Toyota 7HBW30 7HBE30 7HBE40 7HBC30 7HBC40 & 7TB50 Pallet Trucks Service Manual SN 30,001 and up

Service Manual 7HBW30, 7HBE30, 7HBE40, 7HBC30, 7HBC40, and 7TB50 Serial Numbers 30,001 and up

TOYOTA SERVICE MANUAL Pallet Trucks

7HBW30 7HBE40 7HBC40

30,001 and up 30,001 and up 309001 and up

00700-CL390-05,15 March 2005

7HBE30 7HBC30 7TB50

30,001 and up 30,001 and up 30,001 and up

O 2005 by Toyota Industrial Equipment All rights reserved. N o portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher.

Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

Toyota Pallet Truck Service Manual

Table of Contents

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

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

Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 STAEYTPage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 .

Safety 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 .

Generalsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 JackingSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 . .

Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 .

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 .

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Systems Overview 3-1 Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 . .

Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 .

General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 .

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 .

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Planned Maintenance 4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 .

Troubleshooting 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 . .

Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-3 .

Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-5 .

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 .

Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Faultcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 . .

Programmable Maintenance Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 .

List of Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 .

Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 .

Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . 5-25 .

Symptom Tables: Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 .

Symptom Tables: Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Component Procedures 6-1 List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . .

Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 .

Tractor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 .

Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 .

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 .

Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 .

Brakeswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 . .

Lift Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 .

Grab Rail Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19 .

Hydraulic Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 Manualcoast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 . .

Coast Module (DA1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 .

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

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

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00700.CL390.05, 1 5 March 2005

...

III

Toyota Pallet Truck Service Manual

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27 . .

Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 .

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 .

Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 .

Control Handle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 .

Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 .

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39 .

Motors. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 .

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 .

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53 .

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 .

Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-67 .

Load Wheels. Model 7TB50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 .

Pallet Entry Sliders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69 .

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 .

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74 Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . .6-76 .

Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-78 .

Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-84 .

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-88 .

Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90 Appendix A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 . .

Torque Chart . Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . A-3 .

Torque Chart . Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 .

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 . .

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9 Index 1-1

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

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Toyota Pallet Truck Service Manual

Section 1. How to Use This Manual

00700-CL390-05, 1 5 March 2005

How to Use This Manual

How to Use This Manual

Toyota Pallet Truck Service Manual M a p of the Manual

Map of the Manual

1

How to Use This Manual

Table of Contents

Q Map of the Manual

I Systems Overview

I Manual Design I Vehicle Specifications

I Start Page

General System Data

I

Planned Theory of Operations

Trouble-

Component Procedures

Q I

Alphabetical List of Component Procedures

Location Photos

Appendix

Index

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

How to Use This Manual

Manual Design

Manual Design The Toyota Pallet Truck Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise Anticipate your needs and reduce your decisions regarding maintenance Reduce page flipping through a "one-stop shopping" approach The two-line running page header at the top of each page tells you: Name of the manual (Toyota Pallet Truck Service Manual) Current Chapter Title (for example, this page How to Use This Manuall Current topic (for example, this page M a n u a l Design) It is recommended that you go to the START page for guidance to the correct 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 services to keep your truck working most efficiently.

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

Chart "TS1:START TROUBLESHOOTING" on page 5-22 will guide you to the individual troubleshooting symptom chart you need.

00700-CL390-05, 1 5 March 2005

When you're familiar with the symptoms listed, you may instead simply find the symptom chart. See "List of Troubleshooting Charts" on page 5-19.

When you complete a troubleshooting procedure, be sure to follow the steps in chart "END1:End of Troubleshooting Procedure" on page 5-24.

Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order which considers: Frequency of attention Physical attachment (for example, brake must be removed before drive motor) Functional relation (for example, drive motor and drive unit components are grouped together) To find a component procedure, you may use one of three methods: Look up the component name in the "List of Component Procedures" on page 6-2.

Find the component in the "Component Locators" on page 6-5.

Look up the component name in the maintenance manual Index.

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

Index lists subjects alphabetically.

How to Use This Manual

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

START Page

START Page

00700-CL390-05,1 5 March 2005

How To Use This Manual

How To Use This Manual

Toyota Pallet Truck Service Manual

START Page

(

START:

To review safety

Why are you here?

Yes

Go to Section 2 "Safety"

Go to Section 3 "Systems Overview"

Yes

Yes

Go to Section 4 "Planned Maintenance"

Go to Section 5 "Troubleshooting"

List of Troubleshooting Charts

Go to Chart START-2

b

STAIYT Troubleshooting

00700-CL390-05, 1 5 March 2005

How To Use This Manual

Toyota Pallet Truck Service Manual

START Page

START-2

Go to Section 6 "Component Procedures"

Yes

L

No

Yes

To locate an object or name?

00700-CL390-05, 1 5 March 2005

b

Go to the "Appendix

+

> Go to the Index

Alphabetical List of Component F'rocedures

Component Locator

How To Use This Manual

Toyota Pallet Truck Service Manual

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00700-CL390-05 1 5 March 2005

Toyota Pallet Truck Service Manual

Section 2. Safety

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Safety

Safety

Toyota Pallet Truck Service Manual 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 injury.

ACAUTION 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 Pallet Truck 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.

Know the truck's controls and what they do.

Before working on this truck, always turn the key switch to OFF and disconnect the truck's battery connector (unless this manual tells you othenvisel.

Do not wear watches, rings, or jewelry when working on this truck.

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

Follow the scheduled lubrication, maintenance and inspection steps.

Operate this truck only from the operator's position.

00700-CL390-05, 1 5 March 2005

Safety

Toyota Pallet Truck Service Manual General Safety

Follow exactly the safety and repair instructions in this manual. Do not take "shortcuts."

Always park this truck indoors.

Do not wash this truck with a hose.

Do not use an open flame near the truck.

Do not add to or modify this truck until you contact your local Toyota Dealer to receive written manufacturer approval.

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.

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Toyota Pallet Truck Service Manual

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 properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury.

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. If any electrolyte comes in contact with your clothing or skin, flush the area immediately with cold water. If the solution gets 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.

00700-CL390-05, 1 5 March 2005

Make sure a shower and eyewash station are nearby in case there is an accident.

A battery gives off explosive gases. Never

smoke, use an open flame, or use anything that gives off sparks near a battery.

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

Safety

Toyota Pallet Truck Service Manual Battery Safety

Turn the key switch OFF before disconnecting the battery from the truck at the battery connector. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

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

Make sure the vent holes in the filler plugs are open to permit the gas to escape from the cells.

Do not lay tools or metal objects on top of the battery. A short circuit or explosion could result.

Do not permit 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 effect truck stability. See the truck's specification plate for more information.

