Planned Maintenance"

Yes

Go to Chapter 5 "Troubleshooting"

b List of Troubleshooting Charts

No

I Go to Chart START-2

b

START Troubleshooting

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START Page

Yes

Go to Chapter 6 * "Component Procedures"

Alphabetical List of Component Procedures

w L

No

+ general reference

v

A

/

Yes

To locate a n obiect or

Ye

name?

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b

Go to Chapter 7 "Appendix"

Go to the Index

Component Locator

How To Use This Manual

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START Page

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Safety

Safety

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Safety Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

Warning means a potentially hazardous situation exists that, if not avoided, could result in death or serious in jury.

A CAUTION Caution means a potentially hazardous situation exists that, if not avoided, could result in minor or moderate injury or in damage to the truck or nearby objects.

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Toyota Powered Pallet Walkie Service Manual

Safety General Safety

General Safety

Do not operate or work on this truck unless you are trained, qualified and authorized to do so and have read the Owner/Operator Manual.

Know the truck's controls and what they do.

Do NOT operate this truck if it needs repair or if it is in any way unsafe.

Operate this truck only from the operator's position.

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Toyota Powered Pallet Walkie Service Manual

General Safety

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 this truck.

Follow the scheduled lubrication, maintenance and inspection steps.

Follow exactly the safety and repair instructions in this manual. Don't take "shortcuts."

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Safety General Safety

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.

Always park this truck indoors.

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Toyota Powered Pallet Walkie Service Manual

General Safety

Do NOT park this truck in a cold storage area overnight.

Do NOT wash this truck with a hose. .

Do NOT add to or modify this truck until you contact your local Toyota Industrial Equipment dealer to receive written manufacturer approval.

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Safety Battery Safety

Battery Safety

As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not roperly ventilated, this exp osive gas can remain in or around the battery for several hours after charging: Be sure there are no o en flames or sparks in the c ar ing area. An open flame or can ignite this gas, resulting in serious damage or inlury.

P

R spars

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 there is an accident.

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Toyota Powered Pallet Walkie Service Manual

Battery Safety

A battery gives off explosive gases. NEVER smoke, use a n open flame, or use anything that gives off sparks near a battery.

Keep the charging area well-ventilated to avoid hydrogen gas concentration.

Turn the key switch OFF before disconnecting the battery from the truck a t the battery connector. Do not break live circuits a t 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.

Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks.

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Safety Battery Safety

Keep plugs, ter.minds, cables and receptacles good condition to avoid shorts and sparks.

I

Keep filler plugs firmly in place a t all times except when the electrolyte level is checked, when water is added to the cells or when the specific gravity is checked.

Make sure 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.

Make sure you install the correct size battery. A smaller or lighter weight battery could seriously affect truck stability. See the truck's specification plate for more information.

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Toyota Powered Pallet Walkie Service Manual

Battery Safety

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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Safety

Toyota Powered Pallet Walkie Service Manual

Jacking Safety

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 forks completely. Remove any load.

2. Place all controls in neutral.

3. Block the wheels to prevent movement of the vehicle.

4. Disconnect the battery connector.

5. Place the jack under the designated jacking points.

Use extreme care whenever the truck is jacked up. 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.

Fork Section 1. Using the lift button, raise the forks to maximum height.

2. Block the fork section a s shown in Figure 2-1. The tractor section will remain on the floor.

3. Lower the forks onto blocks.

4. Turn the key switch OFF and disconnect the battery connector.

Figure 2- 1:

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Blocking the Fork Section

Safety

Toyota Powered Pallet Walkie Service Manual

Jacking Safety

Tractor Section 1. Place the jack in the designated jacking

position.

2 . Jack one side of the truck so that the drive tire is off the floor no more than 1 in. (25.4 mm).

3. Block that side of the truck in place.

4. Jack the other side of the truck level with the first side.

5. Block that side of the truck in place.

NOTE: After working on a vehicle, test all controls and functions to assure proper operation.

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Safety

Toyota Powered Pallet Walkie Service Manual

Tie-down for Transport

Tie-down for Transport To transport your Toyota Powered Pallet Walkie in an over-the-road vehicle or rail car. follow these steps: 1. Lower the forks and locate the truck in the center of the transport vehicle.

2. Using a suitable lifting device. remove the battery. See "Battery" on page 6-8.

3. Position the adjustable chain over and through the battery compartment.

4. Position an additional adjustable chain over and through the battery compartment.

5. Position the chain ends of one chain toward the front of the vehicle bed and the chain ends of the other chain to the back of the vehicle bed and draw taut. See Figure 2-2.

NOTE: This will secure the truck to the vehicle bed and prevent tip-over and forward or backward movement.

6. Secure the battery according to the battery manufacturer's instructions. If equipped,

remove the battery cover or storage tray from the top of the battery and store separately.

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Figure 2-2:

Tie-Down for Transport

Safety

Toyota Powered Pallet W a lkie Service Manual

Towing

Towing To safely tow a Toyota Powered Pallet Walkie: 1. Lower the forks and remove any load.

2. Turn the key switch OFF and disconnect the battery connector.

3 . Using a suitable towing vehicle, lift the tractor end of the truck until the drive tire is no more than 1 in. (25.4 mm) off the floor.

4. Tow the truck slowly in the tractor-first direction.

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Safety Welding Safety

Welding Safety

Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors.

Prior to performing flame cutting o r , 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. Flame cutting and/or welding operations should be carried out only in well ventilated areas using 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.

Disconnect the battery before you attempt to inspect, service or repair the lift truck.

Discharge residual charge in the motor controller by connecting a load across the controllers B+ and B- (such a s a contactor coil or by pressing the horn button).

Check for shorts to frame a s described on page 5-5. If any shorts are detected, remove them before you proceed with the welding operation.

Clean the area to be welded.

Protect all truck components from heat, weld spatter and debris.

Attach the ground cable a s close to the weld area a s possible.

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Toyota Powered Pallet Walkie Service Manual

Welding Safety

Do not perform any welding operations near the electrical components.

If welding must be done near the battery compartment, remove the battery from the truck.

When you are finished welding, perform all ground tests and electrical inspections before the vehicle is operated.

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Systems Overview

Systems Overview

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Systems Overview Truck Model Identification

Truck Model ldentification

Figure 3- 1:

6HB W20 Powered Pallet Walkie

Vehicle Specifications

The total weight of the load must include the pallet and the container or the device holding the load.

Category Maximum Load Capacity

6HBW20

I

4,000 lb (1.816 kg)

Upright Height

50.8 in. (129.1 cm)

Overall Length (Handle Raised)

,up to 8 1.8 in. (207.8 cm)

Overall Width

30.0 in. (76.2 cm)

Maximum Lift Height

9.25 in. (23.5 cm)

Regular Speed, Maximum

3.9 mph (6.3 kph)

Stopping Distance

6 ft. (1.83 m)

Battery Compartment Width

9.0 in. (22.8 cm)

Battery Voltage

24 volts

Minimum Battery Weight

200 lb (91 kg)

Maximum Battery Weight

660 lb (299 kg)

Truck Weight Without Battery

830 lb (377 kg)

Wheel: Drive

10.5 x 5 in. Rubber

Wheel: Load

3.25 x 5 in. Polyurethane (2)

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Systems Overview General System Data

General System Data

Figure 3-2:

6HBW20 Powered Pallet Walkie General System Data

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Systems Overview

Toyota Powered Pallet Walkie Service Manual

Special Tools

Special Tools Pro rammable Maintenance Too

P

The optional Programmable Maintenance Tool (PMT) (P/N 1 137 132) allows you to test, program (or configure) and diagnose the motor controller in the truck. See Figure 3-3.

The PMT is powered by the host controller through the four-pin connector located at the bottom of the controller.

Figure 3-3:

Programmable Maintenance Tool (PMT)

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Systems Overview Theory of Operation

Theory of Operation The lift/lower system consists of a n electrically operated hydraulic pump assembly and related components.

The hydraulic pump assembly consists of a positive displacement rotary gear pump with reservoir mounted to a n adapter. A DC electric motor is mounted to the opposite side of the pump adapter. An adjustable relief valve, check valve, and a solenoid operated lowering valve are located within the adapter.

With the forks elevated, the normally closed solenoid valve and the check valve prevent hvdraulic fluid from returning to the reservoir.

When the battery is plugged in, the Main ON/ OFF switch is ON, the key switch is ON. and the lift button is pressed: Lift switch (SW12)closes.

Lift pump contactor closes, causing the lift pump to operate.

Hydraulic fluid is drawn through the 100 micron screen in the reservoir into the lift pump and is forced into the lift cylinder.

As the pump rotates, oil is forced out the pressure port through the lift hose to the lift cylinder. Oil cannot return to the reservoir because of the closed pressure relief valve and closed lowering solenoid valve.

Hydraulic pressure in the lift cylinder raises the forks.

Lift cutout switch (SW10) will interrupt power to the lift motor when the forks reach a preset lift limit.

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Systems Overview

Toyota Powered Pallet Walkie Service Manual

Directional/Speed Control

When the lift switch is open. the pump contactor coil is de-energized. This stops the lift motor and pump. The forks are held in position by hydraulic fluid trapped in the cylinder by the check valve, the static position of the relief valve, and the closed lowering solenoid.

Relief valve will open if the hydraulic pressure exceeds the preset limit.

Lower When the battery is connected, the Main ON/ OFF switch is ON, the key switch is ON and the lower button is pressed: Lift switch is closed.

Lowering solenoid opens.

Hydraulic fluid in the lift cylinder returns to the hydraulic reservoir through the lowering valve and the flow control valve.

The forks lower.

Directional/Speed Control The following descriptions assume the battery is charged and connected the Main ON/OFF switch is ON, and the key switch is ON. The control handle must be in the proper position to close the brake (deadman)switch (SW2)and release the brake. See "Brake (Deadman) Switch" on page 5-7.

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Systems Overview Directional/Speed Control

Forward When the twist grip/butterfly control is rotated in the forward direction from neutral: Forward directional switch (SW3) is closed and B+ voltage is applied to PMC-12 of the motor controller.

The motor controller activates the forward contactor by providing B- a t PMC-3.

The resistance across the throttle potentiometer (VR-4 to VR-2) increases from zero ohms to a maximum of 6.5K ohms. Throttle input voltage is then generated a t PMC-8 with respect to PMC-7.

Once the throttle input voltage is above the neutral band threshold the motor controller begins to provide current flow through the drive motor.

The drive wheel begins to rotate in forward direction a t a speed proportional to throttle input.

Reverse When the twist grip/butterfly control is rotated in the reverse direction from neutral: Reverse directional switch (SW4) is closed and B+ voltage is applied to PMC- 11 of the motor controller.

The motor controller activates the reverse contactor by providing B- a t PMC-2.

The resistance across the throttle potentiometer (VR-4 to VR-2) increases from zero ohms to a maximum of 6.5K ohms. Throttle input voltage is then generated a t PMC-8 with respect to PMC-7.

Once the throttle input voltage is above the neutral band threshold the motor controller begins to provide current flow through the drive motor.

The drive wheel begins to rotate in reverse direction a t a speed proportional to throttle input.

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Motor Controller

Emergency Reverse If the emergency reverse switch (belly button switch) is closed with the control handle lowered (SW2 closed) in travel mode, the control system will provide a n immediate, rapid acceleration in the reverse (forks first) direction:

Emergency reverse switch (SW7)is closed applying B+ voltage to PMC-13.

Travel inputs W, SW3, SW4) are ignored.

The reverse contactor is energized.

The motor controller provides maximum torque immediately after the emergency reverse switch is closed and current limit is automatically set to the higher plugging value (approximately 300 Amps).

Maximum reverse travel will continue until the emergency reverse switch is released.

Once the emergency reverse switch is activated, the motor controller inhibits the forward direction. To reset the truck for normal travel. the throttle must be cycled through the neutral position. Turning the key switch OFF and then ON will also reset the motor controller.

Motor Controller The basic functions of the motor controller include: The direction control section controls the directional contactors. The directional contactors then change the field winding polarity based on the directional switch inputs (SW3, SW4).

The throttle control section controls the drive motor speed and torque by monitoring relative position change of the wiper in the travel potentiometer with respect to the static neutral position.

The emergency reverse circuitry controls the ovemde of the directional travel control.

The diagnostics section continuously monitors the travel circuits for fault conditions and responds appropriately, shutting down travel in some cases.

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Planned Maintenance

Planned Maintenance

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Planned Maintenance

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Maintenance Guidelines

Maintenance Guidelines Following a planned maintenance program: Promotes maximum truck performance Prolongs truck life Reduces costly down time Avoids u n n e c e s s q repairs Planned maintenance includes: Lubrication Cleaning Inspection Creating a list of repairs required Perform all of the scheduled checks and maintenance during the suggested intervals.

The intervals given in this guide are based on normal operating conditions. When operating under abnormal or severe conditions, perform these services more often a s required to keep the unit in good operating condition.

See "Lubrication Equivalency Chart" oi page A-2. Refer to the manufacturer's supplements for components not listed on the following pages.

Maintenance Manual Use this manual a s required to perform all repair procedures listed in the Planned Maintenance Schedule.

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Planned Maintenance

--

Planned Maintenance Schedule

Planned Maintenance Schedule Perform all inspections and lubrication in accordance with the Planned Maintenance Schedule. See "Lubrication Equivalency Chart" on page A-2.

NOTE: Daily (8 hour) inspections should be performed by an authorized OwnerEmployee.

All listed repairs should be scheduled for a convenient time between an authorized Customer Representative and the Qualified Service Technician. All repairs should be carried out AFTER the planned maintenance tasks are completed. Labor and parts for repairs should be calculated a s part of the standard truck maintenance costs, separate from the planned maintenance charges.

Time Requirements Performing Planned Maintenance will require approximately 0.75 hour.

General Truck Operation Operate all functions of the truck and check for any abnormal operation.

Talk to the driver to see if any problems were noticed.

Check to see if all the safety and operational decals are in place and legible.

List repairs required.

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Planned Maintenance Daily

Daily Perform the daily checks and report any faults or abnormal conditions to your supervisor.

Item

Daily or Eight Hour Checklist

Battery

Check cleanliness and exterior condition. See "Battery Exterior Cleaning" on page 6-9.

Check the charge.

Check the weight.

Check the connector. Make sure all powered functions shut down when disconnected.

Make sure the battery is properly installed.

Check the "free play" of the battery. Make sure the battery does not move more than 0.5 in. (12.7 mm).

General Operation

Check that the horn operates when you press the horn button. (Battery must be connected and Main ON/OFF switch ON.) Check the speed and directional controls.

Check the steering operation.

Check the lifting and lowering functions.

Check the operation of the emergency reverse button.

Note any unusual noise during operation, and report it to your supervisor or maintenance personnel.

Brake

Venfy the drive motor does not r u n while the brake is applied.

Check that the control handle returns to the vertical position when released.

Decals

Warning/Safety/Operational decals must be in place and legible. Notlfy your local, authorized Toyota Industrial Equipment dealer if any decal is defective.

Hydraulic System

Wheels /Tires

Check for oil leaks.

Check the condition of the drive wheel and load wheels.

Remove any steel chips and foreign material to prevent damage to the wheels.

Check for gouging and chunking of the surface. If damaged, report to your supervisor or maintenance personnel.

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Planned Maintenance Every Month or 2 0 0 Operating Hours

Every Month or 200 Operating Hours Perform daily checks plus the following:

r1

Item

Every Month or Every 200 Hours

Grease Fittings

Lubricate all grease fittings. See "Grease Fittings" on page 4-8.

Forks

Check the lift limit switch for lift motor cut-out. Adjust if necessary.

/ Lubrication Points Lubricate all levers, shafts and linkage points.

Check the lift cylinder for leaks. Replace cylinder if necessary. See "Hydraulic Cylinder" on page 6-82.

Lift Cylinder

Check for proper fluid level - within 1 in. (25.4 mm) of filler plug with the forks fully lowered. Add fluid if necessary.

See "Lubrication Equivalency Chart" on page A-2.

Check hydraulic connections and mountings.

Check the tightness of the pump and motor hardware.

Check hoses, tubes and fittings for leaks. Replace hoses or seals. Clean the fill/vent plug. See "Hydraulic Unit" on page 6-85.

Hydraulic System

Check for loose hardware. Tighten if necessary.

Check the tightness of the drive unit mounting bolts.

Tighten if necessary.

General

Electrical System

I

I1

II/

1

Visually inspect all cables for damage. Replace if necessary.

See "Power Cables" on page 6-16.

Check for electrical shorts to frame. See "Checking for Shorts from Battery to Truck Frame" on page 5-4.

Drive Wheel

Check the tightness of the retaining nut on the drive wheel mounting. Tighten to 250 ft. lbs. (339.2 Nm).

Drive Unit

Check for oil leaks. If leaks are found, check the oil level. If the oil level is low, determine the cause. See "Drive Unit" on page 6-65.

Check and lubricate the transmission pivot bearing.

I Check the condition of brushes, springs and holders.

/

Motor Brushes

I

Check that the brush length exceeds <he minimum length.

Drive motor - 0.62 in. (15.7 mm) Hydraulic pump motor - 0.5 in. (12.7 mm)

Brake (Deadman) Switch

Check adjustment. See "Brake (Deadman] Switch on page 6-27.

Load Wheel

Check and lubricate the load wheel bearings and linkage.

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1

I/

1

11

1

Toyota Powered Pallet Walkie Service Manual

Planned Maintenance Every Month or 200 Operating Hours

Item

Every Month or Every 200 Hours

Brake

Check the brake shoes for wear. Replace if necessary. See "Brake" on page 6-51.

Battery System

Clean the battery a n d the truck. See "Battery Exterior Cleaning" on page 6-9.

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Planned Maintenance Annually or Every 2 4 0 0 Operating Hours

Annually or Every 2400 Operating Hours Perform the monthly checks plus the following:

Item Drive Housing

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I

I

Annually or Every 2400 Hours Change the oil in the drive housing.

See "Drive Housing Lubrication" on page 6-70.

Planned Maintenance

Toyota Powered Pallet W a lkie Service Manual

Grease Fittings

Grease Fittings

Figure 4- 1:

Pivot Bearing

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Troubleshooting

Troubleshooting

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Troubleshooting

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How to Use This Chapter

How to Use This Chapter This chapter uses a set of "decision-tree" charts designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.

See TS1: START TROUBLESHOOTING on page 5-28 to guide you to the individual symptom chart you need.

Once you're familiar with the symptoms listed, you may instead simply look up the symptom from the List of Troubleshooting Charts on page 5-25.

As you work with a troubleshooting symptom chart, you may be instructed to test various electrical connector pins.

Every time you complete a troubleshooting procedure, be sure to follow the steps in END1: End of Troubleshooting Procedure on page 5-31.

If the troubleshooting symptom charts do not isolate the problem, or if the symptoms are not consistent or repeatable, go to GEN1: General Troubleshooting on page 5-29. This chart will help you approach the problem in a systematic and logical manner.

Each chart begins with a oval-shaped symbol containing the title and symptom. Charts are identified a s H for Hydraulic and T for Travel.

The logic generally flows top to bottom and left to right. A symbol shaped like a baseball home plate means the chart is continued on another page (either a continuation of the current chart, or a different chart). Continuation charts have a suffix number added. A continuation chart begins with a circle-shaped symbol containing the chart number and suffm.

For example, look a t Chart H-3 on page 5-39.

One logic path is continued on Chart H-3-2, which is the next page. Another logic path from Chart T-12 goes to the END1: End of Troubleshooting Procedure on page 5-31.

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Troubleshooting Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. Check the electrolyte level and state-of-charge. See "Battery" on page 6-8. Be sure to block the truck whenever a troubleshooting procedure requires turning the key switch ON. This will avoid accidents caused by unexpected truck travel.

A 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.

Visually inspect all wiring and electrical components for: Loose connections or connectors Loose or broken terminals Damaged terminals, blocks, or strips.

Broken wiring and shorted conditions (especially those that are close to metal edges or surfaces) Use a n ohmmeter to check for wiring continuity and shorts.

For information on pin, connector, and harness connections, see "Wiring Harness" on page 6-17 and see "Electrical Connector Locator Chart" on page 5-12.

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Checking for Shorts from Battery to Truck Frame

Checking for Shorts from Battery to Truck Frame 1. Turn the key switch OFF and disconnect the battery connector.

2. Use a voltmeter set on a 50 volt DC scale.

3 . Attach the voltmeter leads a s follows:

Negative (-) lead to a n unpainted, grounded surface on the truck frame Positive (+) lead to the positive battery terminal, see Figure 5-1 4. The voltmeter should show no more than 3 volts.

5. Now attach the voltmeter leads a s follows: Negative (-) lead to the negative battery terminal Positive (+) lead to an unpainted, grounded surface on the truck frame 6. The voltmeter should show no more than 3 volts.

Figure 5- 7 :

Baffery Shorts to Frame, testing

7. If you get more than a three volt reading in Step 4 or 6:

a. Remove the battery from the truck. See "Battery" on page 6-8. b. Thoroughly clean the battery. See "Battery Exterior Cleaning" on page 6-9. c. Reinstall the battery. d. Repeat steps 2 through 6 to see if this has eliminated the problem.

e. If excessive voltage is still found, have the battery checked for internal leakage.

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Troubleshooting Checking for Shorts from Components to Truck

Checking for Shorts from Components to Truck Frame 1. Turn the key switch OFF and disconnect

the battery connector.

2. Use an ohmmeter and measure the resistance to an unpainted, grounded surface on the frame at B+, B-. and all fuses. See Figure 5 - 2 .