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

Never plug a battery charger into the truck's battery connector. Plug the battery charger only into the battery connector from the battery.

Keep plugs, terminals, cables and receptacles in good condition to avoid shorts and sparks.

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Toyota Pallet Truck Service Manual Battery Safety

Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual.

00700-CL390-05, 1 5 March 2005

Safety

Safety

Toyota Pallet Truck Service Manual Jacking Safety

Jacking Safety You may need to jack up the truck off the floor to perform maintenance procedures. When doing so, observe the correct safety precautions: 1. Lower the forks completely. Remove any load.

8. Lower the forks on the blocks.

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

Tractor 10. Place the jack in the designated jacking position. See Figure 2-2.

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. See Figure 2-2.

Use extreme care when 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 6. Using the lift button, raise the forks to maximum height.

7. Block the fork section as shown in

Figure 2-1. The tractor section will remain on the floor.

Figure 2- 1 .

2-8

Figure 2-2.

Jacking Tractor Section

11. Jack one side of the truck so that the drive tire is off the floor no more than 1 in.

(25.4 mm).

12. Block that side of the truck in place.

13. Jack up the other side of the truck level with the first side.

14. Block that side of the truck in place.

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

Blocking the Fork Section

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Tie-down for Transport

Tie-down for Transport To transport your Toyota pallet truck 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 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 rear of the vehicle bed and draw taut.

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.

00700-CL390-05, 1 5 March 2005

Safety

Safety

Toyota Pallet Truck Service Manual Towing

Towing To safely tow a Toyota pallet truck: 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 pallet 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.

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

Safety

Welding Safety

Welding Safety

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

Before performing flame cutting or welding operations, remove the coating 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 must 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 the location of the nearest eyewash station

The key switch is turned OFF and the battery is disconnected before you attempt to inspect, service or repair the lift truck.

Discharge residual charge in the motor controller by pressing the horn button.

Check for shorts to frame as described on Page 5-3. If any shorts are detected, remove them before you proceed with the welding operation.

The area to be welded is clean All truck components are protected from heat, weld spatter and debris The ground cable is attached as close to the weld area as possible

00700-CL390-05, 1 5 March 2005

No welding operations are performed near electrical components If welding must be done near the battery compartment, the battery is removed from the truck When you are finished welding, perform all ground tests and electrical inspections before the vehicle is operated.

Safety

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Section 3. Systems Overview

00700-CL390-05, 1 5 March 2005

Systems Overview

Systems Overview

Toyota Pallet Truck Service Manual Truck Model Identification

Truck Model ldentification

Model 7HBW30 Low-Lift Pallet Truck

Model Model 7HBE30 and Model 7HBE40 End Rider

&

Model 7HBC30 and Model 7HBC40 Center Rider

Model 7TB50 Tow Tractor

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Toyota Pallet Truck Service Manual

Systems Overview

Vehicle Specifications

Vehicle Specifications Category Max. Load Capacity

7HBW30

7HBE30/40

7HBC30/40

7TB50

6,000 lb

6,000 lb

6,000 lb

N/A

(2,724kg)

(2,724kg)*

(2,724kg)**

Normal Rated Drawbar Pull

200 lb (91 kg)

Max. Drawbar Pull***

700 lb (318 kg)

N/A

Upright Height

50.75 in. (128.9 cm)

58 in. (147.3 cm)

Overall Length

up to 92.15 in.

(234.1 cm)

Overall Width

32.5 in. (82.6 cm)

53.11 in. (134.9 cm)

32.5 in. (82.6 cm)

36 in. (91.4 cm)

Max. Lift Height

9.25 in. (23.5 cm) N/A

3.5 mph (5.6 kph) Max.

Regular Speed

3.9 mph (6.3 kph)

6.0 mph (9.6 kph) Max.

Rabbit Speed

N/A

8.8 mph (14.2 kph) Max.

Coast Travel Speed

Stopping Distance Battery Compartment Width

9.19 in. (23.3 cm)

I

13.44 in. (34.1 cm) 24V

Min. Battery Weight

490 lb (222 kg)

Max. Battery Weight

1056 lb (479 kg)

Truck Weight Without Battery

N/A

6 ft. (1.83 m)

Battery Voltage

I

up to 157.6 in.

(400.3 cm)

up to 145.85 in.

(370.5 cm)t

1058 lbtt (480 kg)

490 lb (222 kg) 1500 lb (681 kg)

1

The total weight of the load must include the pallet, the container or the device holding the load, and the operator (on rider models).

00700-CL390-05, 1 5 March 2005

965 lb (438 kg)

1234 lbtt (560 kg)

1

1320 lbtt (599 kg)

1

1190 lb (540 kg)

1

Systems Overview

Toyota Pallet Truck Service Manual General System Data

General System Data

Gauge Console

I

Tractor

Figure 3- 1 .

Grab Bar

Battery Location

Fork Section

Load Wheels

Model 7HBE30

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Toyota Pallet Truck Service Manual

Systems Overview

General System Data

Control Handle Gauge Console

Operator Compartment

Battery Location Tractor Figure 3-2.

Load Wheels

Model 7HBC30

00700-CL390-05, 1 5 March 2005

Systems Overview

Toyota Pallet Truck Service Manual Special Tools

Special Tools Pro rammable Maintenance Too

f

The optional Programmable Maintenance Tool (P/N 00590-49981-71) permits you to test, diagnose, and program the motor controller in this pallet truck.

The Programmable Maintenance Tool (PMT)is powered by the host controller through the four-pin connector at the bottom of the controller. See Figure 3-3.

Figure 3-3.

Programmable Maintenance Tool

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Toyota Pallet Truck Service Manual

Systems Overview

Theory of Operation

Theory of Operation

The relief valve will open if the hydraulic pressure exceeds the preset limit.

Lift/Lower

Lower

The lift/lower system consists of an electrically operated hydraulic pump and related components.

When the battery is plugged in, the key switch is ON and the lower button is pressed:

The hydraulic pump assembly consists of a positive displacement rotary gear pump with reservoir mounted to an 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 release valve are located within the adapter.

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

Lift When the battery is plugged in, the key switch (SW1)is ON and the lift button is pressed: The lift switch closes The lift pump contactor closes, causing the lift pump to operate Hydraulic fluid is drawn through the screen in the reservoir into the lift pump and is forced into the lift cylinders.

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

Hydraulic pressure in the lift cylinders raises the forks. Lift cutout switch will interrupt power to the lift motor when the forks reach a preset lift limit.