A resistance reading of less than 1000 ohms indicates a serious short to frame. If this condition exists, locate the source of low resistance or short to frame using step 6. Do not continue until this condition is corrected.

3 . Remove the battery from the truck. See "Battery" on page 6-8.

4. Connect the battery lead to the truck.

5 . Use an ammeter to measure the leakage current to a n unpainted, grounded surface on the frame at B+, B-, all fuses and all motors. If the current is less than 0.001 ampere (lrnA),the truck system passes. If the current exceeds lrnA, go to step 6.

6. To find the cause of the low resistance, disconnect the power cables from each motor or major sub-assembly to determine if that item is causing the low resistance.

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Figure 5-2: Component Shorts to Frame, testing

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Hydraulic Troubleshooting Guidelines

Hydraulic Troubleshooting Guidelines When you check voltage at solenoids, make sure hydraulic lines and components are fully installed.

Use a n ohmmeter to check for wiring continuity to solenoids. Use an ammeter to check for proper current to solenoids and contactor coils (refer to specific component tests).

A CAUTION Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter.

Electrical current can damage the ohmmeter.

Visually inspect all hydraulic lines and components for: Leaking connections or connectors Loose or broken fittings Damaged tubing, hoses, vents, or seals

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Troubleshooting Definitions

Definitions Acceleration Rate The time required for the controller to increase from 0% to 100% duty cycle (PWM) when a continuous 100% throttle request is applied.

Acceleration rate is an adjustable parameter within program mode. See "Motor Controller Parameters" on page 5-19.

Brake (Deadman) Switch The switch (also known a s deadman switch) in the truck that must be closed to allow truck travel. It is activated by the control handle position. The switch acts to protect against travel while the brake is applied. The handle must be positioned between 10" of vertical and 10" of horizontal in order for the brake (deadman) switch to be closed, allowing- travel.

See Figure 5-3.

Continuity A continuous and uninterrupted path between two or more locations in an electrical circuit, typically having a resistance of less than 1 ohm.

Creep Speed Creep speed is activated when a direction is first selected. It is the speed a t the minimum throttle setting (minimum PWM).-See Pulse Width Modulation on page 5-9 The output maintains creep speed until the throttle is rotated out of the throttle minimum setting (10% of throttle). Creep speed is adjustable from 0-10% PWM duty cycle. The factory default value is 0%.

Current Limiting A protective function of the motor controller to prevent excessive current levels from damaging drive components.

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Figure 5-3: Brake (Deadman)Switch and Brake Actuation

Troubleshooting

Toyota Powered Pallet W a lkie Service Manual

Emergency Reverse

Emergency Reverse Emergency Reverse is activated when the emergency reverse switch ("Belly Button" switch) is pressed while the brake is released and the key switch (SWlj is ON. After the "Belly Button" (BB) switch is released, normal controller operation is not resumed until neutral (no direction) is selected or until the brake is cycled (brake, then brake release).

However, repeatedly pressing the BB switch will reactivate the emergency reverse function each time.

Fault Codes The motor controller provides fault information by flashing fault codes via the status LED built into the controller cover. See "Fault Codes" on page 5-23.

High Pedal Disable (HPD) The HPD feature prevents the truck from being started while the throttle is applied. The motor controller can be programmed to have HPD based on either the brake (deadman) switch or key switch input. The 6HBW20 is Type "1" (only key switch input required prior to 25% throttle).

Open Circuit A lack of a continuous path between two or more electrical connections. Usually greater than one megohm resistance.

Overtemperature (Motor Controller) Overtemperature of the motor controller is 85°C (185°F)and above. At overtemperature the drive current limit is linearly decreased from full set current down to zero.

NOTE: Plugging strength is not decreased at any overtemperature level.

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Troubleshooting Overvoltage Cutoff

Overvoltage Cutoff Overvoltage protection resets the internal microprocessor, zeros out the pulse width modulation, and shuts down the controller.

Controller operation resumes when the voltage is brought within the acceptable range. The cutoff voltage and re-enable voltage are set at the factory and are not adjustable.

Plugging (Plug Braking) The process by which the drive motor creates torque opposite to the direction of travel proportional to the throttle command opposing the current travel direction. The braking (plugging) current limit is a programmable parameter and is normally set higher than the drive current limit. This parameter is factory preset and not user adjustable.

Pulse Width Modulation Pulse Width Modulation (PWM),also called "chopping," controls the speed of the motor by switching the battery voltage applied to the motor on and off very quickly.

Ramp Shape The ramp shape is the relationship between the speed/directional control rotation and truck response (PWM output). It is adjustable (throttle map parameter) so you can provide the proper feel for each truck.

Ramp shape number refers to the PWM output at half throttle, a s a percentage of its full range.

Sequencing Delay Sequencing delay allows the brake (deadman) switch to be momentarily opened within a set time (sequency delay), thus preventing inadvertent activation of high pedal disable (HPD) or static return to off (SRO).See High Pedal Disable (HPD) on page 5-8. See Static Return To Off (SRO) on page 5- 10. This feature is useful in applications where the brake (deadman) switch may bounce or be momentarily cycled during operation.

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Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Overvoltage Cutoff

Short Circuit or "Short" A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit.

Example: Two insulated wires are physically next to each other and the insulation has been worn off each of the wires. Because the conductors inside each wire are now touching each other, there is a short circuit.

Example: A power cable from the battery to a junction post in the truck has had the insulation worn away. Because the wire conductors are touching the tractor frame, there is a short circuit of the battery cable.

Speed Limiting The controller can limit the maximum speed: "Max speed" parameter limits the maximum PWM for both directions of travel. This is a programmable parameter. See "Motor Controller Parameters" on page 5- 19.

Static Return To Off (SRO) The SRO feature prevents the truck from being started (direction selected) prior to the release of the brake (brake [deadman]switch closed). SRO checks sequencing of the brake (deadman) switch input and key switch relative to the direction input. The brake (deadman) switch must be activated before the speed/directional control is rotated. If a direction is selected before or simultaneously (within 50 milliseconds) with the brake input detected, the motor controller will not command travel.

Tractor The body section of the truck that contains the motors, drive unit, controls, and handle.

Undertemperature When the motor controller is operating at less than -25OC (- 13"F),current limit is reduced to about one-half of the set current resulting in reduced travel speed.

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Troubleshooting Overvoltage Cutoff

Undervoltage Cutback Undervoltage protection automatically disables the controller output if the battery voltage is detected below the undervoltage point a t startup, or when the battery voltage is pulled below the undervoltage point by an external load. The undervoltage cutback point is set at the factory and is not adjustable.

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Troubleshooting Electrical Connector Locator Chart

Electrical Connector Locator Chart Refer also to electrical schematics located in the Appendix and wiring harness component procedures.

Connector

Function or Routing

Location

PMC 1

1 Connector on motor controller

1 Motor controller

JP2

Handle functions

In control handle

JP3

' Travel functions (C.S. only)

1 In control handle

JP6

Travel functions

In control handle

JP9

Meters (Options)

I By key switch

JPS 1

Splice for brake switch circuits

I

In control handle

Table 5- 1: Electrical Connector locator Chart

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Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Programmable Maintenance Tool (PMT)

Programmable Maintenance Tool (PMT) The optional Programmable Maintenance Tool (P/N 1137132) allows you to test and diagnose the motor controller in this walkie pallet truck.

See Figure 5-4.

+

The PMT is powered by the host controller through a four-pin connector a t the bottom of the controller. See Figure 5-5.

When the PMT is first plugged into the controller, the PMT displays the controller's model number, date of manufacture, and software revision code. Following this initial display, the PMT displays a prompt for further instruction.

8,

NOTE: Follow the prompt a t the top of the PMT screen, not the blinking icon, to choose the desired menu item.

Figure 5-4: Programmable Maintenance Tool

The operating modes are Program, Test, Diagnostics, Special Program and Special Diagnostics.

The programmer is operated via a n 8-key keypad. The three top keys select the three standard operating modes (Program, Test, Diagnostics), two keys scroll the display up and down, and two keys change the value of selected parameters. The eighth key, the More Info key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the Program or the Diagnostics key, the More Info key selects the Special Program mode or the Special Diagnostics mode.

When one of the menu keys is pressed, the LED a t the corner of the key lights up, identifying the mode of operation. Four lines of a menu are displayed a t a time in the LCD display window.

The item a t the top of the display window is the selected item. To select an item,-scroll within the menu until the desired item is positioned at the top of the display window. In Program mode, the selected item is highlighted by a flashing arrow.

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Figure 5-5:

PMT to Motor Controller Connection

Troubleshooting

Toyota Powered Pallet W a l kie Service Manual

Diagnostics Modes

Diagnostics Modes You can use the PMT (P/N 1137132) to access the diagnostic history file of the motor controller.

The PMT will read out all the faults that the controller has experienced since the last time the diagnostic history file was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator error.

For example, a contactor fault may be caused by loose wires; carefully check contactor wiring.

A High Pedal Disable (HPD)or overtemperature fault may be caused by operator habit or overloading.

In Diagnostics mode, currently active faults detected by the controller are displayed.

In Special Diagnostics mode, the controller's diagnostic history file is displayed. This field includes a list of all faults observed and recorded by the controller since the history was last cleared.

NOTE: Each fault is listed only once, regardless of the number of times it occurred.

Diagnostics Mode Access 1. Turn the key switch OFF 2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Turn the key switch ON.

5. Access the Diagnostics mode by pressing the Diagnostics key to display the currently active faults detected by the controller. See Diagnostics and Special Diagnostics List on page 5-16.

6. Press the More Info key when in the Diagnostics mode to display additional information about the selected item.

Special Diagnostics Mode Access 1. Turn the key switch OFF. 2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Turn the key switch ON.

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Troubleshooting Diagnostics Modes

5. Hold the More Info key, then press the Diagnostics key. See Diagnostics and Special Diagnostics List on page 5-16.

6. Scroll through the line items using either

Scroll Display key. When the item you want is the top line on the display, press the More Info key to display additional information about the selected item.

Clear After you have diagnosed and corrected the problem, you should clear the diagnostic history file. This allows the motor controller to accumulate a new file of faults. By checking the new history file a t a later date, you can easily determine whether the problem was completely fixed.

1. Hold the More Info key, then press the

Program key. Release both keys after you enter the Special Program mode.

2. Scroll through the modes using the Scroll Display keys until "CLEAR DIAG HIST is the top line in the display.

3 . Press the More Info key again. Follow the PMT on-screen instructions to acknowledge or cancel.

4. Press the Change Value U p scroll key to clear the diagnostic history. Press the Change Value Down key to cancel.

NOTE: "CLEAR DIAG HIST" also resets the maximum and minimum temperatures listed in the Test Menu.

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Troubleshooting Test Mode

The table below lists possible messages you may see displayed when the PMT is operating in either Diagnostics or Special Diagnostics mode.

Diagnostics and Special Diagnostics List Explanation

Display BB WIRING CHECK

BB wiring check failed (Emergency Reverse)

CONT DRVR OC

Contactor driver shorted

DIR CONT WELDED

Direction contactor welded

HPD

High-Pedal-Disable (HPD) activated

HW FAILSAFE

Hardware failsafe activated (malfunctioning micro controller)

LOW BATTERY VOLTAGE

Battery voltage too low*

M FAULT

(M-) terminal output fault

MISSING CONTACTOR

Open contactor circuit

NO KNOWN FAULTS

No known faults occurred

OVERVOLTAGE

Battery voltage too hight

PROGRAMMER FAULT

Programmer fault

PROC/WIRING FAULT

Procedure or wiring fault

SRO

Static-Return-to-Off (SRO) activated

THERMAL CUTBACK

Thermal cutback due to temperature

THROTTLE FAULT 1

Throttle input fault

THROTTLE FAULT 2

Throttle low input fault

* less t h a n 16 volts (24-36V models) f greater t h a n 45 volts (24-36V models) Table 5-2: Diagnostics and Special Diagnostics List

Test Mode Real-time status information is displayed in Test mode for various inputs, outputs, temperature, etc. This information can be helpful in troubleshooting many problems and is useful for checking out the operation of the controller during initial installation.

In the Test mode, the item of interest does not need to be the top item on the list; it only needs

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Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Test Mode

to be among the four items visible in the window.

NOTE: Test items may be viewed while operating the truck.

Test Mode Access 1. Turn the key switch OFF. 2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Turn the key switch ON.

5. Press the Test key on the PMT. See Table 5-3.

6 . Scroll through the line items using either Scroll Display key. When the item you want is the top line on the display, press the More Info key for a full screen display of additional information about the selected item.

Test Mode Explanation

Display

Default Setting

THROTTLE%

Throttle reading, in percent of full

0%

BATT VOLTAGE

Battery voltage

24 VDC

HEAT SINK " C

Heat sink temperature

Ambient

MAX TEMP " C

Maximum temperature seen"

95" C

I MIN TEMP " C I! BRAKE INPUT

I Minimum temperature seen* / Deadman switch: on/off

I -26°C 1 Off

SPEED INPUTt

Speed switch: on/off

Off

EMR REV INPUT

Emergency reverse switch: on/off

Off

I FORWARD INPUT

1 Off 1 Off

1

I FWD CONTACTOR

1 Forward switch: on/off I Reverse switch: on/off 1 Forward contactor: on/off

I On

I1

REV CONTACTOR

Reverse contactor: on/off

On

~ & E R S E INPUT

* Maxirnum/minimum temperatures recorded since Diagnostic History was last cleared.

Refers to high speed input a t PMC3. If truck does not have coast option, monitor B+.

Table 5-3: Test Key Display

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1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Program Mode

Program Mode In Program mode, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. All changes occur in "real time"; the parameters can be changed while the truck is in operation.

1. Turn the key switch OFF.

2. Remove the tractor cover.

3 . Connect the PMT to the motor controller.

4. Turn the key switch ON.

5. Press the Program key to enter the Program mode. See Motor Controller Parameters on page 5-19.

6. Press either Scroll Display key until the parameter you want is the top line of the

display (with the flashing arrow).

7. Press either Change Value key until the setting you want is displayed. The parameter is now set at the value you selected.

8. If the display stops changing and you want to go further, press the More Info key. If the display shows "Min Limit" or "Max Limit," you have reached the factory set limit for that parameter.

NOTE: The parameter may depend on another parameter. If so, the display will show this information. Changing the related parameter may allow you to change the setting further.

,

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Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Program Mode

Parameter

Description

Default Value

Range

0%

Speed (Min. PWM) at minimum throttle setting.

Creep Speed/ Min. Duty Cycle

0-25OIo

Sequencing Delay

0-3 seconds

Quick Start

0-6

1.4

Controls how output (PWM)will respond to rate of throttle change.

M1 Accel Rate

0-3 seconds

1 second

Time to reach full output (PWM)from zero output in M1 (high speed, PMC-3 on) mode.

M2 Accel Rate

0-3 seconds

1 second

Time to reach full output (PWM)from zero output in M2 (coast speed, PMC-3 off) mode.

M2 Max Speed

40- 100%

85%

Maximum speed (PWM duty factor) in M2 (high speed) mode.

Emergency Reverse Speed

0- 100%

100%

Maximum speed (PWM duty factor) in emergency reverse mode.

See Caution Below

0.0-0.3 seconds See Caution Below

Delays HPD and SRO from brake input after motor controller is enabled.

Table 5-4: Motor Controller Parameters

A CAUTION While adjustment of these parameters is possible, settings at values other than those listed above will produce improper and unauthorized operational characteristics.

Creep Speed/Min. Duty Cycle must be set to 0%.

Sequencing Delay may only be adjusted between 0.0 seconds and 0.3 seconds.

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Special Program Mode

Special Program Mode The Special Program mode allows you to perform a variety of tasks. Table 5-5, "Special Program Modes," on page 20 shows the line items in Special Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display.

Special Program Mode Access 1. Turn the key switch OFF.

2. Remove the tractor cover.

3 . Connect the PMT to the motor controller.

4. Turn the key switch ON.

5 . Press and hold the More Info key; then press the Program key.

6. Scroll through the line items using either Scroll Display key until the item you want to change is the top line on the display.

Press the More Info key again to find out how to make the adjustment.

7. Press either Change Value key until you reach the value you want.

Special Program Mode

1

Display

/ RESET ALL SJ3TINGS

1

I

1

Explanation

1 Revert to default settings

I1

CONT SETTINGS+PROG

Save controller settings in PMT

I/ PROG SETI'INGSXONT

/ Load programming settings in controller

CLEAR DIAG HISTORY

Clear diagnostic history memory

CONTRAST ADJUSTMENT

Adjust display contrast

LANGUAGE SELECTION

Select displayed language

PROGRAMMER INFO

Display PMT information

CONTROLLER INFO

/ Display controller info

1

1

Table 5-5: Special Program Modes

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Cloning

Cloning Using the PMT, you can copy or "clone" parameters and options from one motor controller to another. Cloning only works between controllers with the same model number and software version.

Copy Parameters 1. Turn the key switch OFF. Remove tractor cover.

2. Connect the PMT to the motor controller you want to clone. See Figure 5-5.

3. Turn the key switch ON. 4. Press and hold the More Info key, then press the Program key. Release both keys after you enter Special Program mode.

5. Scroll through the modes using the Scroll Display keys until "CONT SETTINGS-PROG" is the top line in the display.

6. Press the More Info key again. The PMT will

prompt you to acknowledge (save controller settings in PMT) or cancel.

Enter Parameters 1. Disconnect the PMT from the motor controller that you used to "clone" parameters.

2. Turn the key switch OFF. Remove the tractor cover.

3. Reconnect the PMT to the motor controller you want to program.

4. Turn the key switch ON.

5. Press and hold the More Info key, and press the Program key. Release both keys after you enter Special Program mode.

6. Scroll through the modes using the Scroll Display keys until "PROG SETTINGSC O W is the top line in the display.

7. Press the More Info key again. The PMT will prompt you to acknowledge (load programming settings in controller) or cancel.

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Troubleshooting

Toyota Powered Pallet Wal kie Service Manual

Pin Descriptions

Pin Descriptions An integrated 24-pin low power connector molded into the front of the motor controller provides the low power logic control connections (see Figure 5-6).

Pin connections in use are described below.

NOTE: PMC-1 is the same as pin reference number 1 in Figure 5-6.

PMC-16: key switch input (KS1) PMC- 15: brake input PMC-3: forward contactor driver output PMC-2: reverse contactor driver output PMC-7: travel: pot low

\

Connection

\

PMC-8: travel: pot wiper PMC-12: forward input

/161151413i12 1 1 1 0 1

PMC-1 1: reverse input

91

PMC-13: emergency reverse input PMC-14: high speed Figure 5-6:

Motor Controller /PMC Pin References

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Troubleshooting

Toyota Powered Pallet W a lkie Service Manual

Fault Codes

Fault Codes An internal microcontroller automatically checks the function of the motor controller.

When this microcontroller detects a fault, it signals the appropriate fault code through the LED on the bottom of the motor controller.

Under normal operation, the LED flashes a single flash at approximately one flash every two seconds. A two-digit flash code signals a fault has been detected by the microcontroller.

Correct faults by following the possible cause suggestions listed below.

PMT Display

Fault Code

Explanation / Possible Cause

LED off

No power Defective controller

Solid on

Defective motor controller

Single flash

Normal operation, no faults

1, 2

me

1, 3

* * *

1, 4

**me

2, 1

**

2, 2

2, 3

**

2.4

.

.em

****

HW Fail-safe

Hardware fail-safe error.

Defective controller.

Invalid throttle type selected.

M-Fault

M- output shorted to ground.

Direction contactor not closing or not closing fast enough.

Internal motor short to ground.

SRO

Static Return to Off (SRO) fault.

Improper sequence of KSI, brake and direction inputs.

Wrong SRO type selected.

Brake or direction switch circuit open.

Sequencing delay too short.

Throttle Fault 1

Throttle input wire open or shorted to ground or B+.

Throttle pot defective.

Wrong throttle type selected.

BB Wiring Check

Emergency reverse circuit check fault.

BB wire open.

BB check wire open.

HPD

High-pedal-disable (HPD)fault.

Improper sequence of KSI, brake, throttle inputs.

Wrong HPD type selected.

Misadjusted throttle pot.

Throttle Fault 2

Throttle pot low open or shorted to B+ or B-.

Pot low wire open or shorted.

Wrong throttle type selected.

PDMM-01 05 Issued: 5/2 1 /0 1

5-2 3

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Fault Codes

PMT Display

Fault Code

3, 1

0.0

3, 2

ooo

3,4

0.0

0.

oooo

Explanation / Possible Cause

Cont. Drvr OC

Contactor driver overcurrent (shorted).

Direction contactor coil shorted.

Shunt field shorted.

DIR Cont Welded

Direction contactor did not close or stuck closed.

Missing Contactor

Direction contactor coil open.

Direction contactor missing.

Shunt field open.

Wire to shunt or direction contactor open.

4, 1

o...

Low Battery Voltage

Battery voltage less than 16 volts.

Corroded battery terminal.

Loose battery or controller terminal.

4, 2

oooo

Overvoltage

Battery voltage greater than 45 volts.

Vehicle operating with charger attached.

Thermal Cutback

Temperature greater than 85" C or less than -25" C. Excessive load on vehicle.

Controller improperly mounted.

Operation in extreme environments.

••

4, 3

oooo 0.0

Table 5-6: Fault Codes

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Toyota Powered Pallet Walkie Service Manual List of Troubleshooting Charts

List of Troubleshooting Charts TS1: STAl3T TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 5-28 GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 5-29 MISC: Miscellaneous Problems . . . . . . . . . . . . . . . . . . . . . . . . 5-30 END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . 5-31

Hydraulic Charts H- 1: No Lift. Lift Motor Does Not Run. Travel is OK . . . . . . . . . 5-32 H-2: No Lift or Slow Lift. Lift Motor Does Not Run . . . . . . . . . . 5-37 H-3: No Lower. Lift and Travel OK. . . . . . . . . . . . . . . . . . . . . . 5-39

Travel Charts T- 1: No Travel. Lift/Lower OK . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 T-2: No Travel in Either Direction.

Motor Controller Fault Code 3.1 . . . . . . . . . . . . . . . . . . . . . 5-46 T-3: No Travel in Either Direction. Lift/Lower OK. Motor Controller Fault Code 1.3 . . . . . . . . . . . . . . . . . . . . . 5-47 T-4: No Travel. Lift/Lower OK. Motor Controller Fault Code 1.2 . . . . . . . . . . . . . . . . . . . . . 5-48 T-5: No Travel. Motor Controller Fault Code 3.4 . . . . . . . . . . . 5-49 T-6: Travel in One Direction Only.

Motor Controller Fault Code 3.1 . . . . . . . . . . . . . . . . . . . . . 5-50 T-7: No Travel. Motor Controller Fault Codes 2. 1 or 2.4 (or both) . . . . . . . . . . . . . . . . . . . . . 5-51 T-8: Slow Travel. Lift/Lower OK. No Codes . . . . . . . . . . . . . . . 5-53 T-9: No Emergency Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 T- 10: No Travel. Motor Controller Fault Code 4.2 . . . . . . . . . . 5-60 T- 11: Slow or No Travel. Motor Controller Fault Code 4.1 . . . . 5-61 T- 12: Slow or No Travel. Motor Controller Fault Code 4.3 . . . . 5-63 T- 13: No Travel. Motor Controller Fault Code 1.4 . . . . . . . . . . 5-66 T-14: No Travel. Motor Controller Fault Code 2.3 . . . . . . . . . . 5-69 T-15: No Travel. Motor Controller Fault Code 3.2 . . . . . . . . . . 5-71 T- 16: Plugging Does Not Operate Properly . . . . . . . . . . . . . . . . 5-72 T-17: Truck Does Not Accelerate Properly . . . . . . . . . . . . . . . . 5-73

Wiring Charts W- 1: Truck functions partially . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

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Toyota Powered Pallet Walkie Service Manual Wiring Charts

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

Troubleshooting Flowcharts

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

6 s1: START TROUBLESHOOTING

Yes

I

'(?

Go to C h a r t

Yes

Q Go to C h a r t

\7 Q Go to C h a r t

Go to C h a r t

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting

.

Troubleshooting Flowcharts

J A N 1: General Troubleshooting

Gather a s much information a s you can about the problem.

Eliminate unlikely causes.

Where did it happen?

When did it happen?

What functions are affected?

What conditions trigger the problem?

Talk directly to the operator or foreman.

Operate the truck yourself.

if necessary, identify

all components which could cause the

PDMM-01 05 Issued: 5/2 1 /0 1

Select and prioritize the most likely causes.

Check each likely cause, using the tests in this manual.

Check all other truck functions before returning the truck to senice.

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

6 I S C : Miscellaneous Roblems Not Covered By Other Charts

Is a wiring problem

0 6 Go to Chart

Go to Chart

I

PDMM-0105 Issued: 5 / 2 1 / 0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

6~~1:

End of Troubleshooting Procedure

Operate the truck as it was being operated when the problem occurred.

Verifq. the problem does not recur.

Make sure ALL wires, hoses. and cables that you removed have been re-attached correctly.

Make sure all panels are properly reinstalled.

I

Have the driver operate the truck. VeriQ the problem does not recur.

Make sure any component that was drained has been refilled with the correct level of fluid.

Fill out any required fonns.

Create the same conditions that occurred when the problem first happened.

If you contacted Toyota Industrial Equipment Technical Support to discuss the problem. call them again to let them h o w what fixed the problem.

1 (

PDMM-01 05 Issued: 5/2 1 /0 1

End of Troubleshooting

-

This is especially important if the solution you found is not in the troubleshooting chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

H-1:No Lift, Lift m o t o r D o e s Not Run, Travel is OK.

1 With key switch ON and lift switch depressed. measure voltage between pump contactor coil X a n d Y terminals.

1

No

Using schematics a s a guide, check the following switches a n d associated wiring: SWlO lift cutout switch SW12 lift switch M2 coil

I

Yes

With battery plugged in, measure voltage between B- a n d FU1-2.

present?

Replace Fuse Yes

Go to Chart H-1-2

v Go to Chart

PDMM-01 05 Issued: 5 / 2 1 / 0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

A_With key switch on and Lift switch depressed. measure voltage across E-and lift pump motor MP- 1 terminal.

With key switch off and battery disconnected, check for contin~utyand wiring shorts between F U 1-2 to pump contactor: pump contactor to pump motor.

Yes I With key switch off and battery disconnected, check lift motor brushes.

Are brushes OK?

contactor.

Yes

Go to Chart End 1

PDMM-01 05 Issued: 5 / 2 1 /O 1

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowsharts

Test pump motor.

See Component Procedures.

Is motor OK?

Replace motor.

Yes

I

With key sWtch off and battery disconnected, remove motor fkom pump.See Component Procedures. Turn pump shaft with

----- N~-------.."

Yes

Replace pump.

1

-

Go to Chart

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

-C With key switch off and b a t t e n disconnected. check lift switch SW12 in control handle.

Yes With forks lowered. key switch off, b a t t e q disconnected and lift cut-out switch closed (manually pressed), check for continuity i n lift cut-out switch.

/ Go to Chart

6

Go to Chart H-1-5

PDMM-01 05 Issued: 5/2 1 /0 1

I

Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

Yes

With key switch off. battery disconnected a n d wires removed, measure resistance of p u m p contactor coil M2.

Verify the problem still exists. Repeat H- 1. If you return here. go to General Troubleshooting.

6

I

Go to Chart

1 Go to Chart

Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual

.

Troubleshooting

Troubleshooting Flowcharts

/H-2: No Lift o r S l o w Lift, Lift Motor D o e s Not Run

Check hydraulic pressure. See relief valve settings in Component Procedures.

Check for any mechanical binding in lift linkage.

Check the battery.

See Component Procedures.

OK? Is b a t t e ~

\

Replace or recharge the battery.

I

Yes

With key switch off and battery discormected. check the lift motor and brushes. See Component Procedures.

Q Go to Chart

0 Repair.

Yes

/ Go to Chart I

Yes

I

6 Go to Chart

PDMM-01 05 Issued: 5 / 2 1 /0 1

Verifv that the problem still exists. Repeat H-2.

If you return here. go to General Troubleshooting.

0 Go to Chart

Go to Chart H-2-2

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

Adjust lift pressure.

See Component Procedures.

With kev switch off. battery disconnected, and forks lowered. remove pressure relief valve and check for signs of damage or contarnination.

Yes

Verify the problem still exists. Repeat H-2. If you return here, go to General Troubleshooting.

1

v

I

L'

k Replace pump.

caused by

Replace valve.

Yes

I

Flush system.

Replace hydraulic fluid. See Component Procedures.

Go to Chart

I Yes

I Flush system.

Replace hydraulic fluid. See Component procedures.

(-J Go to Chart

PDMM-01 05 Issued: 5/2 1 / 0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

H-3: No Lower; Lift and Travel OK.

With b a t t e n connected. key switch ON. while pressing lower switch(es). measure voltage across holding solenoid 1: SOLX to SOLY.

Using schematics a s a guide, check the following switches and associated wiring: No

b SW 1 1 lower switch

SOL coil

Yes

With key switch OFF, battery disconnected. loosen, but DO NOT REMOVE. one of the high pressure lines a t the hydraulic pump assembly. Allow forks to slowly lower. Have rags and drain pan ready to catch fluid.

~ k s

Repair mechanical binding in lift cylinders or fork Component Procedures.

With key switch OFF a n d battery disconnected, while pressing switches. check for continuity and shorts across: lift switch S12.

I Yes

I-

PDMM-01 05 Issued: 5/2 1 /0 1

Chart Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

A Allow forks to completely lower.

Remove and inspect solenoid SOL for free movement and for signs of contamination.

movement?

Yes

No

Is solenoid SOL restricted due

Yes

A Clean solenoid SOL. Remove contamination. Flush hydraulic system. clean filter and install new fluid.

7

(,,/

Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

Yes

Verify the problem still exists. Repeat H -3. If you return here, go to General Troubleshooting.

0

v Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

I

Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

f T-1: No Travel. Lift/Lower OK. Directional Contactors Do Not Close. \ Motor Controller LED is Flashing Once Every 2 Seconds.

Check the battery.

See component procedures.

I

Yes

Check the battery terminals a n d quick disconnect plug.

-b

u

Repair or replace.

I

Yes

1 With key off, battery disconnected a n d control

handle in operating position, disconnect wires a t deadman switch.

Check for continuity a t deadman switch SW2-C to SW2-NO. PMT1 can be used here.

See PMT section in Troubleshooting.

Go to Chart T-1-2

'Programmable maintenance tool

Q Go to Chart

PDMM-0105 Issued: 5/2 1 /01

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

Repair, replace. or adjust deadman continuity?

or mechanical actuator.

6

Yes

key switch on, and deadman closed. check for B+ a t PMC-2.

With key off and battery disconnected. check for continuity and wiring shorts between: SW1-BAT on key switch (switch closed/on) to SW2-C SW2-NO to M1 -R Terminal X M 1-R Terminal X to M1 -FTerminal X M 1-FTerminal X to PMC-2

Go to Chart

PMT1 can be used here. See PMT section in Troubleshooting.

lProgrammable maintenance tool

Q Go to Chart

Is there B+ a t

No

Yes

Yes

I Go to Chart T-1-3

Verify the problem still exists. Repeat T-1. If you return here, go to General Troubleshooting.

$J Go to Chart

PDMM-0105 Issued: 5/21/01

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

With truck jacked and blocked, batten' plugged in. key switch O N and handle in travel position: measure voltage at PMC-12 (with reference to B-) while rotating throttle in forward direction. PMT1 can be used here. See PMT section in Troubleshooting.

1 Programmable Maintenance Tool

Using schematics a s a guide, check the following switches and associated wiring: SW2 brake switch SW3 forward switch

I Yes

1

Replace motor controller.

1-

Chart

Yes

(iOml Chart

PDMM-0105 Issued: 5 / 2 1 /01

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

disconnected and FWD a n d R?3V switches alternately closed. check for continuit? a n d wiring shorts between FWD SW-C to n V D SW NO (SW3) RE\' SW-C to RE\' SUTNO (SW4)

Yes

Verify the problem still exists. Repeat T- 1. If you return here, go to General Troubleshooting.

u Go to Chart

PDMM-0105 Issued: 5/2 1 /0 1

0 I

Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

T-2: No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 3 , l .

With key switch off and battery disconnected. remove connector PMC from motor controller.

Measure resistance, and check for shorts. in wiring harness between: PMC- 15 to PMC-2 PMC- 15 to PMC-3

I

i

I

/\

,

Y1

Is wiring OK?

,

battery disconnected. remove connector PMC and check for continuity and wiring shorts between: PMC-15 to FWD Contactor-X PMC- 15 to REV Contactor-X PMC-2 to RE\.' Contactor-Y PMC-3 to FWD Contactor-Y

I

I

Yes

I Disconnect and measure resistance of FWD and REV contactor coils.

I Go to Chart I

Programmable Maintenance Tool can be used here. See PMT section in Troubleshooting.

Replace motor controller.

Replace coils.

I

Yes

\i

exists. Repeat T-2. If you return here. go to General Troubleshooting.

Go to Chart

Repair or replace

I

A Go to Chart

u Go to Chart

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

-

/T-3: No Travel in Either Direction. Lift/Lower OK. Motor Controller Fault Code 1,3.

7

With kev switch off a n d

b a t t e r i disconnected. disconnect drive motor cable a t motor controller terminal M-. Connect battery, t u r n key switch on.

code 1.3 still displayed?

Test motor. See Component Procedures.

Replace motor controller.

-j I

Go to Chart

Yes Vex-$ the problem still exists. Repeat T-3. If you return here. go to General Troubleshooting.

0 Go to Chart

PDMM-0105 Issued: 5/2 1 /0 1

I

'J Go to Chart

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

/T-4: No Travel i n Either Direction. Lift/lower OK. \ Motor Controller Fault Code 1.2

,.

Replace motor controller.

Go to Chart

PDMM-0105 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

T-5: No Travel, Directional Contactors Do Not Close.

Motor Controller Fault Code 3.4.

With key switch off and battery disconnected. remove connector PMC from motor controller.

Measure resistance i n wiring harness between:

Measure resistance of F\VD and REV contactor coils.

PMC- 1 5 to PMC-3

b a t t e n disconnected. check for continuity and wiring shorts between: PMC-1 5 to FWD Contactor-X PMC-1 5 to REV Contactor-X PMC-2 to REV Contactor-Y PMC-3 to F\VD Contactor-Y

PMT1 can be used here. See PMT section in

V e r i e the problem still exists. Repeat T-5. If the problem still exists. go to General

Replace motor controller.

I

Go to c h a r t

I

PDMM-01 05 Issued: 5 / 2 1 / 0 1

0 Go to Chart

Is miring OK?

1 Programmable Maintenance Tool

v Go to Chart

Repair or replace.

Go to Chart

\,.

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts . - .. .

-- . .

Travel in One Direction Only.

Motor Controller Fault Code 3.1.

With key switch off and b a t t e n disconnected. remove connector PMC from motor controller.

Measure resistance between: PMC-15 to PMC-3 PMC-15 to PMC-2.

Check for wiring shorts to frame.

Yes

'F'rogrammable Maintenance Tool

With key switch off a n d b a t t e n disconnected. check for continuity a n d wiring shorts between: PMC-15 to FWD Contactor-X PMC-1 5 to REV Contactor-X PMC-2 to REV Contactor-Y PMC-3 to FWD Contactor-Y PMT1 can be used here.

See PMT section in Troubleshooting.

I

Yes

Go to Chart

Measure resistance of forward a n d reverse contactor coils.

1\/1

there approx.

Replace coil(s).

Check for wiring shorts to B+. B-. and Frame.

no^^^

Is wiring OK?

Verifv problem still exists. Repeat T-6. If you return here. go to General Troubleshooting

0 Go to Chart

Replace motor controller.

./ Go to Chart

/ Go to Chart I

PDMM-01 05 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

/T-7:

No Travel. Directional Contactors DO Close.

Motor Controller Fault Codes 2.1 or 2,4 (or Both)

\

With key switch off and b a t t e n disconnected, remove connector PMC from motor controller. Measure resistance between PMC-7 to PMC-8 while slowly rotating throttle in both directions.

PMT1 can be used here. See PMT section in Troubleshooting.

1 Programmable Maintenance Tool

from 0-6K ohms in

No

With key switch off and b a t t e n disconnected. check for continuity and wiring shorts between: b PMC-8 to JP6-4 JP6-4 to VR-2 VR-4 to JP3- 1 JP3-1 to PMC-7

Check for wiring shorts to B+, B-, and Frame.

Is wiring OK?

Go to Chart T-7-2

I

Yes

0 Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Repair wires.

6 Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

With key switch off and batten. disconnected. remove connector PMC from motor controller and measure resistance of throttle potentiometex between VR-4 to VR-2.

Adjust or Replace

direction?

Component Procedures.

Yes Verify the problem still exists. Repeat T-7.If you return here, go to General

v Go to Chart

v Go to Chart

PDMM-01 05 Issued: 5/2 1 / 0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

T-8: Slow Travel, Lift/Lower OK. No Fault Codes.

With b a t t e n disconnected and k e ~ switch on, measure voltage at PMC- 14 bVRT B-) to verify truck is operating in high speed mode.

Programmable Maintenance Tool can be used here.

Verify b a t t e n is charged.

Yes

Reset the controller to parameters described in Component Procedures. Use the Programmable Maintenance Tool.

VerifS.programming of the motor controller has not changed using the programmable maintenance tool. See the motor controller section in Component Procedures.

T-8-2

With battery disconnected and kej switch on, measure voltage at PMC-14 (WFT B-) to verify truck is operating in high speed mode.

6og;ammable Maintenance Tool can be used here.

Go to Chart

Yes

I Go to Chart I

PDMM-01 05 Issued: 5/2 1 /0 1

Go to Chart

I

1 / Go to Chart I

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

4 No

Yes

With key switch off and b a t t e n disconnected. remove PMC connector from motor controller.

Check for continuity and wiring shorts between: PMC-14 and B+ using wiring diagram (schematic) for specific model of truck.

v With key switch off and battery unplugged, remove connector PMC from motor controller. Measure resistance between PMC-7 to PMC-8 while slowly rotating throttle in both directions. PMT1 can be used here. See PMT section in Troubleshooting.

Repair or replace.

Yes

1

v

Verifi the problem still e.uists. Repeat T8. If you return here, go to General Troubleshooting.

Go to Chart

+ No

from 0-6K ohms in

No+

With key switch off and battery disconnected. check for continuity and wring shorts between: PMC-8 to JP6-4 JP6-4 to VR-2 VR-4 to JP3-1 JP3-1 to PMC-7.

v Go to Chart

-

I

I

Yes

Turn key switch off. jack and block truck. With key switch on and handle in operating position. measure voltage a t B+ of motor controller (with reference to M-) of motor controller with throttle on.

1- 0 I

Yes

1 Programmable ~ a i n t i n a n c eTool

,

PDMM-01 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

to B+ in each direction?

Replace motor controller.

Yes & With key switch off a n d battery disconnected. check the drive motor brushes. See Component Procedures.

Q Go to Chart

no^^^

Are brushes OK?

Yes

With key switch off. test drive motor. See Component Procedures.

Go to Chart T-8-4

PDMM-01 05 Issued: 5/2 1 / 0 1

I

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

Is drive motor

With truck jacked and blocked, key switch off and battery disconnected. release the brake by pulling the handle down into the operating position. Turn the brake drum by hand.

0 Go to Chart

Replace or repair drive motor.

With key switch off, remove brake drum.

See Component Procedures.

Remove drive motor from drive unit. See Component Procedures.

No

brake release: will the drum

armature shaft

Does the armature shaft

Yes

Yes

Yes

i

i

4

Vex@ the problem still exists. Repeat T8. If you return here, go to General Troubleshooting.

Repair. adjust. or replace the brake.

Repair or replace the drive unit.

Repair or replace drive motor.

I

4

f

V Go to Chart

Go to Chart

PDMM-01 0 5 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

With key snitch off and battexy disconnected. remove connector PMC from motor controller.

Measure resistance of throttle potentiometer between: JP6-4 to JP3- 1.

from 0 -6 K ohms in

Yes

Verifv the problem still exists. Repeat T8. If you return here. go to General Troubleshooting.

6 Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Adjust or replace potentiometer. See Com~onent

I

u Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

T-9: No Emergency Reverse, Travel/Lift/Lower OK. No Motor Controller Fault Codes.

(

With truck jacked and blocked. battery connected, key switch ON and handle in travel position: measure voltage a t PMC- 13 (with reference to B-) while pushing emergency reverse switch.

PMT1 can be used here.,See PMT section in Troubleshooting.

I s B+ present?

1 Programmable Maintenance Tool

Using schematics a s a guide. check the following switches and associated wiring: SW2 brake switch SW7 switch

Yes I

Replace motor controller.

Repair or replace.

I

Yes

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

+ With key switch off. battery disconnected and PMC disconnected: check for continuity of emergency reverse switch (SW7) between: C (Common) a n d NO (Normally Open) while holding switch closed.

Is switch OK?

1 Verifv the problem still exists. Repeat T-9. If you return here, go to General Troubleshooting.

Q Go to Chart

PDMM-01 05 Issued: 5/2 1 /01

Replace switch.

0 Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

-10: No Travel. Motor Controller Fault Code 4,2 Excessive Battery Voltage (>45 Volts)

vNo. 1 2 ,

Verif?-the correct battery is installed in

plugged into

~ here.

M T I See PMT used

:ie

,

Maintenance 1 Programmable Tool

section in Troubleshooting.

Yes

into truck.

Disconnect charger immediately to prevent further damage. Only plug specified batten7 into truck.

(24V) installed?

Replace with correct batten.

I

Yes

I

r-5 Go to Chart

/

Replace motor controller.

- 1

1 Go to Chart /

PDMM-0105 Issued: 5 / 2 1 /01

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

- 11: Slow or No Travel

-

Motor Controller Fault Code 4.1 Low Battery Voltage (< 16 V o l t s p

Check the b a t t e n .

See Component Procedures.

Is b a t t e n OK?

Replace or recharge batten..

I

Yes

Check the b a t t e ~ terminals and quick disconnect plug.

/ GO to c h a r t I

Yes

Go to Chart T-11-2

PDMM-0105 Issued: 5/2 1 /0 1

1

Go to c h a r t

1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

b a t t e n disconnected, check for c o n t i n u i h and wiring shorts between: B-BAT to Motor Controller BB+BAT to F U 2 - 1 F U 2 - 1 to F U 2 - 2 F U 2 - 2 to Motor Controller B+

1 Programmable ~ a i n t e n a n c Tool e

PMT' can be used here. See PMT section in Troubleshooting.

QNojT Are wires and

,.

Yes

Replace motor controller.

1 Go to Chart /

Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

(T-

12: Slow or No Travel.

Motor Controller Fault Code 4.3 - Thermal Cutback.

Check the b a t t e n .