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

00700-CL390-05, 1 5 March 2005

The lower switch is closed The lowering solenoid opens Hydraulic fluid in the lift cylinders returns to the hydraulic reservoir through the lowering valve and the flow control valve The forks lower

DirectionaVSpeed Control The directional/speed control descriptions assume the battery is charged and connected and the key switch is ON. The control handle must be in the correct position to close the brake switch (SW2)and release the brake. See "Brake Switch on page 6-16. When the brake switch is closed, the main contactor ( M l ) is energized.

NOTE: When the control handle is released and the brake switch opened, the main contactor (M1) will remain energized for several seconds before de-energizing.

Forward When the directional/speed control is rotated in the forward direction from neutral: The forward directional switch (SW3)is closed and B+ is applied to PMC- 10 of the motor controller Resistance across the throttle potentiometer (VR-4 to VR-2) increases from zero ohms to a maximum of 6,500 ohms. Throttle input voltage is then generated a t PMC-16 with respect to (wrt) PMC-14. As throttle input voltage rises above the neutral band threshold, the motor controller begins to provide current flow through the drive motor armature at M-. It also provides current flow through the field windings in the correct polarity at F1 and F2.

Systems Overview

Toyota Pallet Truck Service Manual Theory of Operation

The drive wheel begins to rotate in a forward direction at a speed proportionate to throttle input.

Reverse When the directional/speed control is rotated in the reverse direction from neutral: The reverse directional switch (SW4)is closed and B+ voltage is applied to PMC-11 of the motor controller Resistance across the throttle potentiometer (VR-4 to VR-2) increases from zero ohms to a maximum of 6,500 ohms. Throttle input voltage is then generated at PMC-16 wrt PMC-14. As throttle input voltage rises above the neutral band threshold, the motor controller begins to provide current flow through the drive motor armature at M-. It also provides current flow through the field windings in the correct polarity (F1 and F2).

The drive wheel begins to rotate in a reverse direction at a speed proportionate to the throttle input.

Emergency Reverse (Models 7HBW30 and 7HBE30 or 7HBE40)

When the emergency reverse switch (belly button switch SW7) is closed with the control handle lowered in travel mode (SW2 closed), the control system responds in various ways, depending upon how the truck was operating when SW7 closed.

Truck traveling in tractor-first direction:full braking torque is applied to the drive motor and then accelerates in the forks-first direction.

Truck stopped or traveling in forks-first direction: full accelerating torque for forks-first direction is applied to the drive motor.

Travel in forks-first direction will continue until the emergency reverse switch (SW7)is released.

When the emergency reverse mode is activated, the motor controller ceases to respond to the normal travel command from the directional/

3-8

speed control. To reset the truck for normal travel, return the directional/speed control to the neutral position.

Strip Curtain Bypass (Models 7HBE30/40 only)

When the truck is traveling tractor first and the horn button on the grab rail is pressed, the emergency reverse switch is disabled until the horn button is released.

Manual Coast Mode (Optional) The manual coast system for Models 7HBE30/40 and Model 7HBW30 uses a spring-applied, cam-type, manually-actuated retainer to keep the control handle in the travel (brake released) position.

To engage manual coast, the control handle is lowered into the operating range (and the coast control lever is placed in coast position).

Manual coast is disengaged by reversing the above process.

The coast system for Models 7HBC30/40 and 7TB50 with a f~ed-positioncontrol handle uses the standard manually-actuated brake lever design to keep the truck in the travel (brake-released) position during coast operation.

Depressing either jog switch (with the truck in coast position) generates a signal to the speed control module (DA1).This generates a speed reference (pot wiper) input to the motor controller. This input, in conjunction with the status of the two mode select inputs (both are low, mode M l),creates a fxed PWM (40%)to the traction motor armature circuit. This limits the fxed speed to 3.5 mph (5.6 km/h).

Even with the manual coast lever in the no coast position the maximum speed is limited to 3.5 mph (5.6 km/h) as the motor controller is restricted to speed mode M1. Top (rabbit) speed in both directions is selected by pressing and releasing the rabbit button while forward or reverse travel is requested through the twist grip. This shifts the motor controller from speed mode M1 to mode M2 (forks first) or mode M4 (tractor first). The rabbit command is "latched"

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Toyota Pallet Truck Service Manual Theory of Operation

until the twist grip is returned to neutral or the brake switch is opened.

Motor Controller The basic functions of the motor controller include: Direction Control section: controls the drive motor direction by manipulating the drive motor field polarity according to the directional switch inputs (SW3, SW4).

Throttle Control section: controls the drive motor speed and torque by monitoring relative position change of the wiper in the throttle potentiometer with respect to the static neutral position. Infinitely variable motor speed is accomplished by separate control of field and armature current.

Emergency Reverse circuitry: controls the override of the directional travel control.

Main Contactor ( M I ) control.

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

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Systems Overview

Systems Overview

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Section 4. Planned Maintenance

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Planned Maintenance

Planned Maintenance

Toyota Pallet Truck Service Manual lntroduction

Introduction Maintenance Guidelines A regularly planned maintenance program will ensure: Maximum truck performance Maximum truck life Reduction of costly down time Avoidance of unnecessary repairs Planned maintenance includes: Cleaning Inspection Lubrication Service 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 as required to keep the unit in good operating condition.

Refer to the Appendix for lubrication equivalents. Refer to the manufacturer's supplements for components not listed on the following pages.

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 that all the safety and operational decals are in place and legible.

List repairs required.

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Toyota Pallet Truck Service Manual

Planned Maintenance

Introduction

Perform Daily or Every Eight (8) Operating Hours

Check the charge.

Check the weight.

Make sure there are solid electrical connections and no damage.

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

e battery. Make sure the battery does

Check for satisfactory brake operation.

Check that travel is cut out and the brake is applied when the control handle is within 10" of the fully raised or lowered position.

amage to the wheels. Check

Check the hour meter (optional). It must operate when the key is turned ON and the handle is in the operating position.

Check the steering operation. other components and hardware, inspecting for looseness as

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Planned Maintenance

Toyota Pallet Truck Service Manual Introduction

Perform Every Two Months or 250 Operating Hours

the contact area

Drive Unit

Check for battery leakage to truck frame.

Check for shorts to truck frame.

Check for dielectric grease when cold storage.

Check for correct cable tie installation.

Drive motor - 9/16 in. (14.3 mm) Lift/Aux. motor - 1/2 in. (13 mm)

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Toyota Pallet Truck Service Manual Introduction

Perform Annually or Every 1 SO0 Operating Hours

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Planned Maintenance

Planned Maintenance

Toyota Pallet Truck Service Manual Introduction

Lubrication Points Figure 4-1 through Figure 4-5 show the lubrication points on the truck.

Figure 4- 1 .

Caster Grease Fittings

Figure 4-2.

Upper Bell Crank Grease Fittings (Behveen Tractor and Fork Section)

-Figure 4-3.

-

Lower Bell Crank Grease Fittings-Left side shown (Between Tractor and Fork Section)

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Toyota Pallet Truck Service Manual Introduction

Figure 4-4.

Load Wheel Grease Fittings and Fork Grease Fittings (Top View)

Figure 4 5 .

Drive Unit Grease Fittings (2), 180" Apart (front location shown)

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Planned Maintenance

Planned Maintenance

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Section 5. Troubleshooting

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Troubleshooting

Troubleshooting

Toyota Pallet Truck Service Manual How to Use This Chapter

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

Use the chart "TS1:START TROUBLESHOOTING" on page 5-22 to guide you to the individual symptom chart you need.

When you're familiar with the symptoms listed, you may instead simply look up the symptom chart, "Troubleshooting" on page 5-21.

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 perform the steps in chart "END1:End of Troubleshooting Procedure" on page 5-24.

If the troubleshooting symptom charts do not isolate the problem, or if the symptoms are not consistent or repeatable, go to the chart "GEN1: General Troubleshooting" on page 5-23. This chart will help you approach the problem in a systematic and logical manner.

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Toyota Pallet Truck Service Manual

Troubleshooting

Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. See "Battery" on page 6-8.

connector. Battery current can damage an ohmmeter.

For information on pin, connector, and harness connections, see "Electrical Connector Locator Chart" on page 5-10 and see "Wiring Harness" on page 6-12.

Checking for Shorts from Battery to Truck Frame

Make sure you block the pallet truck whenever a troubleshooting procedure requires turning the key switch SWl ON. This will avoid accidents caused by unexpected truck travel.

ACAUTION Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter.

Figure 5- 1.

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 digital multimeter such as a Fluke meter for all measurements. Analog meters can give inaccurate readings and load down sensitive electronic circuits enough to cause failure.

Ensure meter cables are connected to the correct meter jacks and that the correct function and scale are selected.

Whenever measuring resistance, turn the key switch OFF and disconnect the battery

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

2. Use a voltmeter set on a 50Vdc scale.

3. Attach the voltmeter leads as follows: (See Figure 5-1 .)

Negative (-) lead to an unpainted, grounded surface on the truck frame Positive (+) lead to the positive battery terminal The voltmeter must show no more than

3v.

4. Attach the voltmeter leads: Negative (-) lead to the negative battery terminal Positive (+) lead to an unpainted, grounded surface on the truck frame

The voltmeter must show no more than

3v.

5. If you get more than a 3V reading in either step:

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Battery Shorts to Frame Testing

Troubleshooting

Toyota Pallet Truck Service Manual Electrical Troubleshooting Guidelines

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 and "Inspection" on page 6-8). c. Reinstall the battery. d. Repeat steps to see if this has eliminated the problem. e. If excessive voltage is still found, have the battery checked for internal leakage.

Checking for Shorts from Components to Truck Frame

Figure 5-2.

motor or major subassembly to determine if that item is causing the low resistance.

Do not continue until this condition is corrected.

3. Remove the battery from the pallet truck.

See "Battery" on page 6-8.

4. Connect the battery lead to the truck.

5. Measure the leakage current to an unpainted, grounded surface on the truck frame at B+, B-, all fuses and all motors with an ammeter. See Figure 5-2. If the current is less than 0.001 ampere (ImA), the truck system passes. If the current exceeds lmA, disconnect the power cables from each motor or major subassembly to determine if that item is causing the leakage.

Component Shorts to Frame, testing

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

2. Measure the resistance to frame at B+, B-, and all fuses with an ohmmeter.

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.

To find the cause of the low resistance, disconnect the power cables from each

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Toyota Pallet Truck Service Manual Hydraulic Troubleshooting Guidelines

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

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

ACAUTION 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 Inspect the hydraulic system for the correct pressure and that the relief valve is functioning correctly. See "Adjusting Hydraulic Pump Relief Valve Pressure" on page 6-76.

Cap any open hydraulic lines to prevent contamination.

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Troubleshooting

Troubleshooting

Toyota Pallet Truck Service Manual Definitions

Definitions

Continuity

Acceleration Rate

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

The time required for the controller to increase from 0% to 100% duty cycle (Pulse Width Modulation) when a continuous 100% throttle request is applied. Acceleration rate is an adjustable parameter from 1.0 to 5.0 seconds.

See "Motor Controller Parameter Settings" on page 5-14.

Creep Speed Creep speed is activated when a direction is first selected. It is the speed at the minimum throttle setting (minimum PWM). See "Throttle Map" 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 0-25% PWM duty cycle. The factory default value is 0%.

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

Figure 5-3.

Brake Switch and Brake Actuation, 7 H B W 3 0 and 7HBE30 or 7HBE40

Emergency Reverse (7HBW30 and 7HBE30/40)

Brake Switch The brake switch in the pallet truck that must be closed to permit truck travel. It is activated by the control handle position on 7HBW30 and 7HBE30 or 7HBE40, and the brake levers on 7HBC30 or 7HBC40 and 7TB50. The brake 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 switch to be closed, permitting travel on 7HBW30 and 7HBE30 or 7HBE40. See Figure 5-3.

Brake Rate This is a programmable parameter (Brake Rate) that determines how quickly the motor controller will ramp braking strength up to 100% of requested amount, thereby determining how soft/harsh the transition to braking will feel. See "Motor Controller Parameter Settings" on page 5-14.

Emergency reverse is started when the brake is released, key switch (SW1)is ON, and the emergency reverse switch (the BB, or "belly button," switch) is pressed. After the 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 restart the emergency reverse function each time.

Fault Codes The motor controller provides fault information by flashing fault codes through two status LED indicators, one built into the controller cover and another on the gauge console. See "Fault Codes" on page 5-11.

High Pedal Disable (HPD) The HPD feature prevents the truck from being started while the throttle is applied. The motor

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Toyota Pallet Truck Service Manual

Troubleshooting

Definitions

controller can be programmed to have HPD based on either the brake switch or key switch input. Toyota pallet trucks are factory preset as Type 1" (key switch ON prior to throttle and not user-selectable). "

Jog Speed Pallet truck travels at reduced fixed speed when jog buttons are pushed (Models 7HBW30 and 7HBE30/40).

Operating Mode The motor controller is capable of up to four operating modes (dependingon model/options).

Each mode has independent programmable Table 5- 1 .

parameters (Accel Rate, Brake Rate, Max Speed, Creep Speed, Throttle Map). A mode is selected by the combination of two inputs, Mode Select 1 and Mode Select 2.