See Component Procedures.

~NojTi Is b a t t e n OK?

Yes

Check for free movement or mechanical binding of load wheels.

I

Yes

I GO to c h a r t I

PDMM-01 05 Issued: 5/2 1 /0 1

Q Go to Chart

0 Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

+

With truck jacked and blocked, key switch off and battery disconnected. release the brake by pulling the handle down into the operating position. Turn the brake drum by hand.

brake release: will

With key off. remove brake drum. See Component Procedures.

Does the armature shaft turn freely?

Remove the drive motor from the drive Procedures.

I

Yes

Go to Chart T-12-3

Repair, adjust. or replace the brake.

A Go to Chart

Repair or replace the drive unit.

v Go to Chart

PDMM-01 05 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

overloaded or operated under e'xtreme

Check mounting of motor controller. It should be mounted securely and in contact with the truck frame (which acts a s a heatsink).

Operate and load within specifications.

1 Go to Chart 1

Replace motor controller.

+ Go to Chart

PDMM-01 0 5 Issued: 5/2 1 / 0 1

A Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

-13: No Travel. Motor Controller Fault Code 1,4 Static Return To Off (SRO).

The handle must be moved to the operating position before the throttle is rotated.

Was proper followed?

Condition: Directional inputs (Forward and/or Reverse) were active prior to the handle being lowered (deadman switch closing). .

..................................................................... ........................................,.,. , .

Lower handle, then apply throttle.

Yes

f With key switch on and b a t t e n plugged in. measure voltage at: PMC-12 and PMC- 11 (with reference to B-).

PMT1 can be used here.

See PMT section in Troubleshooting.

v

Yes

I Go to Chart T-13-2

u Go to Chart

1 Programmable Maintenance Tool

6 Go to Chart

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Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

The motor controller is receixlng a direction command on Pin PMC-12 or PMC-11. before the handle is lowered.

With key switch off. batter?. disconnected and PMC disconnected from motor controller, check for continuity and wiring shorts between: PMC- 1 1 to J P 6 - 3 J P 6 - 3 to J P 1 0 - 3 J P 1 0 - 3 to REVERSE SW(SW4)-NO PMC-12 to J P 6 -2 J P S - 4 to JP6-2 J P 1 0 - 2 to FORWARD SW(SW3)-NO

Yes

Go to Chart T- 13-3

PDMM-01 0 5 Issued: 5 / 2 1 /0 1

/ Go to Chart I

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

With key switch off and battery disconnected. measure resistance of FORWARD (SlV3)and REVERSE (SW4) switches between: NO to C

ohmmeter read I

Yes

I

Verify t h a t the problem still eldsts.

Repeat T-13. If you return here, go to General

1 Go to Chart /

JI Go to Chart

,

PDMM-01 05 Issued: 5/2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

T-14: No Travel, \ Motor Controller Fault Code 2.3 High Pedal Disable)

-

I

..................................

1 Condition: Throttle circuit f

The handle must be moved to the operating position before the throttle is rotated.

:was active prior to the :handle being lowered (brake : i switch closing).

..................................

Lower handle. then apply throttle.

.

;

~ k s

Test and adjust throttle potentiometer.

See Component Procedures.

Programmable Maintenance Tool can be used here. See PMT section in Troubleshooting.

Go to Chart

Adjust or replace potentiometer

potentiometer.

See Component Procedures.

6 'J Go to Chart T- 16-2

PDMM-01 05 Issued: 5/2 1 /0 1

Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

With key switch off and batten. disconnected, and PMC disconnected from motor controller. check for continuity and wiring shorts between: PMC-8 to J P 6 - 4 J P 6 - 4 to VR-2 VR-4 to JP3-1 JP3-1 to PMC-7.

Yes

Replace motor controller.

I

I Go to Chart /

u Go to Chart

PDMM-01 05 Issued: 5 / 2 1 /0 1

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

-15: No Travel, Motor Controller Fault Code 3,2 (Directional Contactor Stuck in Closed Position).

4 With key snitch off and b a t t e n disconnected, check directional contactor tips. See Component Procedures.

With key switch off and b a t t e n disconnected. check for continuity a n d wiring shorts of drive motor cables between: drive motor and directional contactors.

Yes

Yes

' I

With key switch off. battery disconnected. check the contactors' movable tips for freedom of movement.

Do contactor tips

Go to Chart

Repair or replace contactor.

Yes

Q Go to Chart

PDMM-0105 Issued: 5/2 1 /O 1

Replace motor controller.

u Go to Chart

6 Go to Chart

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Troubleshooting Flowcharts

- 16: Plugging Does Not Operate Properly.

Truck Travels OK in Forward and Reverse.

L With key switch off. check brushes and motor.

See Component Procedures.

motor OK?

Yes

I

Repair or replace as n e c e s s q .

v Go to Chart

Replace the motor controller.

PDMM-0105 Issued: 5 / 2 1 /01

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

(T-17:

,

Truck Does Not Accelerate Properly.\

Check to see the b a t t e n is charged.

, With key switch off

and b a t t e n disconnected. check throttle potentiometer adjustment. See Component Procedures.

/,,(

-7

Go to Chart

PDMM-01 0 5 Issued: 5 / 2 1 /0 1

Go to Chart

0 Go to Chart

.

Toyota Powered Pallet Walkie Service Manual

Troubleshooting

Troubleshooting Flowcharts

With key switch off and b a t t e ~ disconnected. check for mechanical reasor for slow acceleration.

(Dragging brake. defective wheel bearing. bad load wheel. etc.)

Connect batten, turn key slyitch on and connect PhTP to motor controller.

Use the PMT to adjust -NO+ "ACCELERATION RATE" to maximum. See Component Procedures.

Drive truck and note results.

1 4 7 I

No

/

With kev snitch off and-batten. disconnected. check motor and brushes.

See Component

Is motor OK?

Repair as required.

No

'I

Repair or replace motor. See Component Procedures.

I

Yes

I

1

Yes

Is acceleration

Yes

' I

Replace motor controller.

!

6 Go to Chart

Return to senice.

t Go to Chart 'I

Go to Chart

Go to Chart

' Programmable maintenance tool

PDMM-0105 Issued: 5/2 1 /01

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

/w-

1: Truck Functions Partially. Some Functions Do Not Work When Commanded.

\

I

Visually check the wiring in the handle a n d where the wiring leaves the handle.

Look for damage to t h e wiring.

( Are wires OK?

>-NO

lUse a DVM a n d check for continuity of wires per the schematic.

I

Yes

Use a DVM a n d check for continuity of wires in the handle per t h e schematic.

Repair or replace

I continuiw measurements

Repair or replace

Yes

Visually check the wiring a n d connectors in t h e a r e a of the motor

PDMM-01 05 Issued: 5/2 1 /0 1

0

Yes Vet-@ t h e problem still efists. Repeat W- I . If you return here, go to General

I

Go to Chart

Q Go to Chart

I

Troubleshooting

Toyota Powered Pallet Walkie Service Manual

Troubleshooting Flowcharts

This page intentionally left blank.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures

Component Procedures

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

List of Component Procedures

List of Component Procedures

Batteries Maintenance Free . . . . . . . . . . . . . . . 6- 15 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Adding Water . . . . . . . . . . . . . . . . . . 6- 13 Charging . . . . . . . . . . . . . . . . . . . . . . 6- 10 Exterior Cleaning . . . . . . . . . . . . . . . . 6-9 Multiple Packs . . . . . . . . . . . . . . . . . . 6-8 Storage . . . . . . . . . . . . . . . . . . . . . . . 6-15 Voltage Check . . . . . . . . . . . . . . . . . . 6- 15 Battery Pack Multiple . . . . . . . . . . . . . . . . . . . . . . . 6-8 Single . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Brake (Deadman) Switch . . . . . . . . . . . . . 6-27

Circuit Breaker . . . . . . . . . . . . . . . . . . . . 6-21 Cold Storage Conditioning . . . . . . . . . . . . 6-91 Contactors . . . . . . . . . . . . . . . . . . . . . . . 6-43 Directional . . . . . . . . . . . . . . . . . . . . 6-45 Main . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Tip Replacement . . . . . . . . . . . . . . . . 6-46 Cover. Tractor . . . . . . . . . . . . . . . . . . . . . . 6-7

Deadman Switch . . . . . . . . . . . . . . . . . . . 6-27 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . 6-72

Fuses

Hydraulic Fluid . . . . . . . . . . . . . . . . .6-78 Hydraulic Unit . . . . . . . . . . . . . . . . . .6.85 Filter Screen . . . . . . . . . . . . . . . . .6-87 Pump . . . . . . . . . . . . . . . . . . . . . . 6.88 Relief Valve Adjustment . . . . . . . . 6.80 Reservoir . . . . . . . . . . . . . . . . . . .6.86 Solenoid . . . . . . . . . . . . . . . . . . . .6.30 Suction Tube . . . . . . . . . . . . . . . .6.87

Lift Limit Switch . . . . . . . . . . . . . . . . . . . . 6.29 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . .6.89 Load Wheel Pull Rod Adjustment . . . . . . . . . . . . . . 6.76 Load Wheels . . . . . . . . . . . . . . . . . . . . . . . 6.75 Lubrication Drive Housing . . . . . . . . . . . . . . . . . .6.70

Motor Controller . . . . . . . . . . . . . . . . . . . . 6.39 Motors Brush Spring Tension . . . . . . . . . . . . . 6.55 Brushes . . . . . . . . . . . . . . . . . . . . . . .6.53 Commutator . . . . . . . . . . . . . . . . . . . .6.56 Drive . . . . . . . . . . . . . . . . . . . . . . . . .6.61 General . . . . . . . . . . . . . . . . . . . . . . .6.53 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .6-89 Tests . . . . . . . . . . . . . . . . . . . . . . . . .6.57

Power Cables . . . . . . . . . . . . . . . . . . . . . .6. 16 Pump. Hydraulic . . . . . . . . . . . . . . . . . . .6.88

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 G

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Hydraulic Components Hydraulic Cylinder . . . . . . . . . . . . . . 6-82

Switches Brake . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 Control Handle . . . . . . . . . . . . . . . . . .6.23 Deadman . . . . . . . . . . . . . . . . . . . . . . 6.27 General . . . . . . . . . . . . . . . . . . . . . . .6.22 Key Switch . . . . . . . . . . . . . . . . . . . . . 6.26 Lift Limit . . . . . . . . . . . . . . . . . . . . . . 6.29 Main ON/OFF . . . . . . . . . . . . . . . . . .6.25

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Toyota Powered Pallet W a l kie Service Manual

Component Procedures List of Component Procedures

Wheels Drive . . . . . . . . . . . . . . . . . . . . . . . . .6-72 Load . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Wiring Harness . . . . . . . . . . . . . . . . . . . . 6-17

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

List of Component Procedures

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Component Locator Photos

Component Locator Photos Main ON/OFF Switch page 6-25

Key Switch page 6-26

Battery Connector (rear view) page 6-8

Main Contactor page 6-45

Lift Cylinder page 6-82

Directional Contactor page 6-46

Motor Controller page 6-40

, Plug

Horn page 6-39

Hydraulic Reservoir page 6-86

Fill/Vent page 6-78

Drive Unit page 6-65

Figure 6- 1:

Tractor Interior

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Component Locator Photos

Relief Valv page 6-80

Fill/Vent PI page 6-78

Lift-Limit S n tch page 6-29

Figure 6-2: Hydraulic Components

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Toyota Powered Pallet W a lkie Service Manual

Component Procedures Tractor Cover

Tractor Cover Removal To remove the tractor cover. unscrew the two captive screws on top of the cover and lift the cover slightly outward and upward away from the truck.

Installation To install the cover, slide it back into the original position. and screw the two captive screws in on top of the cover.

PDMM-0105 Issued: 5/21/01

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Battery

Battery

A CAUTION Before working on the battery, see "Battery Safety" on page 2-7.

Batteries may weigh more than 500 pounds. Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

The 6HBW20 may be equipped with either a multiple battery pack, single battery or a maintenance free battery and charger.

Multiple Battery Pack Removal 1. After the truck is stopped and the handle is returned to the full u p position, turn the key switch OFF.

2. Disconnect the battery connector located at the top of the tractor cover. Remove the battery cover.

3. To gain access to the lower two batteries, lift up on one of the top battery frames.

4. As the frame is lifted, swing the battery toward the center of the forks.

5. The cables may now be disconnected from the battery terminals and the batteries may be serviced or replaced if necessary. See Figure 6-3.

Installation 1. Position the fully charged and tested batteries in the battery pack.

2. Reconnect the battery cables to the battery terminals in accordance with the battery wiring hookup shown on the decal in the battery frame.

3. Reconnect the battery connector, reinstall the battery cover, turn the key switch ON, and test the operation of the pallet truck.

Figure 6-3: Battery Wiring Hookup

PDMM-01 05 Issued: 5 / 2 1 /01

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Battery

Single Battery Pack (Optional) Removal 1. Turn the key switch OFF.

2. Disconnect the battery connector located at the top of tractor cover.

3. Position the battery replacement device above the battery and attach to the battery manufacturer's designated lift points, see Figure 6-4.

4. Remove the battery with the lifting device.

5 . Place the discharged battery on the charging stand.

Installation 1. With a fully charged and tested battery on the lifting device, position the lifting device in accordance with the manufacturer's recommendations.

2. Position the battery in the compartment. Be sure the battery has no more that 0.50 in.

(12.7 mm) of "free play" movement in the battery compartment.

Figure 6-4:

Battery with Hoist

3 . Move the lifting device from the area.

4. Reconnect the battery connector, turn the key switch ON, and test the operation of the truck.

Battery Exterior Cleaning 1. Inspect the battery.

a. Make sure the cables are not frayed or loose. b. Make sure there is no foreign material inside the connector. c. Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure 6-5.

2. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

Figure 6-5: Battery Filler Plugs and Vent Holes

PDMM-01 05 Issued: 5/2 1 /0 1

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Battery

A CAUTION Do not clean the top of the battery with the soda solution while it is installed in the truck. Water would seep into the electrical compartments and cause serious damage. a. Disconnect the battery connector, and remove the battery from the truck before you clean it. b. Tighten the battery filler plugs. c. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb (0.45 kg) of baking soda added to 1 / 2 gal (1.9 liters) of hot water. d. Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized. e. Rinse the battery with clean water. f. Dry the battery completely before reinstalling it. g. Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

Charging To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge. Charging time is 5% to 20% longer than discharge time.

The most important element in battery service and prolonging battery life is proper charging.

Make sure you follow the proper method for each application, following the battery and battery charger manufacturers' instructions.

Figure 6-6:

Multiple Battery [Swing-Out] Pack Charger

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Toyota Powered Pallet W a l kie Service Manual

Component Procedures Battery

A CAUTION The vent holes in the filler plugs must be open to allow hydrogen gas to escape from the cells. When you charge the battery, make sure the polarity connections are correct. The positive lead of the charger must be connected to the positive terminal, and the negative lead must be connected to the negative terminal.

1. Familiarize yourself with the following:

Charging rate, starting rate, and finish rate Time available for charge Overheating, excessive gassing, or overcharging Variations between cell voltage 2. Battery performance varies depending on the type of application. If you use more than one truck, one battery, and one charger, keep the same batteries and charger assigned to each truck. This makes it easier to diagnose any battery or charging problem.

3. Consult your battery and battery charger manufacturer's manual for specific charging procedures.

4. Wear personal protective equipment. see "Battery Safety" on page 2 - 7 .

5 . Turn the key switch OFF, disconnect the battery, and remove the battery from the truck.

6. Inspect the battery.

7 . Check the electrolyte level in each cell.

Electrolyte should cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. See "Adding Water" on page 6-13. Do not fill to level yet.

Electrolyte level will rise during charging.

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Component Procedures

Toyota Powered Pallet W a lkie Service Manual

Battery

8. Using a hydrometer, measure and record the specific gravity of each cell. See "Specific Gravity" on page 6-14.

9. Check and record the voltage of each cell.

10. To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged will decrease battery life. At maximum recommended discharge, the specific gravity should read 1.140- 1.160 or less.

11. Ensure that the filler plugs are clean and the vent holes are open. Tighten all filler plugs.

A CAUTION NEVER plug the battery charger into the truck. This will severely damage the truck's electrical system. Plug the charger ONLY into the connector from the battery.

12. Charge the battery, following specific instructions in your battery and battery charger manufacturer's manual.

13. Using a hydrometer, check the specific gravity of each cell. No amount of charging will increase battery capacity or raise specific gravity above its fully charged level (specific gravity 1.280 to 1.300).

14. If, after charging, the electrolyte level is below the fill port, add water to bring it to the fill level. See "Adding Water" on page 6- 13. Do not overfill the cells or allow electrolyte to spill onto the battery case.

In general, a lead-acid battery may be charged a t any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 1 10 F (43 C).

Temperatures of 120°F (490C) are allowed only for short periods of time.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Adding Water

Adding Water Water must be added to battery cells periodically. Frequency and quantity depend on the water level above the plates and the amount of gassing during charge.

Guidelines: Wear personal protective equipment, see "Battery Safety" on page 2-7. Use only distilled water or water approved by the battery manufacturer.

Before charging, make sure battery plates are covered with electrolyte. Add water, if necessary, only to cover plates.

Electrolyte level rises during charging. To avoid overflow, add water to fill port, if necessary, after charging, and after hydrometer and voltmeter readings are taken.

Keep the outside of the battery case clean and dry.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Adding Water

Specific Gravity Specific gravity readings for lead acid batteries with electrolyte temperatures a t 80°F (27°C) vary with the state-of-charge a s follows:

Charge

Specific Gravity

100%

1.280-1.300

75%

1.250-1.260

50%

1.200-1.210

25%

1.150-1.160

0%

1.080

Most industrial deep-cell discharge batteries are considered discharged when 20°/0 of the charge remains (specific gravity 1.140).

NOTE: Maintenance-free batteries do not require specific gravity checks.

Procedure: 1. Wear personal protective equipment. See "Battery Safety" on page 2-7.

2. Insert the nozzle of the hydrometer into the battery cell and draw enough electrolyte into the tube to permit the float to ride free.

3. Leave the hydrometer nozzle in the battery and read the specific gravity of the cell.

4. If there is not enough electrolyte in the battery to get a hydrometer reading:

Add just enough water to cover the battery plates Charge the battery, then take readings 5. Record the specific gravity reading on the battery chart.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Voltage Check

Voltage Check Take a voltage check on each cell after performing the specific gravity check on page 6- 14. Connect the leads of a voltmeter to the positive and negative terminals of each cell.

Voltage readings will vary with the state of charge:

Charge

Voltage Reading

Record the voltage reading for each cell on the battery maintenance chart. There should be a difference of no more than 0.2 volt between cells.

Maintenance-Free Batteries The truck may be equipped with a maintenance-free battery and charger, in which case, the specific gravity need not be checked.

See Figure 6-7. Please follow manufacturer's recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery should be kept clean and dry and may be washed to remove any accumulated foreign matter. See "Battery Exterior Cleaning" on page 6-9.

Storage Before you store a battery, make sure the electrolyte is a t the proper level in all the cells, the filler plugs are tight, and the battery is fully charged.

Store the battery in a clean, cool, dry location away from radiators and other sources of heat.

Check the electrolyte level and the specific gravity every 30 days during storage. Whenever the specific gravity is less than 1.230, charge the battery.

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Figure 6-7: Maintenance-Free Baffery Charger

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Power Cables

Power Cables Power cables should be checked for damage, including: Evidence of overheating Burned spots in the cable Nicks in the insulation Damaged or overheated terminal lugs Damaged mounting hardware or brackets Repair or replace damaged cables or mounting hardware a s necessary.

Power cables are marked on the terminal lug with the location where they belong. If the marking is missing or is not readable, remark the cable with the correct information.

The terminal lugs should be crimped tightly and securely on the wire. Replace the lug if overheating is evident and repair or replace faulty connectors a s necessary.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Wiring Harness

Wiring Harness All wires in the harness are marked every 1 to 1.5 in. (2.54 to 3.81 cm) with a wire identification number. These numbers correspond to wire identification given in the schematic. See "Schematics" on page A-9.

Terminology The term "connector J P x means a mated connector consisting of two connector halves.

One half contains male connectors, or pins (P): the other half contains female connectors, or jacks (J).

When you disconnect a mated J P connector, you will have two connector halves. The individual connector halves are designated by "Jx" and "k."

For example, connector J P 2 is the mated connector in the control handle. 5 2 represents the jack connections. P2 represents the pin connections.

To locate electrical connectors on the truck refer to the electrical schematic located in the Appendix or see "Electrical Connector Locator Chart" on page 5- 12.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Wiring Harness

Inspection Whenever working on the truck. use care around wiring harnesses.

Do not pull on wires.

Carefully mate and unmate all connectors.

Do not pry apart connectors with unspecified tools.

Examine and maintain any added materials used to dress or protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, etc.

Check harness wires for abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage.

Replace terminations with exposed wire visible at the connectors. Damaged terminations, exposed wires. or damaged connectors can cause operational failure of the truck.

During troubleshooting and repairs, it is sometimes necessary to unmate a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note carefully the location of the wire and all protective or securing attachments before moving the harness.

After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performance of the interconnect system.

In addition to the wire identification number printed every 1 to 1.5 in. (2.54 to 3.81 cm) on the wire, there should be a wire marker at each termination. If the marker is missing or unreadable, remark the wire to allow easier identification.

NOTE: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Diodes

Diodes Test Check diodes with a digital multimeter or use a Simpson 260 multimeter or its equivalent. Use the diode testing feature on the digital multimeter. Use the RX1 ohm scale on the .

Simpson 260 multimeter.

A CAUTION Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter.

Electrical current can damage the ohmmeter.

Replace the entire assembly if defective diodes are found.

Positive lead (+) Negative lead (-) Simpson 260 Multimeter Reading Digital Multimeter Reading

Anode Cathode

1

Cathode

8-30 Ohms

Anode Infinity

0.3-1.0 V

Infinity

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Fuse

Fuse Examine the fuse for signs of overheating, discoloration, cracking, or other physical damage. Replace the fuse if you find damage.

See Figure 6-8.

To test a fuse, remove it or isolate it from the electrical circuit. Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse.

Use an ohmmeter set to Rxl scale and measure the resistance across the fuse. The resistance should be less than 1 ohm.

Figure 6-8:

Fuse

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Circuit Breaker

Circuit Breaker Under extreme operating conditions the current demand on the battery may exceed the rating for the main circuit breaker and force it open.

This will cause the truck to become inoperable until the circuit breaker automatically resets itself.

Examine the circuit breaker for signs of overheating, discoloration, or other physical damage. See Figure 6-9. Replace the circuit breaker if you find damage.

To test a circuit breaker, remove it or isolate it from the electrical circuit and allow it to cool (or reset itself). Do this by removing the circuit breaker from the truck or by removing all the connections from one side.

Use an ohmmeter set to Rxl scale and measure the resistance across the circuit breaker. The resistance should be less than 1 ohm.

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Figure 6-9:

Circuit Breaker

Component Procedures -

Toyota Powered Pallet Walkie Service Manual

-

Switches (General)

Switches (General) Refer to the electrical schematic in the Appendix to identify the electrical circuit location of the switch.

Examine the switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace the switch if you see such damage.

To test a switch, isolate it from the electrical circuit. Do this by removing all the connections from the switch, making sure all wires are labeled and identified for reconnection.

Use a n ohmmeter set to a low resistance scale to measure the resistance across the switch. In a closed position, the switch should be less than 1 ohm. In a n open position, the switch should show a resistance greater than 10 megohms.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Control Handle Switches

Control Handle Switches Removal 1. Turn the key switch OFF and disconnect

Screws

the battery connector.

2. Remove the switch cover assembly by unscrewing the four phillips head screws.

See Figure 6-10.

3. Note the position of the function buttons for

reassembly later. Remove the three function buttons (horn, lower, and lift) and six compression springs from the hex head standoffs.

Figure 6- 10: Control Handle Cover Assembly

4. For access to the travel potentiometer and emergency reverse switch, lift the switch bracket up and out of the handle assembly.

See Figure 6- 11 and Figure 6-12.

5. Disconnect the wires from the switch to be replaced.

6. Remove the switch mounting plate if

applicable.

Figure 6- 1 1 : Control Handle Switches

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Control Handle Switches 7. Remove the switch mounting hardware,

noting the position of the washer.

Installation 1. If applicable, attach new switch to the

switch mounting plate.

2. Connect the wires.

3 . Install the three function buttons (horn, lower, and lift) and six compression springs on the hex head standoffs. Make sure the function buttons are placed on the correct switch.

4. Reinstall the switch cover assembly.

5. Reconnect the battery connector and t u r n the key switch ON. 6. Test the control handle switch function.

Adjust the throttle potentiometer setting a s required. See "Throttle Potentiometer Adjustment" on page 6-42.

Figure 6- 12: Accessing Throttle Potentiometer a n d Emergency Reverse Switch

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Main ON/OFF Switch

Main ON/OFF Switch A Main ON/OFF switch (SW13) is provided on

the gauge console.

See Figure 6-13. In the OFF position (0). battery power to all control functions is interrupted. In the ON position (I), battery potential is provided to all control functions via the key switch.

Inspection 1. With the battery plugged in and the Main ON/OFF switch in the ON position, battery voltage Bt should be present on both terminals of the switch.

2. Test the Main ON/OFF switch with an ohmmeter after disconnecting the battery and removing the wires from the switch terminals.

In the OFF position, the ohmmeter should read greater than 1 megohm, and in the ON position, the ohmmeter should read less t h a n 1 ohm. If not, replace the switch.

Removal 1. Disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the gauge console from the electrical panel.

4. Disconnect the wires from the switch.

5. Remove the Main ON/OFF switch.

Installation 1. Install the new Main ON/OFF switch.

2. Connect the wires to the new Main ON/OFF switch terminals.

3. Re-install gauge console onto electrical panel.

4. Reconnect the battery connector and check operation.

5. Install the tractor cover.

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Figure 6- 73: Main ON/OFF Switch location

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Key Switch

Key Switch A two-position (ON/OFF) key switch (SWl),

located on the gauge console, energizes all truck control functions when in the ON position, provided the Main ON/OFF switch is in the ON position. See Figure 6-14.

Inspection 1. Remove the tractor cover.

2. With the battery plugged in and the key switch ON, battery voltage B+ should be present on both terminals of the switch.

3. Test the key switch with an ohmmeter after turning it off, disconnecting the battery and removing the wires from the switch terminals.

In the OFF position, the ohmmeter should read greater than 1 megohm, and in the ON position. the ohmmeter should read less than 1 ohm. If not, replace the switch.

Removal 1. Turn key switch OFF.

2. Disconnect the battery connector, 3 . Remove gauge console from electrical panel.

4. Remove the mounting nut from the stem of the key switch.

5. Disconnect the wires from the key switch.

Figure 6- 14: Key Switch location

6. Remove the key switch.

Installation 1. Install the new key switch and tighten the locking nut.

2. Connect the wires to the new key switch terminals.

3 . Re-install the gauge console onto the electrical panel 4. Reconnect the battery connector and check

operation.

5 . Install the tractor cover.

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Toyota Powered Pallet W a lkie Service Manual

Component Procedures Brake (Deadman) Switch

Brake (Deadman) Switch Adjustment The brake (deadman) switch (SW2)is located near the brake drum, a t the side of the drive motor. See Figure 6- 15.

1. Turn the key switch to OFF and disconnect

the battery connector.

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck. Aher the truck is jacked, DO NOT rely on the jack alone to support the truck. For details, see "Jacking Safety" on page 2- 1 1.

Figure 6 -15: Brake [Deadman] switch

2. Jack the truck and block the frame.

3. Remove the drive unit cover.

4. Loosen the two (2) screws holding the

switch on the bracket. Slide the switch to the left a s far a s possible. See Figure 6-16.

5 . Slide the switch back to the right until the switch "clicks". Move the switch to the left (approximately 1 /32 in. [0.7 mm]) until it "clicks" again. Retighten the screws.

6. Check that the brake arm makes solid contact with the switch lever.

7. Check that the switch "clicks" near the middle of the cam arm movement. The brake switch should operate within 10 degrees of the full u p or down handle ~ o s i t i o nBe . sure the switch does not bottom out when fully compressed.

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Figure 6 - 16: Brake [Deadman) Switch Inactive, Brake ON

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Brake (Deadman) Switch

8. Install the drive unit cover and torque to 35 ft. Ibs. (49 Nm).

9. Remove the blocks, connect the battery connector and turn the key switch ON. Test the operation of the truck.

Lower the forks completely.

Turn the key switch OFF and disconnect the battery connector.

Remove the drive unit cover.

Disconnect the wires on the deadman switch.

Remove the screws holding the deadman switch on the mounting bracket.

Remove the deadman switch.

Figure 6- 17: Brake (Deadman) Switch Active, Brake OFF

Installation 1. Mount the deadman switch to the mounting

bracket.

2. Connect the wires to the deadman switch.

3. Reconnect the battery connector and turn the key switch ON. 4. Test drive the truck.

5. Adjust the switch if necessary. See "Brake (Deadman) Switch" on page 6-27.

6. Turn the key switch OFF and disconnect the battery connector.

7. Install the drive unit cover.

8. Reconnect the battery connector.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Lift-Limit Switch

Lift-Limit Switch When the forks are fully raised, the lift-limit switch (SW10)turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure 6- 18.

Adjustment 1. Raise the forks until they reach their fully raised position. If the lift-limit switch does not shut the pump down when the lift cylinder reaches its upper limit, the relief valve on the hydraulic pump will make a high-pitched squeal, indicating that the relief valve is opening.

2. Turn the key switch OFF and disconnect the battery.

3 . Loosen the bolt and slide the switch bracket up or down to activate (cut power offl when the lift is 1/2 to 1 in. (12.7 to 25.4 mm) before its fully raised position.

4. Tighten the bolt.

5. Reconnect the battery and turn the key switch ON. Lower the forks and then raise them until they reach their fully raised position. The lift-limit switch should cut power off to the pump when the lift cylinder reaches 1/2 to 1 in. (12.7 to 25.4 mm) before its fully raised position.

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Figure 6- 18: lib-limit Switch

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Hydraulic Solenoid

Hydraulic Solenoid Removal 1. Make sure that the forks are fully lowered.

2. Turn the key switch to OFF. Disconnect the battery connector.

3. Remove the two wires from the terminals on the solenoid.

4. Remove the n u t holding the solenoid coil to the solenoid valve;

5. Lift the solenoid coil off the solenoid valve.

6. Remove the solenoid valve from the manifold.

Installation 1. Inspect the seat where the solenoid seals against the manifold. The sealing surface should be completely clean and free from any nicks or damage.

2. Inspect the O-ring for any damage. If the O-ring is damaged or deformed in any way, replace it.

3. Thread the solenoid valve into the manifold.

Torque the solenoid valve to 25 ft. lbs.

(35 Nm).

4. Install the solenoid coil onto the solenoid

valve and tighten the nut.

5. Connect the wires to the terminals.

6. Reconnect the battery connector and turn the key switch ON. Test the functions of the truck.

Figure 619: Hydraulic Solenoid

7. Turn the key switch OFF. Disconnect the battery.

8. Install any covers that were removed.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Gauges

Gauges Toyota Powered Pallet Walkies are available with one of three optional gauge packages: hour meter, battery discharge meter, and hour meter/battery discharge combination meter.

Hour Meter , When the battery is connected, this meter shows the number of hours. The digital quartz "hour glass" icon flashes and the counter increases when the brake (deadman) switch is closed.

Inspection If the numbers do not illuminate when the battery is plugged in, use a voltmeter to check for B+ at pin 1 on the back of the gauge (with respect to pin 2 , B-). If voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery).

If the meter does not log hours, verify that B+ is present on pin 3 when the brake (deadman) switch is closed (the handle is in drive position).

If voltage is not present, use the schematic in the Appendix and trace B+ to the source (brake (deadman) switch).

If the required voltages are present (as outlined above) and no other problems are found, replace the hour meter gauge.

Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the gauge console from the electrical panel.

4. Remove wires from the back of the gauge and make careful note of their orientation.

5. Remove the mounting nuts (2) and slide off the gauge mounting bracket.

6. Remove the gauge by lifting through the top

of the gauge console.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Gauges

Replacement 1. Place the new gauge in the mounting hole.

2. Replace the gauge bracket, install the nuts, and tighten them securely.

3. Connect the wires to the proper terminals.

4. Re-install the gauge console on the electrical panel.

5. Reconnect the battery connector and test operation.

6. Install the tractor cover.

Battery Discharge Meter The battery discharge meter measures the battery state of charge when the key switch is ON. When the battery is fully and properly charged, the green bar closest to 1 is lit. As the battery loses its charge, a green or yellow bar moves closer to 0. Two red bars begin flashing when the battery is almost fully discharged.

Inspection If the point does not move when the key switch is ON, use the voltmeter to check for B+ a t terminal labeled B+ on the back of gauge (with respect to pin labeled B-). If the voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery via the key switch).

If the required voltages are present (as outlined above) and there are no other problems, replace the battery gauge.

Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the wires from the back of the gauge and make careful note of their orientation.

4. Remove the mounting nuts (2) and slide off the mounting bracket.

5. Remove the gauge by lifting through the top of the mounting bracket.

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Component Procedures Gauges

Replacement 1. Place the new gauge in the mounting

bracket hole.

2. Replace the bracket, install the nuts, and tighten them securely.

3. Connect the wires to the proper terminals.

4. Reconnect the battery connector and test operation.

5. Install the tractor cover.

Combination Hour/Battery Discharge Meter Hour Meter

When power is applied, the hour meter's digital quartz "hour glass" icon flashes and counter increases. The meter logs hours when the brake (deadman) switch is closed.

Battery Discharge Meter

The battery discharge meter measures the battery state of charge when the key switch is ON. When the battery is fully and properly charged, the green bar closest to 1 is lit. As the battery loses its charge, a green or yellow bar moves closer to 0. Two red bars begin flashing when the battery is almost fully discharged.

Inspection If the displays do not illuminate when the key switch is ON, use the voltmeter to check for B+ at pin 6 on the back of the gauge (with respect to pin 2, B-). If the voltage is not present. use the schematic in the Appendix and trace B+ and B- to the source (battery via key switch).

If the point does not move when the key switch is ON, use the voltmeter to check for B+ at pin 5 on the back of gauge (with respect to pin 2, B-).

If the voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery via FU 1).

If the meter does not log hours, v e d y that B+ is present on pin 3 when the brake (deadman) switch is closed (handle is in drive position). If

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Installation

the voltage is not present, use the schematic in the Appendix and trace B+ to the source (brake (deadman)switch.

If the required voltages are present (as outlined above) and there are no other problems, the gauge is faulty.

A CAUTION If the battery is replaced with another battery that is not fully charged (i.e., the gauge does not reset its indication to a full charge state) the display may provide wrong information for the battery state of charge.

Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Remove the gauge console from the electrical panel.

4. Remove wires from the back of the gauge and make careful note of their orientation.

5. Remove the mounting nuts and slide off the mounting bracket.

6. Remove the gauge by lifting through the top

of the gauge console.

Installation 1. Place the new gauge in the mounting hole.

2. Replace the bracket, install the nuts, and tighten them securely.

3. Connect wires to the proper terminals 4. Re-install the gauge console onto the electrical panel.

5. Reconnect the battery connector and test operation.

6. Install the tractor cover.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Control Handle

Control Handle The control handle is designed so that some repairs can be made without removing the entire handle. A cable connector in the handle can be disconnected to allow the head unit to be removed for bench repair.

Head Unit Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the four hex head cap screws at the base of the head unit. See Figure 6-20.

3 . Disconnect the cable connector.

See Figure 6-2 1.

Figure 6-20: Head Unit Removal

Head Unit Disassembly 1. With a small diameter punch. drive the spring pins in the butterfly knobs out.

See Figure 6-22.

2. Slide the butterfly knob and hand grip off the actuator shaft.

3 . Remove the six hex head cap screws

securing the controller assembly to the knuckle guard. See Figure 6-22.

Figure 6-2 1 : Control Handle Cable Connector

Head Unit Reassembly 1. Secure the controller assembly to the knuckle guard with the six hex head cap screws previously removed.

2. Slide the butterfly knob and hand grip onto the actuator shaft.

3. Drive the spring pins into the butterfly knobs.

Figure 6-22: Head Unit Disassembly

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Head Unit Installation

Head Unit Installation 1. Connect the cable connector.

NOTE: If the tmck is a Cold Storage Unit, apply a n ample amount of sealing compound (Dow Corning 111) where wires enter plugs or receptacles. The amount applied should be enough to prevent moisture from entering the connector.

Disconnect connector to apply compound both internally and externally. Avoid sealing compound on pin contact area.

2. Reinstall the head unit on the control handle stem with the four hex head cap screws previously removed.

3. Connect the battery connector and turn the key switch ON.

4. Test the operation of the truck.

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Component Procedures Control Handle Stem Removal

Control Handle Stem Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the head unit. See "Head Unit Removal" on page 6-35.

3. Disconnect the cable connector.

See Figure 6-21. Remove the cable clamp near the base of the control handle stem.

A CAUTION Before removing the chain master link in the next step, make sure you are holding the handle. When the master link is removed, the handle will fall.

4. Pull the handle down to operating range.

Insert a wire or punch through a chain link close to the handle (or use a pair of vise grip pliers to grasp the chain close to the handle).

Figure 6-23: Detaching liandle

5. Release the handle to relieve tension on the chain and the anchor.

6. Disconnect the handle return chain at the

master link located near the transmission case. See Figure 6-23.

7 . Pull the electrical cable out the bottom of the handle.

8. Remove the motor side cover. Remove the cotter pin retaining bolt and cotter pin and slide the pivot pin out. See Figure 6-24.

9. Carefully remove the handle.

Figure 6-24: Removal of Handle Pivot Pin

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Control Handle Stem Reassembly

Control Handle Stem Reassembly 1. During reassembly, be certain that the brake release cam on the handle pivot pin is in the correct position before installing the cotter pin.

2. Slide in the handle pivot pin through the lower control handle assembly and reinstall the cotter pin and retaining bolt.

3. Raise the handle and reconnect the handle return spring at the chain master link located near the transmission case.

4. Pull handle down to operating range and remove the wire, punch or pliers installed earlier.

5 . Thread the electrical cable through the handle base and connect the cable connector.

6. Reattach the control handle head unit.

7 . Install the motor side cover.

8. Connect the battery connector and turn the key switch ON.

9. Test the operation of the truck.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Horn

Horn The horn can be sounded regardless of key switch position, provided the Main ON/OFF switch is in the ON position.

Removal 1. Turn the key switch OFF and disconnect the battery connector.

2 . Remove the tractor cover.

3 . Disconnect the two wires from the horn.

See Figure 6-25.

4. Remove the horn mounting bolt.

Installation 1. Attach the new horn to the electrical panel and tighten the mounting bolt.

2. Attach the two wires.

3 . Reconnect the battery connector and test operation.

4. Install the tractor cover.

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Figure 6-25: Horn location

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Motor Controller

Motor Controller

A CAUTION Do not open the controller. Opening the controller could damage it and will void the warranty.

Cleaning 1. Turn the key switch OFF and disconnect the battery connector.

2. Discharge the capacitors in the controller by connecting a load (such a s a contactor coil or a horn) across the controller's B+ and B- terminals.

Figure 6-26: Motor Controller location

3. Clean the controller with a moist rag. Allow it to dry before connecting the battery.

4. Make sure the power cable connections are tight. Avoid stressing the cable connections and putting strain on internal connections.

Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Discharge the capacitors in the controller by connecting a load (such a s a contactor coil or a horn) across the controller's B+ and B- terminals.

4. Push the locking tab and disconnect the PMC connector (control wires) from the motor controller. See Figure 6-27.

5. Disconnect the cables from the M- terminal on the motor controller. Avoid stressing the power cable connection.

6. Disconnect the three power cables (terminals B+, B- and M-) on the motor controller. Avoid stressing the power cable connections. Disconnect wiring harness connectors (terminals F1 and F2).

Figure 6-27: Motor Controller Connections

7. Remove the three hex head cap screws securing the motor controller to the electrical panel. Pull the controller out.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Motor Controller

Installation 1. Secure the motor controller to the truck frame with the three previously removed hex head cap screws.

2. Reconnect the three power cables (terminals B+, B- and M-) and wiring harness connectors (terminals F1 and F2) on the motor controller. Torque screws to 12 ft. lbs. (16.3Nm) maximum.

3 . Connect the PMC connector (control wires)

to the motor controller.

4. Connect the battery connector and t u r n the key switch ON.

5 . Test operation of the truck.

6. Turn the key switch OFF. 7 . Install the tractor cover.

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Toyota Powered Pallet W a lkie Service Manual

Component Procedures ---

-

Throttle Potentiometer Adjustment

Throttle Potentiometer Adjustment The throttle is a two wire resistive throttle that connects the pot wiper pin (PMC-8)and the pot low pin (PMC-7).Zero speed corresponds to 0 ohm and full speed corresponds to 6.5K ohm.

1. Turn the key switch OFF and disconnect the battery connector.

Screws

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck. After the truck is jacked, DO NOT rely on the jack alone to support the truck. For details, see "Jacking Safety" on page 2-1 1.

2. Jack and block the truck.

3. Remove the control handle head unit and disconnect the cable connector. See "Head Unit Removal" on page 6-35.

4. Remove the switch cover assembly by unscrewing the four phillips head screws.

See Figure 6-28.

Figure 6-28: Switch Cover Assembl y Removal

5. Lift the switch bracket up and out of the handle assembly.

6. To electrically center the potentiometer, the throttle must be in the neutral position.

Loosen the nut on the potentiometer shaft.

See Figure 6-29.

7. Connect the ohmmeter to pins VR-2 and VR-4. Measure the potentiometer resistance while rotating the potentiometer body until the ohmmeter reads a s close to '0' ohms a s possible. Retighten the potentiometer shaf? nut.

8. With the ohmmeter still connected to pins VR-2 and VR-4, verify that the forward and reverse throttle positions are equal by rotating the Directional/Speed Control Handle fully in both directions.

Figure 6-29: Control Handle Switch Cover Removal

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Throttle Potentiometer Adjustment

9. Record the maximum resistance value in

both directions. In either direction, the resistance value should be 6.5K r 500 ohms. In addition, the difference between the two readings must be 300 ohms or less.

Maximum Variation Example Handle Position

Resistance (Ohms)

Fully clockwise

6,500

Fully counterclockwise

6,200

10. To determine the ideal potentiometer position, add the previously recorded readings in Step 8 and divide that result in half. (See example below.) Loosen the potentiometer nut (1/2 turn) so that the potentiometer will move in the bracket when you apply force with your finger.