Maximum speeds, controlled by the motor controller, are determined by the four possible combinations (modes) of the two mode select inputs at PMC-3 (Mode Select 1) and PMC-4 (Mode Select 2).

The maximum speed of Model 7HBW30 is limited by a different drive motor, motor controller and gear ratio, not the mode select inputs at PMC-3 and PMC-4.

See Table 5-1.

Operating Mode Select Input

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

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 user-adjustable.

Plugging (Plug Braking) Overtemperature (Motor Controller) Overtemperature of the motor controller as measured a t the internal heatsink is 185°F (85°C)and above. At overtemperature, drive current limit is linearly decreased from full set current down to zero.

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

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

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Plugging is a process where the drive motor creates torque opposite to the direction of travel proportionate to the throttle command opposing the current travel direction. The braking (plugging)current limit 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.

Troubleshooting

Toyota Pallet Truck Service Manual Definitions

Ramp Shape

Short Circuit or "Short

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

A short circuit is an unspecified path in a

The ramp shape number refers to the PWM output at half throttle, a s a percentage of its full range. See "Throttle Map" on page 5-9.

The throttle map adjustment is called "ramp shape.

Regenerative Braking Regenerative braking occurs when current, generated by the motor during braking, is permitted to flow back into the batteries.

Regenerative braking results in less motor heating and reduced brush wear compared with plug braking. Regenerative braking also provides some return of energy to the battery pack, for longer vehicle operating periods.

The Brake Rate defines the time it takes the controller to increase from 0% to 100% regenerative braking current when braking is requested. The braking rate is an operating parameter and is programmable from 0.1 to 5.0 seconds.

Sequencing Delay Sequencing delay permits the brake 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).This feature is useful in applications where the brake switch may bounce or be momentarily cycled during operation. The motor controller can be adjusted from 0 to 3 seconds delay. The Toyota pallet truck is factory preset at 0 seconds and is not user-adjustable.

ff

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 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 for each of the four possible modes (see "Jog Speed" on page 5-7).

"Max speed" parameter limits the maximum PWM for the two directions of travel. This is a programmable parameter. See "Motor Controller Parameter Settings" on page 5-14.

Static Return To Off (SRO) The SRO feature prevents starting the truck (direction selected) prior to the release of the brake (brake switch closed). SRO checks sequencing of the brake switch input and key switch input relative to the direction input. The 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, the motor controller will not command travel.

The programmable motor controller recognizes different types of SRO. Toyota pallet trucks are factory preset as Type 1" and are not user -adjustable. "

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Toyota Pallet Truck Service Manual Definitions

Throttle Map Throttle map is the programmable parameter of the motor controller that assigns the desired ramp shape for the application. See "Ramp Shape" on page 5-8. The throttle map sets the acceleration rate (speed)across the range of throttle positions. Change the throttle map to change vehicle response a t low throttle positions.

Throttle map settings are adjustable between 20% and 80%, in 5% increments, for example 20%, 25%,30%, 35%. Each setting represents a specific ramp shape. Changing the creep speed setting changes (shifts) the output range of the controller. See "Creep Speed on page 5-6.

Throttle map is always a percentage of that defined range. (With creep speed equaling 1096, range shifts up 10% a t half throttle for each ramp shape.) Higher settings result in faster starts, lower settings result in slower starts.

The factory default value is 50%.

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

Undertemperature When the controller is operating at less than -25°C (-13°F)as measured at the internal heatsink, the current limit is cut back resulting in reduced travel speed.

Undervoltage Cutback Undervoltage protection automatically disables the controller output if the battery voltage is detected below the undervoltage point at start-up, 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

Troubleshooting

Toyota Pallet Truck Service Manual Electrical Connector Locator Chart

Electrical Connector Locator Chart Refer also to electrical schematics located in the Appendix and wiring harness component procedures (see "Wiring Harness" on page 6-12).

Table 5-2.

Electrical Connector Locator Chart Connector

Function or Routing

Location

J P1

Connector for ID1

By key switch

JP2

Connector for handle functions

In control handle

JP3

Connector for travel functions

In control handle

JP4

Connector for grab rail functions (7HBE30/40 only)

By key switch

JP6

Connector for travel functions

In control handle

JP7

Connector for jog functions (optional)

In control handle

JP9

Connector for meters (optional)

By key switch

JPlO

Connector for travel configurations

By controller

JPS1

Splice for throttle control

In control handle

JPS3

Splice for reverse travel

By controller

JPS4

Splice for forward travel

By controller

JPS5

Splice for mode control

By rail connector

JPS7

Splice for jog switch B Neg

In control handle

JPS8

Splice for jog signal

In control handle

J P S 10

Splice for jog switch feed

In control handle

PMC 1

Connector on motor controller

Motor controller

PMC-PROG

Connector for programmer

Motor controller

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Toyota Pallet Truck Service Manual

Troubleshooting

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 two LED indicators, one on the front of the motor controller and another on the gauge console.

See Figure 5-4.

Under normal operation, each 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.

See Table 5-3.

Correct faults by obeying the Troubleshooting Charts. See "TroubleshootinrT" on D * arTe 5-2 1.

Figure 5-4.

Fault Code LED Indicator

Table 5-3.

Fault Codes

-

Fault Code LED off Solid on

-

-

Explanation/Possible Cause No power or bad controller Bad motor controller

Single flash

n

1, 2

TX lJrX

Hardware fail-safe error / Motor controller bad

1, 3"

n nnn

Internal M- short to B- / Motor controller bad

1, 3*

TX lJrXrX

Field winding fault / Motor field winding or its connection open

1, 3"

n nnn

Armature current sensor fault / Motor controller bad

1, 3*

TX lJrXrX

Field current sensor fault / Motor controller bad

2, 1"

nn n

Pot wiper out of range / Throttle pot low wire open or shorted to B- or B+

2, l*

Pot low fault / Throttle pot bad. Incorrect throttle type selected.

2, 2

rXrX TX rXrX rXrX

2, 3

rXrX rXrXrX

High Pedal Disable (HPD) sequencing fault / Incorrect sequencing of key switch and throttle input. Misadjusted throttle pot. Sequence delay too short.

2, 4

nn nnnn

Belly button wiring fault / Belly button wire open. Belly button check wire open.

3, 1

rXrXrX TX

Contactor driver output overcurrent / Main contactor coil shorted.

3, 2

nnn nn

Main contactor welded / Main contactor stuck closed. Main contactor driver shorted.

3, 3

nnn nnn

Internal voltage too low a t start-up / Motor controller bad. External short, or leakage to B- a t external B+ connection.