Example: 6,500 ohms CW + 6,200 ohms CCW = 12,700 ohms 12,700 s 2 = 6,350 ohms (ideal maximum resistance value setting) 11. Rotate the throttle control fully in one direction. Move the potentiometer body until the ideal maximum resistance value is obtained. Once the potentiometer is electrically centered, tighten the potentiometer shaft nut securely to prevent the pot from moving in the bracket.

12. Reassemble the head unit and connect the cable connector.

13. Reattach the head unit to the control handle stem.

14. Reconnect the battery connector.

15. Test the truck's operation.

16. Turn the key switch OFF and disconnect the battery connector.

17. Jack and remove the blocks from underneath the truck. See "Jacking Safety" on page 2-11.

18. Reconnect the battery connector.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Contactors

Contactors Two types of contactors are used on the 6HBW20. The main contactor is a sealed unit and is not repairable. See "Main Contactor" on page 6-45. The directional contactor allows for the replacement of the contactor tips. See "Directional Contactor" on page 6-46.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Main Contactor

Main Contactor The main contactor is not repairable.

Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires from the X and Y terminals on the contactor coil. Note the location of the wires for correct installation later.

4. Remove the two nuts securing the b u s bar, cables, and pre-charge resistor to the contactor. Note the location for assembly later. See Figure 6-30.

5. Remove the two mounting screws holding

the contactor assembly to the electrical panel.

Ins 1. Secure the contactor to the electrical panel with the two screws previously removed.

See Figure 6-30.

2. Secure the bus bars, cables, and precharge resistor to the contactor with the nuts previously removed.

3. Connect the wires to the X and Y terminals.

4. Install the tractor cover.

5. Connect the battery connector and turn the key switch ON. 6. Test the operation of the truck.

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figure

6-30: D~~~~~~~~~~~~ M~~~ c

~

~

,

~

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Directional Contactor

Directional Contactor Tip Inspection When you inspect the contactor tips, follow these guidelines: Darkened points do not indicate burning.

Burning indicates a loss of contact point material.

Replace the contact points if there is not enough contact point material to last until the next regular inspection.

The silver alloy part of the point is usable contact material; the copper backing is not.

Do not file contact points to remove discoloration or minor irregularities. This practice produces a surface more susceptible to sticking.

The contactor has special textured tips that provide a mechanical self-cleaning when the contactor opens or closes; DO NOT FILE,use sandpaper or emery cloth on the tips.

A CAUTION When repairing contactors, use only Toyota authorized contactor kits.

Contactor Removal Turn the key switch OFF and disconnect the battery connector.

Remove the tractor cover.

Disconnect the wires from the X and Y terminals on the contactor coils. Note the location of the wires for correct installation later. See Figure 6 -3 1.

Remove the four bolts securing the bus bar and cables to the contactor. Note the location for correct installation later. See Figure 6-31.

Remove the two screws holding the contactor assembly to the frame. See Figure 6-3 1.

Figure 6-3 1 : Directional Contactor

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Tip Replacement

Tip Replacement 1. Loosen and remove the three top cover

screws. See Figure 6-32.

2. Hold the contactor together so that it does not come apart. Turn it upside down and place it on a work bench so it rests on its fzed contacts.

Figure 6-32: Removing Top Cover

3. Separate the magnet frame assembly from the top cover assembly. See Figure 6-33.

Top Cover Assembly

Magnet Frame Assembly

Figure 6-33: Separated Contactor Assembly

4. Remove the normally closed fixed contact insulator and the pegs from the top cover assembly. See Figure 6-34.

5. Remove the normally closed fxed contact from the top cover assembly. This will allow the moving contacts to lift up on one side and expose the return springs.

Fixed Contact Figure 6-34: Removing the Fixed Contact

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Tip Replacement 6. Insert a thin screwdriver or similar

instrument into the coils of the return spring and depress the spring to take the pressure off the moving contact. See Figure 6-35.

7. Remove the moving contact sideways from the top cover assembly.

Figure 6-35: Accessing the Return Springs

8. Remove the two return springs from the top cover assembly. See Figure 6-36.

9. Place the top cover assembly upside down on a work bench so it rests on its fxed contacts.

10. Place the two return springs into the

recesses in the top cover.

1 1 . Use a thin screwdriver or similar

instrument to depress the return spring.

Now slide a new moving contact assembly in from the side, so the top of the plunger engages into the return spring.

NOTE: Make sure the return spring and the moving contact assembly are correctly located before you continue.

Figure 6-36: Return Springs and Moving Contacts

12. Repeat step 1 1 with the other new moving contact assembly.

13. Place the normally closed fixed contact in its correct position in the inverted top cover.

See Figure 6-37.

Insulator

Elastic Band

14. Place the normally closed fixed contact insulator into the top cover assembly, and add the two pegs in both the insulator and the normally closed fixed contact.

15. Carefully place the coil assembly onto the top cover assembly. Place the moving contact plungers in the holes in the center brushes and the pegs in the holes in the top of the frame. pegs

Normally Closed Fixed Contactor

Figure 6-37: Assembling Top Cover Assembly

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Toyota Powered Pallet Walkie Service Manual

Component Procedures

Tip Replacement NOTE: It may be easier to place the top assembly into the frame if you secure a n elastic band around the top cover assembly to hold the normally closed contact and its insulator in place. This makes it easier to put the moving contact plungers in the center brushes by centering the plungers. Once the top and bottom assemblies are together. cut and remove the elastic band.

With the top cover positioned on the coil frame, position the contactor assembly with the coil frame down. See Figure 6-38.

A CAUTION not over tighten the screws.

Insert the three screws into the top cover and tighten to 16-20 in. lbs. (2 Nm). See Figure 6-39.

Figure 6-38: Assembling the Contactor

Make sure the moving contacts are sitting firmly on the normally closed fixed contact and there is sufficient spring pressure.

Check the free movement of the moving contacts by pushing the solenoid armature from underneath the contactor.

Test the coil resistance. See the following procedure.

Figure 6-39: Securing Top Cover Assembly

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Tip Replacement

Coil Resistance NOTE: If the contactor is already removed from truck, go to step 4.

1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the two wires from the contactor. These wires are marked with an X and Y. 4. Connect one lead of the ohmmeter to the X lead from the contactor. Connect the other lead to the Y lead from the contactor. See Figure 6-40.

Figure 6-40: Testing Coil Resistance

5. The reading should be 28.5-30.5 ohms.

Contactor Installation 1. Secure the contactor assembly to the frame with the two screws previously removed.

2. Install the four bolts securing the b u s bar and cables to the contactor.

3. Connect the wires to the X and Y terminals on the contactor coils.

4. Install the tractor cover.

5. Connect the battery connector and t u r n the key switch ON. 6. Test operation of the truck.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Brake

Brake

A CAUTION Allow the brake to cool completely before servicing.

Brake Shoe Adjustment 1. Turn the key switch OFF and disconnect the battery connector.

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle whik jacking the truck. After the truck is jacked, DO NOT rely on the jack alone to support the truck. See "Jacking Safety" on page 2-1 1.

2. Jack the truck and block the frame.

3. Remove the drive motor cover.

4. Fully raise the control handle and remove

the brake application spring. This will allow the brake to release. See Figure 6-33.

Figure 6-33: Brake Adjustment Location

5. Lower the control handle into the operating range so that the brake linkage bearing is on top of the brake release cam.

Adjust the brake rod linkage to the clevis so that the clevis pin just goes in the brake lever. See Figure 6-34.

Reinstall the spring and test braking ability.

ITE:

Use a maximum rated load when you measure the stopping distance. The truck should stop within approximately 6 feet (1.83 meters).

If the brake is inadequate, then shorten the brake rod linkage to the clevis to get adequate braking. This establishes the braking force on the brake shoes.

Figure 6-34: Brake Adjustment Close-up

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Brake Shoe Adjustment

NOTE: The brake drum may be removed and the brake lever moved one "spline" to compensate for brake wear.

Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the drive motor cover.

3. Fully raise the control handle and remove the brake application spring. Disconnect the clevis from the brake lever.

4. Loosen the nut and remove the brake

drum.

5. Remove the springs and remove the brake shoes.

6. Remove the screws holding the brake assembly to the drive motor assembly.

7. Remove the brake assembly.

Figure 6-35: Brake Removal

NOTE: By lifting one brake shoe of the brake assembly a t a time, the mounting screws can be removed without disassembling the brake assembly.

Installation 'TE:

During reassembly, the brake lever should be checked to see that it is set a t 60 degrees and that the brake drum nut is torqued to 75 ft lbs (105 Nm).

Install the brake assembly to the drive motor. Apply thread-locking compound (Loctite 243) to mounting screws and torque to 11 ft lbs (15 Nm).

Install the brake drum and secure with the locking nut.

Install the brake adjusting rod assembly.

Install the clevis pin holding the lever.

Reinstall the brake application spring.

-

-

6. Adjust the brake. See "Brake Shoe Adjustment" on page 6-51.

Figure 6-36: Brake installation

7. Install the drive motor cover.

8. Reconnect the battery connector. Turn the key switch ON and test-operate the truck.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Motors, General

Motors, General Drive Motor Brushes Inspection Conduct a partial inspection of the drive motor after every 1,000 hours of truck operation. If you work in an abnormally severe or caustic environment or if you have a rigorous duty cycle, inspect the motor more frequently.

Set u p and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment.

Each partial inspection of the motor should include the following: 1. Inspect the brushes for wear and for proper contact with the commutator. Record the level of wear on the brushes. This history will give you a n indication of whether a brush should be changed or if it can wait until the next inspection. Refer to page 6-55 for acceptable brush length and general motor information.

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore, you must take this into account when considering brush replacement.

2. Check brush spring tension. See "Drive Motor Brush Spring Tension" on page 6-55.

3. Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. DO NOT USE lubricants of any kind on or around the commutator.

4. Check brush holders for solid connection to the mounting support. Tighten the mounting screws a s necessary.

5 . Check the cap screws holding the brush cross connectors to the brush holder body.

6. Make sure the motor terminals are secured tightly to the motor frame. Be careful not to strip the threads or crush the insulating parts.

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Figure 6-37: Drive Motor Brush, Typical location

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Motors, General

7. Check all the cap screws around the frame for tightness.

8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

Replacement If one brush needs replacement, always replace the entire set of brushes.

Use only genuine Toyota brushes. Using another type of brush could damage the commutator or cause excessive brush wear.

If the end of the brush is not already contoured to fit the commutator, use the following procedure to seat the brush to the commutator: NOTE:If the motor commutator is not accessible, form the brush contour using a brush seating stone.

1. Move the motor brush springs out of your

way.

2. Wrap a piece of 00 sandpaper around the commutator. DO NOT use emery cloth to seat brushes.

3. Move the brushes back down in their holders so that the face of the brushes matches the curve of the commutator.

4. Remove the sandpaper.

5. Blow any dust out of the motor with clean, compressed air a t a maximum of 30 psi (207 kPa).

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Component Procedures

Tovota Powered Pallet Walkie Service Manual I

Motors, General

Drive Motor Brush Spring Tension inspection 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the drive motor cover.

3. Slide the brush up slightly in its holder.

4. Insert a paper strip between the brush face and the commutator.

5. Place a small leather loop around the coil spring for the brush. If the brush spring has a loop at the brush, hook the spring scale directly to the spring.

Coil Spring

barn..

LOOP

/&$

6. Attach a 5 lbs (2.27 kgm) spring scale to the leather loop.

7. While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates.

8. When the paper strip begins to move freely,

the spring scale will read the spring brush tension.

9. Refer to the table below for proper spring

tension.

Figure 6-38: Motor Brush Spring Tension lnspection

Minimum

spring Tension

Brush

Motor

Length 1

Drive Motor

,I 0.62 in.

(15.7 mm)

20 oz min (568 grams)

10. Repeat steps 3 through 9 for the remaining brushes.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Motors, General

Commutator Inspection The commutator should be inspected for surface condition and high mica. Most armatures have the mica undercut. If the armature on your motor does not, do not attempt to cut it. See Figure 6-39.

Mica

The commutator must be smooth and clean to provide maximum brush wear. When commutators are not properly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature.

NORMAL UNDERCUT

Good commutation will be indicated by a dark brown polished commutator and an evenly polished brush wearing surface.

HIGH MICA

If the comm~itatorappears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, the motor should be removed for servicing.

Segments

/ High Mica

Figure 6-39: M i c a lnspection

Servicing If the commutator requires service, you will need to remove the armature from the motor.

DO NOT use a stone to even out high and low spots on the commutator. Use only a suitable abrasive rubber polisher.

Servicing a motor for an abnormal commutator surface condition and high mica or mica undercutting requires special equipment a t a motor rebuilding facility. Do not attempt to service the motor yourself.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Terminal Nuts

Terminal Nuts Terminal Stud

Whenever you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing n u t to avoid twisting the stud. Check these torques each time you check motor brushes.

1

Stud Size 3/8 in.

(M10) 5 / 16 in.

(M8) 1/4 in.

(M6)

/

Motor Cable securing Nut 100- 120 in. lbs (11.2-13.6 Nm) 90-1 10 in. lbs (10.2-12.4 Nm) 40-50 in. lbs (4.5-5.6 Nm)

/

Stud Terminal Securing Nut 140- 160 in. lbs (15.8-18.1 Nm) 110-140 in. lbs (12.4-15.8 Nm) 50-60 in. lbs (5.6-6.8 Nm)

Motor Cable Securing Nut

Flat

, Washer

Fiber Washer

/

Stud Terminal Securing Nut

I

Housing

Figure 6-40: Motor Terminal Nuts

Electric Motor Tests Motor Types See Figure 6-41.

A shunt-wound or separately-excited motor h a s four external connections: two armature (A) and two field (E).

A series-wound motor has only two external connections because the armature and field windings are connected internally.

Shunt-Wound or Separately-Excited Drive Motor

Open Circuit Motor Test An open circuit is one in which the electrical circuit within the motor has been broken. This can be caused by:

Series-Wound Lift Motor

Bad brushes or brush springs A broken wire in the field or armature winding A loose or bad connection

Figure 6-4 1 : Motor Circuits

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Electric Motor Tests

Refer to Figure 6-41 for the following procedure: 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal stud.

2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor.

3. Observe the following measurements:

Motor Traction (Drive)

Terminals

Acceptable Resistance Readings

Unacceptable Resistance Readings

Armature

A1 to A2

0.01 - 0.10 ohms

Greater than 0.10 ohms

Field

El to E2 (S1 to S2)

0.1 - 1.0 ohms

Greater than 1.0 ohms

A to S

0.020 - 0.030 ohms

Greater than 0.1 ohms

Lift

Measure all readings at room temperature.

Table 6-2: Motor Resistance Readings

4. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor.

5. If a n open circuit is found in a serieswound motor, the motor must be disassembled by a motor rebuilding facility ' to isolate the problem to the field or armature circuit.

Grounded Motor Test In a grounded motor, a n electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused either by direct contact or through conductive foreign material.

The ground may be caused by: Insulation breakdown Brush leads touching the motor housing Build-up of carbon dust or other materials

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Toyota Powered Pallet W a lkie Service Manual

Component Procedures Electric Motor Tests

To test a motor for grounds: Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal studs.

Attach one lead of a digital ohmmeter to a motor terminal and the other lead to a n unpainted surface of the motor housing. Set the ohmmeter to the highest scale.

If the ohmmeter reads resistance of less than 100,000 ohms, the motor is grounded. Clean, repair or replace the motor a s necessary.

Short-circuited Winding A short-circuited winding is one in which the insulation on the field or armature has broken down a t two or more points. The breakdown creates a low resistance path, allowing current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and a n increase in the current flow. The severity of the short circuit depends on its location.

A shorted motor may be indicated by: Slow or sluggish operation Running faster than normal Overheating * Blowing a power fuse Severe burning or discoloring on one or two commutator segments every 90" of rotation These symptoms can be caused by problems other than the motor itself: Brake too tight or dragging Wheel bearings too tight Faulty transmission Binding in an attached pump Testing a motor for short-circuited windings requires special equipment a t a motor rebuilding facility.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Electric Motor Tests

Short Circuited Armature A short circuit in the armature will cause heating, which will probably result in burning

of: The armature coil Brush wires Commutator segments Visual inspection may reveal these conditions.

Positive determination of a short-circuited armature requires special equipment a t a motor rebuilding facility.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Drive Motor

Drive Motor Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the drive motor cover.

NOTE: While it is not necessary to remove the drive tire to remove the drive motor, it makes removing/installing the motor a lot easier with the tire off.

3. Disconnect the brake (deadman)switch and remove the mounting bracket from the case.

4. Remove the brake assembly. See "Brake" on page 6-51.

5. Disconnect the power cables from the drive motor, noting their proper position. Use two wrenches to avoid twisting the motor stud.

6. Remove the four hex head bolts securing the motor to the drive unit.

7. Remove the motor from the drive unit.

Brush Replacement 1. Lift out the drive motor from the drive unit mounting location.

2. Remove any shields around the motor end cover to expose the brushes.

3.. Lift the spring off the brush, pull the brush out of the holder.

4. Follow the brush replacement instructions.

See "Drive Motor Brushes" on page 6-53.

5. Replace the shields around the motor end removed in step 2.

Motor Disassembly 1. Remove the pinion gear lock n u t and pinion gear from the motor armature shaft.

2. Remove and discard the old O-ring.

3. Remove the four screws holding the brush end bell to the field housing.

4. Separate the end bell from the field housing. The armature will come out with the end bell.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Motor

5. To remove the end bell from the armature, remove the snap ring that holds the bearing in the end bell. If needed, press off the bearing and replace.

Installation 1. Thoroughly clean all parts with solvent or other non-corrosive cleaning fluid. Air dry all parts. The O-ring on the drive end of motor should be replaced at this time with a new O-ring.

NOTE: Install the drive motor in a dirt-free area.

2. Install the brake assembly by lifting one brake shoe a t a time and attach with two (2) hex head cap screws. Apply thread-locking compound (Loctite 243) and torque to 25 to 30 ft lbs (35to 42 Nm).

3. Position the brake actuating lever. See "Brake Shoe Adjustment" on page 6-51.

4. Install the brake drum and the lock nut.

5. Install the pinion gear and the lock nut on the armature shaft. Place a wrench on both lock nuts and torque to 75 ft lbs (105 Nm).

6. Install a new O-ring on the motor drive end.

NOTE: Always make sure that the O-ring has been lubricated with petroleum jelly before reinstalling.

NOTE: When reinstalling the drive motor the power cables must be kept to the back side of the gear housing or the motor will not go into the gear case.

7. Slide the drive motor in the gear case and work it around until the motor lines u p with the cluster gear.

8. Install the four hex head cap screws and torque to 35 ft lbs (49 Nm).

9. Attach the power cables with four hex head bolts. Torque to 60 to 84 in. lbs (6.8 to 9.5 Nm). Use a second wrench on the stud terminal securing nut to avoid twisting the motor stud. See 'Terminal Nuts" on page 6-57.

10. Reattach' the deadman switch and wires a s described on page 6-27.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Drive Motor

11. Reattach the brake linkage and spring and adjust a s necessary.

12. Install the control handle. See "Control Handle" on page 6-35.

13. Install the drive tire, if removed. Torque nut to 250 ft lbs (339 Nm).

14. Install the drive motor cover. Torque screws to 3 5 ft lbs (49 Nm).

15. Before testing operation, move the handle from extreme left to right and down into operating position and back several times.

Check for any wire and cable interference.

Repair or adjust a s necessary.

16. Test the operation of the truck.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Motor

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Drive Unit

Drive Unit Removal 1. Lower the forks, turn the key switch OFF

and disconnect the battery connector.

Use extreme care whenever the truck is jacked up. 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. For details, see " ~ a c k i nSafety" ~ on page 2-1 1.

Figure 6-42: Pivot Bearing Retaining Nut

2. Jack the truck and block the frame.

3. Remove the tractor cover.

4. Disconnect the control wiring harness and power cables from the electrical panel.

5. Remove the control handle. See "Control Handle" on page 6-34.

6. Remove the pivot bearing retaining nut. See Figure 6-42.

Transmission assemblv mav fall free from mounting after At is kemoved.

7. Remove the transmission assembly by lowering through the pivot-frame mount.

8. Feed the control wiring harness and power cables through the transmission pivot mount.

9. Remove the drive unit drain screw (lower cover screw). See Figure 6-43. M o w the gear oil to drain.

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Figure 6-43: Drive Unit Fill piug

Component Procedures

Toyota Powered Pallet W a lkie Service Manual

Drive Unit

Disassembly 1. After draining the gear case lubricant, thoroughly clean the outside with solvent or other non-corrosive cleaning fluid. Air dry all parts, and proceed with disassembly of transmission.

2. Remove the drive wheel. See "Drive Wheel" on page 6-72.

3. Remove the drive motor. See "Drive Motor" on page 6-53.

4. Remove the 14 hex head cap screws securing the gear case cover. Remove the gear case cover.

5. Block the transmission with the gear case side down. Allow room for the gears to drop between the blocks.

6. Press the drive axle through the collar and bearing. The gear/axle and the cluster gear will come out together.

7. Remove the old bearings and races from the gears and case. Clean the transmission case, making sure that the vent hole located in the upper corner is free of obstructions.