3, 4"

QQQ

3, 4"

nnn nnnn

~J~J~JQ

Controller operational, normal operation, no faults

Static Return to Off (SRO) fault / Incorrect sequence of key switch, brake switch, or direction inputs. Brake or direction switch circuit open. Sequence delay too short. Wrong SRO type selected.

Missing contactor / Main contactor coil open. Wire to main contactor coil open or shorted to B-.

Main contactor did not close / Main contactor missing. Main contactor wire to coil open.

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Troubleshooting

Toyota Pallet Truck Service Manual Fault Codes

Table 5-3.

Fault Codes

Fault Code

Expbation/Possible Cause Low Battery Voltage / Low battery voltage (less than 16V).Corroded or loose

4, 1

nnnl~n

4, 2

rXrXrXlJ rXlJ

Overvoltage / High battery voltage (more than 27.5V).Vehicle operating with charger attached/activated.

4, 3

nnnn nnn

Overtemperature or under-temperature cutback / Temperature greater than +85"C or less than -25°C. Excessive load on vehicle. Operation in extreme environments.

4, 4

nnnn nnnn

Mode 2 or Mode 4 selected at startup / Mode switches shorted to B+. Mode switches taped or "tied" down.

battery terminal. Loose controller terminal.

NOTE: *Certain fault codes have more than one specific meaning. The specific fault may be obtained using the Progammable Maintenance Tool (PMT).

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Toyota Pallet Truck Service Manual

Troubleshooting

Programmable Maintenance Tool

NOTE: The Bookmarks are not permanently stored in the PMT. They are cleared when the PMT is unplugged.

Programmable Maintenance Tool

The Main Menu is the starting point for the PMT. The main menu displays menu titles: Program Monitor Bookmark

:

Faults Functions Information Programmer Setup

Menu

3

If there are no entries within a Menu, then the Menu title will not be displayed.

Program Mode Figure 5-5.

Programmable Maintenance Tool

The optional Programmable Maintenance Tool (PMT)(P/N 00590-4998 1-71) lets you test and diagnose the motor controller in a pallet truck.

See Figure 5-5.

NOTE: When using PMT P/N 00590-49981-71, always refer to the manufacturer's manual.

You can use the PMT to customize the operating parameters of the motor controller.

In Program mode, all the adjustable parameters and features of the controller are displayed, 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.

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

2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Turn the key switch ON.

The Menu Navigation Key moves the screen curser up or down through the Menu list (top or bottom arrow), and opens or closes Sub Menus (right or left arrows). See Figure 5-5.

The Data Inc/Dec Key changes the value of the parameter indicated by the curser.

The Bookmark Keys allow you to quickly go back to your favorite selections without having to navigate back through the Menu.

To select a position in the menu, hold a Bookmark Key down for three seconds until the bookmark set screen is displayed.

To jump to a selected Bookmark position, press the appropriate Bookmark Key.

00700-CL390-05, 1 5 March 2005

5. Use the Menu Navigation Key to select Program.

6. Press the right arrow on the Menu Navigation Key to enter the sub-menu. Use the Up and Down Buttons arrows to scroll through the sub-menu list until the parameter you want is displayed.

7. Press the Data Inc/Dec Key up or down until the setting you want is displayed.

The parameter is now set at the value you selected.

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

Troubleshooting

Toyota Pallet Truck Service Manual Programmable Maintenance Tool

To find definitions of each parameter, see "Definitions" on page 5-6.

Table 5-4.

Motor Controller Parameter Settings

ACAUTION While adjustment of these parameters is possible, settings at values other than those listed in Table 5-4 will produce incorrect and unauthorized operational characteristics. DO NOT adjust these parameters to values other than those listed. *Creep Speed must be set to 0%.

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Toyota Pallet Truck Service Manual

Troubleshooting

Programmable Maintenance Tool

Monitor Mode

7. Use the Up and Down Buttons arrows to

Real-time status information is displayed in the Monitor 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.

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. Use the Menu Navigation Key to select Monitor.

6. Press the right arrow on the Menu Navigation Key to enter the sub-menu.

Table 5 5 .

scroll through the sub-menu list of monitor variables.

8. Use the right arrow to select and view a single variable. See Table 5-5.

9. To change the value of the parameter use the Data Inc/Dec Key. Alternately, you can press the right arrow Menu Navigation Key once more and enter the detail screen. A bar graph appears as well a s min and max data points. Change the parameter value by pressing the Data Inc/Dec Key. The new value is set as soon as the Data Inc/Dec Key is released.

10. To close a Monitor Menu, sub-menu, or detail screen, press the left arrow on the Navigation Key.

Monitor Mode Display

11 THROTTLE%

I Throttle reading, in percent of full throttle

11

ARM CURRENT

Motor armature current, in amps Motor field current, in amps Armature duty cycle (PWM)- applied, a s % Motor field duty cycle (PWM) - applied, a s % Battery voltage (B+ to B- connection) at key switch input Voltage - of controller B+ (bus bar) Heat sink temperature - "C Fonvard switch: on/off Reverse switch: on/off Controller operating mode: 1 to 4 Interlock (brake) switch: on or off I (not used) Emergency reverse switch: on or off (not used) Main contactor: on or off (not used) (not used) (not used) (not used) (not used) (not used) Mode select 1 switch: on/off Mode select 2 switch: on/off

11

FIELD CURRENT

ARM PWM FIELD PWM BATT VOLTAGE CAP VOLTAGE HEAT SINK TEMP FORWARD INPUT REVERSE INPUT MODE INTRLCK INPUT PEDAL INPUT EMR REV INPUT MOTOR RPM MAIN CONT AUX CONT REV OUTPUT BRAKE OUTPUT FAULT 1 OUTPUT FAULT 2 OUTPUT CONTROL STATE MODSEL 1 MODSEL 2

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Troubleshooting

Toyota Pallet Truck Service Manual Programmable Maintenance Tool

Faults Mode In System Faults mode, currently active faults detected by the controller are displayed.

In Faults History 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.

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. To view the present status of the unit, use the Menu Navigation Key to select Faults -> System Faults 6. To access the log, use the Menu Navigation Key to select Faults -> Fault History.

7. Use the Up and Down Buttons arrows on the Menu Navigation Key to scroll through list of multiple faults.

Table 5-6.

After you have diagnosed and corrected the problem, clear the diagnostic history file. This permits 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. To clear the fault history of the unit, use

the Menu Navigation Key to select Faults -> Clear Fault History.

2. Press the increment arrow (+) for yes and the decrement arrow (-) to cancel and not clear the fault history.

Table 5-6 lists possible messages you may see displayed when the PMT is operating in either System Faults or Fault History mode.

System Faults and Fault History List

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Toyota Pallet Truck Service Manual

Troubleshooting

Programmable Maintenance Tool Table 5-6.

System Faults and Fault History list

Functions Mode Motor controller parameters and options can be copied (cloned)from one motor controller to another using the PMT.

NOTE: Cloning only works between controllers with the same model number and software version.

Copy Parameters 1. Turn the key switch OFF. 2. Remove the tractor cover.

3. Connect the PMT to the motor controller of the unit that you want to clone.

4. Turn the key switch ON.

5. Use the Menu Navigation Key to select Functions -> Settings.

6. Select Get Settings From Controller. This will upload the data from the unit you are cloning.

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.

Controller.

This will download the data stored in the PMT to the unit you are programming.

Resetting Original Parameters You can also restore the original settings of the unit. Each time the PMT is connected to a unit, it uploads the present data and stores it in a "temporary archive" memory. You can revert back to the original settings any time during a programming session by selecting the Menu: Functions -> Settings -> Reset All Settings.

Any inadvertent change of parameters can be undone using this procedure, even if you can not remember what the previous settings were as long a s the PMT has not been unplugged and power has not been removed from the controller.

Information Mode The Information Menu provides access to product information describing the basic revision level of the PMT. To view, use the Menu Navigation Key to select Information in the Main Menu. Remember to press the right arrow to select a Menu. Press the left arrow to exit.

3. Turn the key switch ON.

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

Programmer Mode

5. Use the Menu Navigation Key to select Functions -> Settings -> Write Settings To

Programmer mode permits you to perform a variety of tasks. Table 5-7 shows the line items in the Programmer mode.

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Troubleshooting

Toyota Pallet Truck Service Manual Programmable Maintenance Tool

1. Turn the key switch OFF.

7. Use the Up and Down Buttons arrows to

2. Remove the tractor cover.

scroll through the sub-menu list of Programmer displays.

3. Connect the PMT to the motor controller.

4. Turn the key switch ON.

5. Use the Menu Navigation Key to select Programmer.

6. Press the right arrow on the Menu Navigation Key to enter the sub-menu.

Table 5-7.

8. Use the right arrow to select and view a single variable.

9. Change the parameter value by pressing the Data Inc/Dec Key. The new value is set a s soon a s the Data Inc/Dec Key is released.

Programmer Modes

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Toyota Pallet Truck Service Manual

Troubleshooting

List of Troubleshooting Charts Symptom Tables: TS1: STAFYT TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22 .

GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23 . .

END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24

Lift/Lower System No Lift. Lift Motor Does Not Run. Travel OK (from control handle or grab rail switch)5-25 No Lift or Slow Lift. Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26 . .

No Lower. Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26 .

Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27 SlowLower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 .. .

Load Drifting/Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27

Travel No Travel. Lift/Lower OK. Main Contactor Does Not Close. Motor Controller LED is Flashing .

Once Every 2 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28 No Travel in Either Direction. Lift/Lower OK. Motor Controller Fault Code 3.1 . . . . 5-28 No Travel in Either Direction. Lift/Lower OK. Motor Controller Fault Code 1.3 . . . . 5-28 No Travel in Either Direction. Lift/Lower OK. Motor Controller Fault Code 1.2 . . . . 5-29 No Travel. Main Contactor Does Not Close. Motor Controller Fault Code 3.4 . . . . . .5-29 No Travel. Main Contactor Does Close. Motor Controller Fault Code 2.1 . . . . . . . . .5-29 .

Slow Travel. Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 No Emergency Reverse. Travel/Lift/Lower OK. No Motor Controller Fault Codes . . . 5-30 Slow Travel. Lift/Lower OK. Speed Limited to 15%. Motor Controller Fault Code 2.4 .

(Emergency Reverse Circuit Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 No Rabbit Speed. Travel/Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . .5-31 No Travel. Motor Controller Fault Code 4.2 (Excessive Battery Voltage) . . . . . . . . . .5-32 Slow or No Travel. Motor Controller Fault Code 4.1 (Low Battery Voltage) . . . . . . . .5-32 Slow or No Travel. Motor Controller Fault Code 4.3 (Thermal Cutback) . . . . . . . . . .5-32 No Travel. Motor Controller Fault Code 2.2 - Static Return To Off (SRO) . . . . . . . . .5-33 No Travel. Motor Controller Fault Code 2.3 - High Pedal Disable . . . . . . . . . . . . . . .5-33 Plugging Does Not Operate Correctly. Truck Travels OK in Forward and Reverse . . . 5-33 .

Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 Jog Speed Does Not Activate. Lift and Travel OK. (Center Rider Models Only) . . . . .5-34 Jog Speed Does Not Function. Lift and Travel OK. (End Rider Model w/Manual Coast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 .

Electrical Truck Functions Partially. Some Functions Do Not Work When Commanded . . . . .5.35

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Troubleshooting

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Toyota Pallet Truck Service Manual Troubleshooting Flowcharts

Troubleshooting Flowcharts

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Troubleshooting

Troubleshooting

Toyota Pallet Truck Service Manual Troubleshooting Flowcharts

( T S 1: START TROUBLESHOOTING

Follow Symptom Table directions in Chapter 5

\

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Toyota Pallet Truck Service Manual

Troubleshooting

Troubleshooting Flowcharts

GEN1: General Troubleshooting

+ Gather as much information as you can about the problem.

What is the problem?

Eliminate unlikely causes.

Where did it happen?

When did it happen?

What functions are affected?

Select and prioritize the most likely causes.

What conditions trigger the problem?

Talk directly to the operator or foreman.

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

Operate the truck yourself.

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

.

Using the schematics if necessary, identify all components which could cause the problem.

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Troubleshooting

Toyota Pallet Truck Service Manual Troubleshooting Flowcharts

END1:

End of Troubleshooting Procedure

v

1

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

Operate the h c k a s it was being operated when the problem occurred.

Verify the problem does not recur.

v

v

Make sure all panels are properly reinstalled.

Have the driver operate the h c k . Verify the problem does not recur.

v

v

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

Fill out any required forms.

v

v

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

If you contacted Toyota Field Service to discuss the problem, call them again to let them know what fixed the problem.

This is especially important if the solution you troubleshooting chart.

c3 End of Troubleshooting

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Lift/Lower System

Symptom Tables: Lift/Lower System NOTE: If you determine that a component failed as a result of hydraulic fluid contamination, replace the failed component and flush, fill, and bleed the hydraulic system. See "Hydraulic Fluid on page 6-74.

NOTE: Reference electrical and hydraulic schematics beginning on page A-9.