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Component Procedures

Toyota Powered Pallet W a lkie Service Manual

Drive Unit

Figure 6-44: Drive Unit, Cross-Sectional View

Legend: 1 2 3 4 5 7 9

10 11 12

13

i 14

/ Housing, Gearbox 1 Cover, Gearbox Motor

/ Cover, Gearbox

Pinion, Drive 1s t Stage Gear Set, 2nd Stage 1 Gear Set, O u t ~ u t Sleeve I Spacer, Output Shaft 1 Pin, Dowel Plug, Fill/Level Bearing Set, Cup & Cone Screw

/ t

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15 16 / 17

/ 18

1 19 1 20

1 21 / 22

/ 23 25 26 27

Screw Seal Bearing, Bronze Bearing, Sealed Locknut, Output Shaft 1 Locknut, DC Motor Key, Woodruff / 0-Ring, - Motor / Hub, Wheel (not shown) Key, Input Key, Output (not shown) Ring, Retaining

I

1

1

I

I

1

1

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Unit

Assembly 1. Install the new bearings [18]on the cluster gear El. 2. Install the new bearing [13] on the drive axle [7].

3. Place the case in a fabricated assembly base and press the new bearing cups [ 131 in the transmission case.

4. Position the transmission on the work bench with the gear case side up. Place the drive axle [7] and cluster gear [5]in the case a s a unit with the gears meshed. Because of the gear size and bearing tolerances, the gear set and bearing cannot be installed separately.

5. Use Permatex gasket eliminator on the mating surface and install the drive unit gear case cover [3].Be sure that the two dowel pins [ l11 are in the case to position the cover. Torque the cover bolts to 30 ft lbs (42 Nm).

6. Reposition the transmission case so that it rests on the gear case cover.

7. Temporarily install the drive motor in the transmission case using only two bolts to hold the motor in place.

8. Install the outer drive axle bearing cone [13] and retaining collar (131:

a. Place the bearing cone over the shaft.

Use a standard 1 - 14 nut and bearing installation tool to push the bearing on the drive axle. At this time the bearing will not seat on the shoulder of drive axle. Remove the nut and pusher. b. Install the drive axle seal 116)in the transmission case. c. Install the bearing collar in the drive axle. Use a bearing installation tool and nut to press the collar on the shaft. This should also press the bearing down, seating it on the shoulder. Turn axle shaft while torquing nut to 250 ft lbs (339 Nm).

Control the drive axle turning by holding the brake lever on the drive motor.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Installation

Installation

A CAUTION Be sure the key switch is OFF and the battery connector is disconnected before you begin.

1. Install the drive motor. See "Drive Motor" on page 6-53.

2. Install the bearing cups in the frame. Install a Nilos ring over the pivot tube on the top of the transmission assembly and install the bearing cone.

3. Feed the wire harness and power cables through the pivot tube.

4. Reinstall the drive unit assembly through the pivot frame while feeding the harness and cables through the pivot frame mount.

Install the bearing cone and Nilos ring.

5. Liberally grease the top and bottom bearing cones on the pivot bearing.

6. Unblock and lower the truck.

7. While tightening the drive unit locking nut, rotate the drive unit to simulate the steering action. Continue to tighten the nut until the nut is snug and the drive unit will not rotate. Back the nut off 1/4 turn and move steering. If the steering feels free, lock the nut with thread-locking compound Loctite 243. If the steering still feels snug, back the nut off another 1/4 turn before applying thread-locking compound.

8. Install the control handle. See "Control Handle" on page 6-34.

9. Reconnect the wiring harness.

10. Ensure the drive unit is filled to the proper level with gear oil. Install the fill/level plug.

11. Install the tractor cover.

12. Install the battery, reconnect the battery connector and the turn key switch ON.

13. Check the controls for proper operation.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Housing Lubrication

Drive Housing Lubrication Gear Oil Level 1. Remove the fill/level plug. See Figure 6-45.

2. Check the oil level. When the truck is level, the oil should be u p to the bottom of the plug opening.

3. If necessary. add the specifled oil through the plug opening, but do not overfill.

4. Install the fill/level plug securely.

Changing Gear Oil 1. Remove the drain screw (lower cover screw) from the bottom of the gear housing cover and allow the oil to dr&. See Figure 6-45.

Figure 6-45: Drive Unit Fill/Drain Plugs

2. After the oil has drained completely, flush the housing with a suitable solvent and allow it to drain.

3. Install the drain screw.

4. Fill the drive housing with the specified gear oil through the fill/level plug opening in the cover of the transmission. The drive housing will hold 0.8 qts (0.75liter) of gear oil. Do not overfill.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Drive Housing Lubrication

Drive Axle Seal Replace the drive axle seal without removing the gear case cover by doing the following:

Removal 1. Turn the key switch OFF and disconnect the battery connector.

Use extreme care whenever the truck is jacked up. 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. For details, see "Jacking Safety ' on page 2-1 1. f

2. Jack the truck and block the frame.

3. Remove the drive unit fill plug and drain

screw and allow gear oil to drain.

4. Remove the drive motor cover.

5. Remove the nut holding the drive tire to the drive axle.

6. Remove the drive tire by hand or if wheel is stubborn, use three bolts from the drive motor cover and thread in hub to push drive tire off drive axle.

7. Remove the axle seal with a seal puller. Do not damage the sealing surface or mounting bore.

Installation 1. Install the new oil seal.

2. Reinstall the drive tire. Torque the drive tire retaining nut to 250 ft lbs (339 Nm).

3. Install the drive motor cover. Torque screws to 3 5 fi lbs (49 Nm).

4. Replace the drain screw. Replace the gear oil and replace the fill plug.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Housing Lubrication

Drive Wheel Removal 1. Turn the key switch OFF and disconnect the battery connector.

Use extreme care whenever the truck is jacked up. 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. For details, see "Jacking Safety" on page 2-11.

2. Jack and block the truck under the tractor frame.

3. Remove the locking nut holding the drive wheel to the drive axle. See Figure 6-46.

4. Remove the drive wheel by hand or if necessary use three bolts from the side cover over the drive wheel and thread in the hub to push the drive wheel off the drive axle.

Figure 6-46: Drive Wheel locking Nu!

5. Press the drive tire from the wheel hub.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Drive Housing Lubrication

Cushion Tire Replacement Any misalignment of the tire and hub while the tire is being pressed onto the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire's metal insert. The chamfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

OUTSIDE OF HUB AND TIRE ASSEMBLY

A CAUTION To prevent damage, the hub must be installed on the circular ram with the chamfered side up.

1. Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert.

2. Place a circular ram on the press table. See Figure 6-47. The length of the ram must be longer than the width of the old tire to allow complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

3 . If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightly smaller in diameter that the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the proper amount of recession.

4. Position the hub assembly with the old tire on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when a tire is pressed onto the hub.

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CIRCULAR RAM

PRESSTABLE

Figure 6-47: Cushion Tire Replacement

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Drive Housing Lubrication

5. Center the hub assembly on top of the ram and make sure they mate squarely.

6. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

7. Begin pressing the new tire onto the hub and the old tire off the wheel. Run the press slowly for the first few inches of travel because this is the critical stage of the operation. If the tire begins to cock, stop the press immediately and realign the tire. Use a soft-headed mallet to realign the tire on the hub.

NOTE: If the new tire does not press on with a minimum pressure of 5 tons (68,947 kPa), replace the hub.

8. Release the press. Remove the wheel, tire assembly and the old tire from the press table. Inspect the wheel and tire assembly.

9. Install the wheel and tire assembly on the drive axle of the truck. Torque the drive retaining nut to 250 ft lbs (339 Nm).

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Component Procedures

Toyota Powered Pallet W a lkie Service Manual

Load Wheels

Load Wheels Replacement 1. Lift the forks to maximum height and block them. See "Jacking Safety" on page 2-11.

2. Remove the axle set screw. See Figure 6-48.

Figure 6-48: Removing Set Screw

3 . Drive the axle out of the load arm casting with a hammer and brass drift pin. See Figure 6-49.

4. Push the tire out. See Figure 6-50.

5. If the bearings are to be reused, insert a brass drift pin into each end of the load wheel and knock the bearings out.

6. Install the bearings in the load wheel with the shields facing out.

Figure 6-49: Removing Axle from load Arm Casting

7. Place the new load wheel upright on a flat surface. Position the bearing over the load wheel. Place a flat metal plate over the bearing, and hammer the bearing in place with a plastic mallet. Make sure the bearing is fully seated in the load wheel.

8. Align the tire with the holes in the load arm casting.

9. Drive the axle through the load arm casting and tire. Align the "dimple" in the axle with the set screw hole.

10. Install and tighten the set screw.

11. Lubricate the grease fittings if necessary.

Wheel Figure 6-50: Removed load Wheel and Components

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Load Wheel Pull Rod

Load Wheel Pull Rod Removal and Replacement NOTE: It may be easier to work with the truck upside down. Remove the battery before turning the truck over. Some oil may leak from the hydraulic reservoir.

1. Extend the load wheel forks and remove the shaft connecting the wheel fork to the pull rod.

2. Remove the pivot pin by first removing the

locking bolt, and then driving the pin out with a brass drift pin.

3. With the lower links out of the lift frame

channels, the links can be separated and the pull rod removed from the link pin.

Each link has one set screw attached at opposite ends. The link can be pulled apart without removing any other setscrews.

4. Press new bushings in the pull rods, if

necessary.

5. Reassemble the pull rods on the lower links and press the links together so they will fit in the frame channel.

6. Reinstall the pivot shaft and the retaining bolt in the lower links.

7. Reconnect the pull rod to the wheel fork.

8. Place the truck upright and install the battery. Connect the battery. Check the reservoir fluid level. Test the operation of the lift frame.

Carrier Frame Linkage The bushings on the upper links can be replaced by removing the links from one side a t a time and pressing in new bushings.

1. To separate the lift and carrier frames, remove all electrical connections before removing the links.

2. Remove linkages and lift the lift frame off

the carrier frame.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Hydraulic Components

Hydraulic Components General Guidelines To prolong the life of your Toyota Powered Pallet Walkie, adhere to the following guidelines: Keep all fittings and connections tight to prevent leaks. Be careful not to over-tighten brass fittings or they may become damaged or distorted.

Before you remove any component from the hydraulic system, wash the component and surrounding area with cleaning solvent to prevent foreign matter from entering the system. Cap and plug all openings immediately.

Whenever you remove a fitting with a pipe thread, use a sealing compound on the outside of the threads before you reinstall the fitting. (Never use ~ e f l o n @ tape.) Make sure all parts are clean.

When you install a hose assemb'ly, make sure that it is not twisted when the fittings are tightened. Always use two wrenches on a swivel-type fitting; one to hold the fitting and the other to tighten the hose.

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Hydraulic Fluid

Hydraulic Fluid Proper Level To prevent air from entering the lines, the fluid level (with the forks fully lowered) should be filled and visible to within 1 in. (2.54 cm) below the bottom of the fill plug elbow.

See Figure 6-51. Add the specified fluid if necessary. See "Lubrication Equivalency Chart" on page A-2.

Changing Fluid Store and handle the hydraulic fluid with extreme care to prevent moisture and foreign matter from entering the hydraulic system.

Contaminated hydraulic fluid is the major cause of hydraulic system failuies. Any service equipment, such a s containers, funnels and hand pumps, should be kept clean a t all times.

Cover them when not in use.

1. Lower the forks.

2. Turn the key switch OFF and disconnect

the battery connector.

3 . Remove the tractor cover.

Figure 6-5 1: H y draulic Unit

4

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Changing Fluid

4. Remove the lift cylinder hose from the fitting at the hydraulic pump.

See Figure 6-52.

5. Connect a drain hose (high pressure) to the open fitting on the pump and tighten. (A pressure gauge hose is acceptable.) Place the hose in a waste fluid container.

Fluid will be under pressure and may spray or splash. Point hose away from your body and hold firmly In waste fluid container.

6. Connect the battery connector and turn the key switch ON. 7. Run the hydraulic pump by pressing the lift button until all the hydraulic fluid is pumped from the system.

8. Turn the key switch OFF and disconnect the battery connector.

9. Remove the drain hose and reconnect the

lift cylinder hose.

10. Remove the vent plug and fill the reservoir to within 1 in. (2.54 cm) of the bottom of the filler port with the recommended hydraulic fluid. See "Lubrication Equivalency Chart" on page A-2. Replace the vent plug.

11. Connect the battery and turn the key switch ON.

12. Raise and lower the forks several times to purge air from the system.

13. Install the tractor cover.

14. Dispose of the waste fluid properly.

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Figure 6-52: Hydraulic connection^

Toyota Powered Pallet Walkie Service Manual

Component Procedures Adjusting Hydraulic Pump Relief Valve Pressure

Adjusting Hydraulic Pump Relief Valve Pressure The hydraulic system is protected by a relief valve located in the adapter body.

See Figure 6-51. The relief valve is set by the manufacturer to open a t a specified pressure.

0-3000 PSI GAUGE

FEMALE RUN TEE 7 / 1 6 - 2 0 JIC X 1/BU NPT X 7/16"-20 JIC

/

RELIEF VALVE

Relief Valve Settings

Truck

Pressure Settings

Capacity

PSI

kPa

4,000 lb.

(1,816 kg)

2,000

13,789

Table 6-3: Truck Pressure levels

RESERVDI R

Figure 6-53: Checking Relief Valve Pressure

Check Setting 1. Attach a jumper wire across the terminals of the lift-limit switch so the switch will not shut the pump down when the forks reach their upper limit.

2. Retract the lift cylinder completely. Turn the key switch OFF. Remove the 90" elbow.

Install a female run tee with a 1/8" NPT 0 to 3,000 psi (0 to 20684 kPa) pressure gauge in place of the elbow.

See Figure 6-53.

3. Turn the key switch ON. Leave the control handle in the neutral (vertical) position.

4. Press the lift button and observe the indicator on the pressure gauge. When the forks reach the upper lift limit, the pump will make a high pitched squeal indicating that the relief valve is opening.

5. If the relief valve opens at a lower or higher pressure than the specified pressure, adjust the relief valve a s follows: a. Remove the hex cap covering the relief valve adjustment screw.

See Figure 6-51.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Adjusting Hydraulic Pump Relief Valve Pressure

b. As you depress the lift button, turn the adjusting screw inward to increase the pressure setting or outward to decrease the pressure setting. c. Check the indicator on the pressure gauge. After the relief valve is properly set, release the lift button. d. Reinstall the hex cap. e. Check the relief valve setting. f. Lower the forks completely. Turn the key switch OFF.

g. Remove the pressure gauge. Replace the elbow. h. Turn the key switch ON. Raise the forks.

Inspect all hoses and fittings for leaks. i. Adjust the lift-limit switch to shut down

the pump when the forks reach their upper limit. See "Lift-Limit Switch" on page 6-29.

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Hydraulic Cylinder

Hydraulic Cylinder Fluid leakage indicates that the seal is worn.

Replace the seal, wiper, and retaining ring (Seal Kit P/N 00590-40809-71) when fluid leakage becomes excessive.

Cylinder Removal 1. Remove the tractor cover.

2. Turn the key switch ON. Leave the control handle in the neutral (vertical) position.

3 . Press the lift button and raise the forks to maximum height and block them. See "Jacking Safety" on page 2- 11.

4. Lower the forks onto the blocking to release pressure on the hydraulic cylinder.

Manually press down on the cylinder after the forks come to rest on the blocking to disengage the cylinder from the tractor frame.

5. Turn the key switch OFF and disconnect the battery connector.

Figure 6-54: Removing Hydraulic Line from Cylinder

Hot oil under pressure may be resent. Be certain truck is safe1 glocked and pressure is release

J.

6. Thoroughly clean the outside of the cylinder before removing the hydraulic hose.

Remove the hose from the cylinder. Cap and plug the fittings. See Figure 6-54.

NOTE: Be prepared to catch hydraulic fluid under the hydraulic cylinder in a suitable container.

7. Lift the cylinder up and out of the tractor frame. Some spillage of hydraulic oil may occur.

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Toyota Powered Pallet Walkie Service Manual

Cylinder Disassembly 1. Thoroughly clean the outside of the cylinder.

2. Pull the rod out until the end of the rod and the retaining ring can be seen through the inlet port. See Figure 6-55.

3. Insert a screwdriver into the inlet port and slide the retaining ring into the deep groove in the piston rod assembly.

-

Component Procedures Hydraulic Cylinder

inlet Port

Barrel

4. Remove the rod assembly from the barrel.

5. Remove the retaining ring from the piston rod.

6. Remove the wiper and seal from inside the barrel assembly.

Cylinder Inspection 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

2. Inspect the inside surface of the barrel assembly for excessive wear or scoring.

3. Inspect the outside surface of the rod for

nicks, scratches, or scoring.

Cylinder Assembly 1. Make sure all parts are cleaned and dried thoroughly. Metal parts should be lightly oiled before reassembly.

2. Install new seal in the barrel. Install new wiper in the barrel with lips facing inward.

3. Install new retaining ring in deep groove of the piston rod end.

4. Oil outside of piston rod and carefully insert rod into barrel.

5. Push rod into barrel until the retaining ring can be seen through the inlet port.

6. Insert a screwdriver into the inlet port and slide the retaining ring into the lock position.

7. Extend rod to full out position to make sure the retaining ring is locked in place.

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Seal Snap Ring Figure 6-55: Hydraulic Cylinder Disassembly

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Installation

Installation 1. Place the new cylinder into position in the tractor frame.

NOTE: To prevent air from filling the cylinder, install the cylinder with the rod retracted.

2. Connect the hydraulic hose.

3 . Reconnect the battery connector.

4. Press the lift button to extend the cylinder.

5. Check the hydraulic reservoir fluid level. If necessary, add fluid. See "Lubrication Equivalency Chart" on page A-2.

6. Remove the blocking. Lift and lower the forks several times. Look for leakage around the fittings and cylinder seal.

7. Recheck the hydraulic reservoir fluid level.

If necessary, add fluid.

8. Install the tractor cover.

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Component Procedures

Toyota Powered Pallet W a lkie Service Manual

Hydraulic Unit

Hydraulic Unit Draining and cleaning the hydraulic reservoir is important to control the accumulation of condensation and contamination which can damage the hydraulic system.

Condensation is caused by the repeated heating and cooling of hydraulic fluid during normal operation. Contaminants include dirt, rust, scaling and products of fluid deterioration.

Removal The hydraulic pump and motor assembly must be removed from the truck in order to separate the pump from the motor.

1. Lower the forks completely.

2. Turn the key switch OFF and disconnect the battery. Remove the tractor cover.

3. Remove and tag all wires and cables connected to the pump motor.

See Figure 6-56.

4. Remove and cap the hydraulic line from the hydraulic unit. Disconnect the solenoid control.

5. Remove the bolts that secure the hydraulic unit mounting bracket to the tractor frame.

6. Remove the hydraulic unit from the truck.

Installation 1. Install the hydraulic unit on the tractor frame and secure with the previously removed screws.

2. Install the hydraulic line on the hydraulic unit.

3. Fill the reservoir with the specified hydraulic fluid. See "Lubrication Equivalency Chart" on page A-2. Use a funnel with a flexible neck. Fill the reservoir to within 1 in. (2.54 cm) of the fill plug elbow. See Figure 6-56. Use up to 1.58 qts (1.5 liters).

4. Install the vent plug. See Figure 6-56.

5. Connect all wires and cables to the pump motor. Connect the battery.

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Figure 6-56: Hydraulic Unit

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Hydraulic Reservoir

6. Raise and lower the forks. Check all hoses and fittings for leaks.

7. Lower the forks.

8. Check the hydraulic fluid level in the reservoir.

Hydraulic Reservoir Removal 1. Remove the hydraulic unit from the truck.

See "Removal" on page 6-85.

2. Remove the four cap screws that connect the hydraulic reservoir to the adapter housing. See Figure 6-57.

3. Tap the reservoir lightly to loosen. Wiggle the reservoir sideways while pulling up a t the same time to remove.

4. Remove the reservoir and properly dispose of the old hydraulic fluid. See Figure 6-58.

Figure 6-57: Adapter Cap Screws

5. After the fluid has drained, flush the inside of the reservoir with a suitable cleaning solvent.

6. Dry the inside of the reservoir with clean, dry compressed air.

Installation 1. Inspect the reservoir O-ring and the inside leading edge for defects and replace if necessary.

2. Lubricate the O-ring (with applicable hydraulic fluid) and install the O-ring. See Figure 6-58.

3. Carefully install the reservoir on the adapter housing and secure with four (4) cap screws.

4. Install hydraulic unit in the truck. See "Installation" on page 6-85.

Figure 6-58: Removed Reservoir

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Toyota Powered Pallet Walkie Service Manual

Component Procedures Filter Screen and Suction Tube

Filter Screen and Suction Tube 1. Remove the reservoir. See "Hydraulic Reservoir" on page 6-86.

2. With the pump assembly inverted, push the spring clip toward the pump housing. See Figure 6-59.

3 . Grasp the suction tube with the filter screen and pull out of pump housing.

4. Clean the filter screen a t the bottom of the suction tube with a suitable solvent. See Figure 6-60.

5. From the pump side, blow dry with clean, dry compressed air.

Figure 6-59: Pump Housing Components

Installation 1. Inspect the filter screen and tube for defects

and replace if necessary.

2. Lubricate the pump end of the suction tube with hydraulic fluid.

3 . Push the spring clip toward the pump housing and insert the suction tube through the spring clip and into the pump housing until it stops. See Figure 6-59.

4. If necessary, rotate the suction tube so that the filter screen is toward the center line of the pump.

5. Install the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-86.

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Figure 6-60: Cleaning Filter Screen

Component Procedures

Toyota Powered Pallet Walkie Service Manual

Hydraulic Pump

Hydraulic Pump Removal 1. Remove the hydraulic unit from the truck and place on a clean bench for disassembly. See "Hydraulic Unit" on page 6-85.

2. Remove the reservoir to gain access to the

pump. See "Hydraulic Reservoir" on page 6-86.

3. Grasp the suction tube with the filter screen and pull out of the pump housing.

See Figure 6-61.

4. Remove the eight pump mounting bolts.

Figure 6-6 1 : Pump and Adapter Body

Remove the pump from the adapter body.

Installation 1. Stand the motor assembly on end, with the adapter body facing up.

2. Lubricate the O-ring and install on the adapter body facing up.

3. Insert the pump drive coupling onto the end of the motor armature shaft and fill the cavity with lubricant (Molybdenum antisieze compound).

4. Align the splines on the motor drive and

pump shaft. Gently push the pump pilot on the adapter. See Figure 6-61.

5. Secure the pump with the eight (8)pump mounting bolts and torque to 10 to 12 ft lbs (13.5 to 16.3 Nm).

6. Check the inlet screen for clogging. Clean with a suitable solvent. Insert the inlet tube into the pump.

7. Install the reservoir. See "Hydraulic

Reservoir" on page 6-86.

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Component Procedures Lift Motor

Lift Motor General Data Brush Replacement Spring Tension

I

Replace brushes when they have worn to the minimum length of 1/2 in. (12.70 mm).

Adjust the spring tension of new brushes to 32 to 40 oz. (908.8 to 1136 grams).

Removal 1. Remove the hydraulic unit from the truck.

See "Hydraulic Unit" on page 6-85.

2. Remove the two (2) bolts from the end plate that attach the motor to the adapter body.

See Figure 6-62.

3. Separate the motor and the adapter body.

See Figure 6-63.

4. Remove the solenoid from the side of the

motor housing to be reused.

See Figure 6-63.

*

Figure 6-62: Bolts Securing Motor to Adapter

Figure 6-63: Separated Reservoir and Motor

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Component Procedures

Toyota Powered Pallet Walkie Service Manual

Installation

Installation Stand the pump assembly on end, with the adapter body facing up.

Set aside the pump drive coupling to be reused. See Figure 6-64.

ITE:

The coupling is the mechanical connection between the pump shaft and the electric motor armature shaft. It may have been removed with the motor.

Insert the pump drive coupling onto the end of the pump shaft and fill coupling cavity with lubricant (Molybdenum antisieze compound). See Figure 6-64.

Rotate the pump or motor shafts to make sure the motor shaft fits correctly into the coupling.

figure 6-64: ~

~caviv ~

~

l

;

5. Install the new motor onto the adapter body. Rotate further if necessary until the motor contacts the adapter body.

NOTE: There is a n indexing pin on the end of the motor housing that fits into a hole in the adapter body to make sure the motor mounting screws align with the threaded holes in the adapter body.

See Figure 6-65.

Figure 6-65: Indexing Pin

6. Insert the screws into the motor end plate, through the motor and into the adapter body. See Figure 6-66.

7. Make sure the motor is mating flush with the adapter body and torque screws to 6.3 to 7.4 ft lbs (8.5 to 10 Nm) maximum.

8. Install the solenoid.

9. Install the hydraulic unit. See "Hydraulic Unit" on page 6-85.

Figure 6-66: Securing the Motor and Adapter Body

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~

~

Toyota Powered Pallet Walkie Service Manual

Component Procedures Cold Storage Conditioning

Cold Storage Conditioning New Toyota Walkie Pallet Trucks to be used in a cold storage environment are equipped a t the factory with cold storage components for Cooler and Freezer applications..

A CAUTION When a truck is to be installed in a cold storage environment, change the fluid in the hydraulic reservoir and the drive unit according to the following items.

Classes of Cold Storage Toyota Walkie Pallet Trucks can be conditioned for two classes of cold storage:

Cooler Environment where temperatures fluctuate C) to 70" F (21 " C) in a from 20" F (-7" continuous duty cycle.

Application where the truck goes in and out of the freezer for short periods of time.

Freezer Environment where temperatures fluctuate from -20" F (-29"C) to 40" F (4"C).

Application where truck operates continuously in a temperature of -20" F (-29"C).

For a listing of the recommended fluids see "Lubrication Equivalency Chart" on page A-2.

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Component Procedures

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Classes of Cold Storage

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Appendix

Appendix

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Appendix Lubrication Equivalency Chart

Lubrication Equivalency Chart I

I

1

Approved Toyota Lubricants 1

Where Used

Specification

=YPe

I

Drive Unit Gear Case (above +30° F/- 1 " C)

80W - 9 0 Gear Oil AF'I Service GL-5

Drive Unit Gear Case (below +30°F/- 1" C) (cold storage)

Oil

IOW-30 Motor Oil API Service CE,CD,CC,SG,SF

Hydraulic Reservoir (non-cold storage trucks) (+50°F to + 120"F) (+10" C t o +4g0C)

Hydraulic Fluid

IS0 46

Hydraulic Reservoir (-20" F to 0" F) (-29"C to - 18" C)

Hydraulic Fluid

MIL-H-5606A/B

Hydraulic Reservoir (-20"F to +70° F) (-29"C t o +2 1" C)

Hydraulic Fluid

IS0 32

Hydraulic Reservoir (for high performance/ high temperature applications)

Hydraulic Fluid

10W-30 Motor Oil AF'I Service CE,CD,CC,SG,SF

Bearings, etc.

Grease

NLGl Grade 2

Bearings, etc.

(Cold Storage)

Grease with Teflon

NLGI 2

Table I - I : lubrication Equivalency Chart

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Appendix

Toyota Powered Pallet Walkie Service Manual

Torque Chart - Standard

Torque Chart Grade Identification Marking

Size 4-40 4-48 6-32 8-32 8-36 10-24 10-32 1 /4-20 1 /4-28 5/16-18 5/ 16-24 3/8-16 3/8-24 7/ 16-14 7/ 16-20 1 /2- 13 1 /2-20 9/ 16- 12 9/ 16- 18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8- 14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12 Figure A- 1 :

- Standard 1

None

/ \

SAE Grade 2 Bolts Tightening Torque Oiled* "13' in. lbs. in. lbs.

4 5 5 6 8 10 14 19 15 20 21 27 23 31 49 66 56 76 ft. lbs. ft. lbs.

11 8 12 9 15 20 17 23 24 30 25 35 35 50 40 55 70 55 60 80 75 100 110 85 130 175 145 195 165 125 140 185 250 190 270 200 270 350 400 300 500 380 420 550 490 660 740 560 650 870 730 980

SAE Grade 5 Bolts Tightening Torque Oiled* Dry in. Ibs. in. lbs.

8 6 9 7 16 12 30 22 31 23 43 32 49 38 96 75 120 86 ft. lbs. ft. lbs.

17 13 19 14 30 23 35 25 50 35 55 40 75 55 90 65 110 80 120 90 150 110 170 130 260 200 300 220 430 320 350 470 640 480 700 530 800 600 880 660 1120 840 1240 920 1460 1100 1680 1260 1460 1940 2200 1640

Torque Chart - Standard

*NOTE: Use "oiled" values for bolts with thread-locking compound.

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\I/ I' SAE Grade 8 Bolts Tightening Torque Oiled* Dry in. lbs. in. lbs.

12 9 10 13 17 23 31 41 32 43 45 60 68 51 108 144 120 168 ft. Ibs. ft. lbs.

18 25 20 25 45 35 35 50 70 55 80 60 80 110 90 120 150 110 130 170 170 220 240 180 280 380 320 420 600 460 500 660 900 680 1000 740 1280 960 1440 1080 1820 1360 1500 2000 1780 2380 2720 2040 3160 2360 3560 2660

Toyota Powered Pallet W a lkie Service Manual

Appendix Torque Chart - Metric

Torque Chart

- Metric

Ferrous Metric Bolts (The grade rating is stamped on the head of the bolt.)

Diameter (in millimeters)

Figure A-2:

Grade 8.8

Grade 10.9

Torque (with bolts oiled*)

Torque (with bolts oiled*)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

6

8.6

6

12

9

8

21

15

29

21

10

42

30

58

43

12

72

55

101

75

16

174

130

245

181

20

340

255

475

350

24

580

435

820

605

Torque Chart - Ferrous Metric *NOTE: Use "oiled" values for bolts with thread-locking compound

Metric Bolts, Coarse Thread

Figure A-3:

Torque (with bolts oiled*)

Diameter (in millimeters)

Newton-meters

Foot-pounds

3

0.5

4.4

3.5

0.79

7.0

4

1.2

10.6

5

2.2

19.4

6

3.9

34.5

8

9

79.6

10

17

150

Torque Chart - Non-Ferrous Metric *NOTE: Use "oiled" values for bolts with thread-locking compound.

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Appendix Decimal Equivalent Chart

Decimal Equivalent Chart

Figure A-4:. Decimal Equivalent Chart

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Appendix Decimal Equivalent Chart

Figure A-4:

Decimal Equivalent Chart

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Appendix

Toyota Powered Pallet Walkie Service Manual

Standard/Metric Conversions

Standard/Metric Conversions

...

.

Multiply

To Convert..

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

- -

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

Square Yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.113

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to Grams

Ounces x 28.35

Grams to Ounces

Ounces x 0.035

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Appendix Standard/Metric Conversions

.

.

Multiply..

To Convert..

Ounces to kilograms

Ounces x 0.028

Kilograms to ounces

Kilograms x 35.27

Pounds to Kilograms

Pounds x 0.454

Kilograms to pounds

Kilograms x 2.2

Pounds per Square Inch to Kilo pascals

Pounds per Square Inch x 6.894

Kilo pascals to Pounds per Square Inch

Kilo pascals x 0.145

Inch Pounds (in. lbs.) to Newton Meters (Nm)

Inch Pounds x 0.113

Newton Meters (Nm) to Inch Pounds (in. lbs.)

Newton Meters x 8.85

Foot Pounds (ft. lbs.) to Newton Meters (Nm)

Foot Pounds x 1.3568

Newton Meters (Nm)to Foot Pounds (ft. lbs.)

Newton Meters x 0.737

Miles per hour to kilometers per hour

Miles per hour x 0.6214

Kilometers per hour to miles per hour

Kilometers per hour x 1.609

Fahrenheit to Celsius

(OF - 32) x 0.555

Celsius to Fahrenheit

("Cx 1.8) + 32

Figure A-5:

Standard/Metric Conversions

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Appendix Schematics

Schematics

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Appendix Schematics

13

Figure A-6:

Standard 6HBW20 Electrical Schematic (Refer to Page A- 14 for Component legend]

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Toyota Powered Pallet Walkie Service Manual

Appendix Schematics

Standard 6HBW20 Electrical Schematic - continued (Refer to Page A- 14 for Component legend]

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Appendix

Figure A-7:

Toyota Powered Pallet Walkie Service Manual

Cold Storage (CS) 6HBW20 Electrical Schematic (Refer to Page A- 14 for Component legend)

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Appendix Schematics

Cold Storage {CSJ6HBW20 Electrical Schematic - continued {Refer to Page A-14 for Component Legend)

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Toyota Powered Pallet Walkie Service Manual

Appendix Schematics

HOUR METER OPTION

DISCHARGE METER OPTION

MZ-Y COMC+t (BNEGI

METER

WllONS CONNECTOR

COMPONENT LEGEND CB FUSE POWER CIRCUIT 80 AMPS FUI FUSE CONTROL CIRCUIT 15 AMPS HTRl HEATER IN HANDLE

HOUR/DISCHARGE METER OPTION

JP2 CONNECTOR IN HANDLE FOR FUNCTIONS JP3 CONNECTOR IN HANDLE FOR TRAVEL (C.S. ONLY) JP6 CONNECTOR IN HANDLE FOR TRAVEL JP9 TERMINAL CONNECTIONS FOR METER OPTION JPSl SPLICE CONNECTION IN HANDLE FOR BRAKE MI-F CONTACTOR FORWARD Ml-R CONTACTOR REVERSE M2 CONTACTOR PUMP MD MOTOR DRIVE MP MOTOR PUMP PMCl CONNECTOR O N MOTOR CONTROLLER SOL SOLENOID LOWER SWI KEYSWITCH SW2 BRAKE SWITCH SW3 TRACTOR FIRST SWITCH SW4 FORKS FIRST SWITCH SW7 BELLY BUTTON SWITCH SW9 HORN SWITCH SWlO LIFT LIMIT SWITCH SWI 1 LOWER SWITCH SW 12 LlFT SWITCH SWI 3 MAIN ON/OFF VR THROmE POTENTIOMETER

Figure A-8:

6HBW20 Options Electrical Schematic

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Appendix Schematics

Figure A-9:

6HB W20 Hydraulic Schematic

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Schematics

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Index

Index

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Index

Acceleration Rate

. . . . . . . . . . . . . . . . . 5.7

Battery . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 Discharge Meter . . . . . . . . . . . . . . 6.32 Specific Gravity . . . . . . . . . . . . . . . 6. 14 Brake . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 1 Shoe Adjustment . . . . . . . . . . . . . . 6.51 Brake (Deadman) Switch . . . . . . . . . . . .5.7 Brake Switch . . . . . . . . . . . . . . . . . . . .5.7 Brushes . . . . . . . . . . . . . . . . . . . . . . . 6.53

Circuit Breaker . . . . . . . . . . . . . . . . . - 6 - 21 Cloning . . . . . . . . . . . . . . . . . . . . . . . . 5.2 1 Cold Storage Conditioning . . . . . . . . . . 6.91 Connector Locator Chart . . . . . . . . . . . 5. 12 Contactors . . . . . . . . . . . . . . . . . . . . . 6.43 Coil Resistance . . . . . . . . . . . . . . .6.49 Directional . . . . . . . . . . . . . . . . . . 6.45 Main . . . . . . . . . . . . . . . . . . . . . . . 6-44 Tip Inspection . . . . . . . . . . . . . . . . 6.45 Tip Replacement . . . . . . . . . . . . . .6.46 Control Handle . . . . . . . . . . . . . . . . . . 6.35 Cover, Tractor . . . . . . . . . . . . . . . . . . . . 6.7 Installation . . . . . . . . . . . . . . . . . . . 6.7 Removal . . . . . . . . . . . . . . . . . . . . . 6.7 Creep Speed . . . . . . . . . . . . . . . . . . . . .5.7 Current Limiting . . . . . . . . . . . . . . . . . .5.7 Cushion Tire Replacement . . . . . . . . .6.73

Deadman Switch . . . . . . . . . . . . . . . . . . 5.7 Decimal Equivalent Chart . . . . . . . . . . .A.5 Definitions . . . . . . . . . . . . . . . . . . . . . . 5.7 Diagnostics . . . . . . . . . . . . . . . . . . . . .5. 14 Diodes . . . . . . . . . . . . . . . . . . . . . . . . 6. 19 Drive Axle Seal . . . . . . . . . . . . . . . . . . 6.7 1 Drive Unit . . . . . . . . . . . . . . . . . . . . . . 6.65

Fault Codes . . . . . . . . . . . . . . . . .5.8. 5-23 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Gauges . . . . . . . . . . . . . . . . . . . . . . . 6-33 Battery Discharge Meter . . . . . . . . 6-32 Hour Meter . . . . . . . . . . . . . . . . . . 6-31

High Pedal Disable . . . . . . . . . . . . . . . . 5-8 High Pedal Disable (HPD) . . . . . . . . . . . 5-8 Hour Meter . . . . . . . . . . . . . . . . . . . . 6-31 HourlBattery Discharge Meter . . . . . . 6-33 Hydraulic Components . . . . . . . . . . . .6-77 Check Valve . . . . . . . . . . . . . . . . . 6-82 Cylinder . . . . . . . . . . . . . . . . . . . . 6-82 .Assembly . . . . . . . . . . . . . . . . 6-83 Diassembly . . . . . . . . . . . . . . . 6-83 Inspection . . . . . . . . . . . . . . . . 6-83 Fluid . . . . . . . . . . . . . . . . . . . . . . 6-78 Hydraulic Unit . . . . . . . . . . . . . . . 6-85 Pump . . . . . . . . . . . . . . . . . . . 6-88 Relief Valve Adjustment . . . . . 6-80 Reservoir . . . . . . . . . . . . . . . . 6-86 Solenoid . . . . . . . . . . . . . . . . . 6-30 Suction Tube . . . . . . . . . . . . . 6-87

Lift Motor . . . . . . . . . . . . . . . . . . . . . . 6-89 Load Wheel Pull Rod Adjustment . . . . . . . . . . . 6-76 Lubrication Gear Oil . . . . . . . . . . . . . . . . . . . . 6-70 Lubrication Equivalency Chart . . . . . . . A-2

Electrical Connector Locator Chart . . . 5. 12 Emergency Reverse . . . . . . . . . . . . . . . .5.8

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Toyota Powered Pallet Walkie Service Manual

Maintenance . . . . . . . . . . . . . . . . . . . . 4- 1 Annual/2400 Hours . . . . . . . . . . . 4-7 Daily . . . . . . . . . . . . . . . . . . . . . . . 4-4 Guidelines . . . . . . . . . . . . . . . . . . . 4-2 Lubrication Drive Unit . . . . . . . . . . . . . . . 6-70 Grease Fittings . . . . . . . . . . . . . 4-7 Monthly/200 Hours . . . . . . . . . . . . 4-5 Schedule . . . . . . . . . . . . . . . . . . . . 4-3 Map. Navigating the Manual . . . . . . . . 1-2 Motor Brush Spring Tension . . . . . . . . . 6-55 Commutator . . . . . . . . . . . . . . . . 6-56 Drive . . . . . . . . . . . . . . . . . . . . . . 6-61 Terminal Nuts . . . . . . . . . . . . . . . 6-57 Tests . . . . . . . . . . . . . . . . . . . . . . 6-57 Motor Controller . . . . . . . . . . . . . . . . 6-39 Overtemperature . . . . . . . . . . . . . . 5-8 Undertemperature . . . . . . . . . . . . 5- 10 Motors . . . . . . . . . . . . . . . . . . . . . . . 6-53 Lift . . . . . . . . . . . . . . . . . . . . . . . 6-89

Operation . . . . . . . . . . . . . . . . . . . . . . 3-5 Directional/Speed Control . . . . . . . 3-6 Lift/Lower . . . . . . . . . . . . . . . . . . . 3-5 Motor Controller . . . . . . . . . . . . . . 3-8 Theoryof . . . . . . . . . . . . . . . . . . . . 3-5 Overtemperature (Motor Controller) . . . 5-8 Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-9

Plugging . . . . . . . . . . . . . . . . . . . . . . . 5-9 PMC-1 Pin Descriptions . . . . . . . . . . . 5-22 Power Cables . . . . . . . . . . . . . . . . . . . 6- 16 Programmable Maintenance Tool (PMT)5- 13 Pulse Width Modulation . . . . . . . . . . . 5-9 Pump. Hydraulic . . . . . . . . . . . . . . . . 6-88

Ramp Shape . . . . . . . . . . . . . . . . . . . . 5-9 Relief Valve Settings . . . . . . . . . . . . . 6-80

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Index

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1 Battery . . . . . . . . . . . . . . . . . . . . . . 2.7 General . . . . . . . . . . . . . . . . . . . . . . 2-3 Jacking . . . . . . . . . . . . . . . . . . . . . 2-11 Towing . . . . . . . . . . . . . . . . . . . . . 2-14 Transport . . . . . . . . . . . . . . . . . . . 2-13 Welding . . . . . . . . . . . . . . . . . . . . 2-15 Schematics Cold Storage . . . . . . . . . . . . . . . . . A- 12 Hydraulic . . . . . . . . . . . . . . . . . . . A- 15 Options . . . . . . . . . . . . . . . . . . . . . A- 14 Standard . . . . . . . . . . . . . . . . . . . A- 10 Sequencing Delay . . . . . . . . . . . . . . . . . 5-9 Speed Limiting . . . . . . . . . . . . . . . . . . 5-10 Standard /Metric Conv rsions . . . . . . . .A- 7 Static Return To Off (SRO) . . . . . . . . . 5-10 Switches . . . . . . . . . . . . . . . . . . . . . . . 6-22 Brake (Deadman) . . . . . . . . . . . . . 6-27 Control Handle . . . . . . . . . . . . . . . 6-23 Key . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Lift-Limit . . . . . . . . . . . . . . . . . . . 6-29 Main ON/OFF . . . . . . . . . . . . . . . . 6-25 Systems Overview General System Data . . . . . . . . . . . 3-3 Special Tools . . . . . . . . . . . . . . . . . . 3-4 Specifications . . . . . . . . . . . . . . . . . 3-2 Truck Model Identification . . . . . . . 3-2

Throttle Potentiometer Adjustment . . . 6-41 Torque Chart Metric . . . . . . . . . . . . . . . . . . . . . . . A-4 Standard . . . . . . . . . . . . . . . . . . . . A-3 Tractor Cover Installation . . . . . . . . . . . . . . . . . . . 6.7 Troubleshooting . . . . . . . . . . . . . . . . . . 5. 1 Diagnostics Modes . . . . . . . . . . . . 5-14 Electrical . . . . . . .e. . . . . . . . . . . . . 5.3 PMT . . . . . . . . . . . . . . . . . . . . . . . 5.13 Program Mode . . . . . . . . . . . . . . . . 5. 18 Special Program Mode . . . . . . . . . . 5-20

Undertemperature . . . . . . . . . . . . . . . 5-10 Undervoltage Cutback . . . . . . . . . . . . 5-11

Index

Toyota Powered Pallet Walkie Service Manual

Wheels Drive . . . . . . . . . . . . . . . . . . . . . . . 6.72 Load . . . . . . . . . . . . . . . . . . . . . . . 6-75 Wiring Harness . . . . . . . . . . . . . . . . . . 6.17

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