Table 5-8.No Lift, Lift Motor Does Not Run, Travel OK (from control handle or grab rail switch) Possible Cause

Action

Bad lift pump contactor

With key switch ON and lift switch depressed, does pump contactor (M2)energize (click)?...if NO...measure voltage between pump contactor coil M2-X and M2-Y terminals. If B+ is present, replace the pump contactor.

Bad fuse FU1

With key switch ON and lift switch depressed, does pump contactor (M2)energize (click)?...if YES...measure voltage between B- and FU1-2. If voltage is not present, verify wiring between battery B+ and FU1 -1. If OK, replace fuse FU1.

Bad wiring continuity or wiring shorts

With key switch OFF and battery disconnected, check for continuity and wiring shorts in wiring harness.

Bad control handle switches or grab bar switches (end rider models only) Bad lift cutout switch

With key switch OFF and battery disconnected, check for continuity through the control handle lift switch and grab bar lift switch (end rider only).

Bad lift pump motor brushes

With key switch ON and lift switch depressed, does pump contactor (M2)energize (click)?...if YES...measure voltage between B- and lift pump motor terminal MP- 1. If OK, check lift motor brushes.

OR Bad lift pump motor

If brushes are OK, test the pump motor.

OR Bad pump

If pump motor is OK, remove the motor from the pump and turn the pump shaft by hand. Replace pump if bad.

00700-CL390-05, 1 5 March 2005

With key switch OFF and battery disconnected, with forks lowered, check continuity through the lift cutout switch. Replace if necessary.

Troubleshooting

Toyota Pallet Truck Service Manual Symptom Tables: Lift/Lower System

Table 5-9.No Lift or Slow Lift, Lift Motor Does Run Possible Cause

Action

Battery problems

Replace battery with fully-charged known good battery.

Mechanical binding in lift mechanism

Repair lift mechanism.

Low hydraulic pressure or relief valve setting

Check hydraulic pressure setting and adjust if necessary. See "Adjusting Hydraulic Pump Relief Valve Pressure" on page 6-76.

Relief valve contaminated or bad.

(Unable to get the correct hydraulic pressure)

With key switch OFF and battery disconnected, remove the pressure relief valve and check for damage or contamination. Replace valve or flush system and replace the hydraulic fluid. See "Hydraulic Fluid" on page 6-74.

Bad lift pump motor or brushes

Check the lift pump motor brushes. If OK, replace the pump.

Contamination found in pump

Flush the system and replace hydraulic fluid.

Table 5- 10.No Lower, Lift and Travel OK Possible Cause

Action

Bad lower solenoid valve

With key switch ON, cycle the lower switch. Does the lower solenoid energize (click)?If YES, disconnect the battery, then slowly loosen, but do not remove one of the hydraulic lines at the hydraulic pump assembly. Permit the forks to slowly lower. Have rags and drain pan ready to catch fluid.

If the forks do not lower, check for mechanical binding in lift cylinders or fork mechanism.

Replace lift cylinders or repair lift mechanism.

If the forks lower, remove and inspect the solenoid valve.

Inspect for free movement and for signs of contamination. Clean the solenoid valve or flush the system, clean the filter and replace hydraulic fluid. If no contamination is found, repair or replace the solenoid valve or pump assembly.

Check for continuity and wiring shorts.

If the solenoid does not energize, measure the voltage across lower solenoid SOL1-X to SOL1-Y. If B+ is not present, check for continuity and shorts between the solenoid and battery, and lower switch and grab bar switch (end rider models only).

Check for bad control handle switches or grab bar switches (end rider models only)

With key switch OFF and battery disconnected, check for continuity through the control handle lower switch and grab bar lower switch (end rider only).

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Lift/Lower System Table 5- 1 1.Unable to Pick Up a Load Possible Cause

Action

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.

Battery problems

Replace battery with fully-charged good battery.

Incorrect lift pressure adjustment

Check and adjust lift pressure setting.

Contaminated or bad pressure relief valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system and clean the relief valve. If no contamination is found, replace relief valve.

Bad lift pump

Replace lift pump.

Bad lift motor

Replace lift motor.

Table 5- 12.Slow Lower Possible Cause

Action

Bad lift/lower solenoid valve or wiring

Repair or replace the solenoid valve or wiring.

Plugged or malfunctioning flow control valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system and clean the relief valve.

If no contamination is found, replace the flow control valve.

Contamination in lowering solenoid valve

Inspect solenoid for contamination or binding.

Mechanical binding in lift mechanism

Adjust or replace mechanism.

Table 5- 1 3.Load Drifting/Settl;ng Possible Cause

Action

Incorrect lift pressure adjustment

Check and adjust lift pressure setting.

Contaminated or bad pressure relief valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system and clean the relief valve.

If no contamination is found, replace relief valve.

Leaking or contaminated lowering solenoid valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system and clean the solenoid valve.

If no contamination is found, replace the solenoid valve.

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.

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Troubleshooting

Toyota Pallet Truck Service Manual Symptom Tables: Travel

Symptom Tables: Travel NOTE: Reference electrical and hydraulic schematic schematics beginning on page A-9.

Table 5- 14.No Travel, Lift/Lower OK, Main Contactor Does Not Close.

Motor Controller LED is Flashing Once Every 2 Seconds Possible Cause

Action

Battery problems

Replace battery with fully-charged good battery.

Bad battery terminals or quick disconnect plug

Repair or replace.

Bad brake switch or wiring

Repair, replace or adjust brake switch or mechanical actuator.

Bad wiring between key switch, battery and motor controller

Check for continuity and wiring shorts between SW1-Bat on key switch and SW2-C, SW2-NO to PMC-2

Bad motor controller

With battery connected, key switch ON, and brake switch closed check for B+ a t PMC-2. If B+ is present, replace motor controller.

Table 5- 15.No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 3,1 Possible Cause

I ~ction

Bad Motor Controller

With key switch OFF and battery disconnected, remove PMC from motor controller. Measure resistance between PMC-9 to PMC-17. If resistance is approx. 30 ohms, check wires for shorts to frame, B+, B-, or other conductors. If none found replace motor controller.

Bad wiring between motor controller and main contactor

With key switch OFF and battery disconnected. Remove PMC. Check wiring between PMC-17 to M1-Y, PMC-9 to M1-X.

1 Bad main contactor coil

I Disconnect and measure resistance of main contactor coil M1. If not 1

I approx. 3 0 ohms, replace coil.

Table 5- 16.No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 1,3 Possible Cause Bad Motor Controller

I ~ction With key switch OFF and battery disconnected, disconnect drive motor cable a t motor controller terminal M-. Reconnect battery, t u r n key switch ON. If Code 1 , 3 is still displayed, replace motor controller.

If Code 1,3 is not displayed, disconnect battery, remove wires F1 and F2 a t motor controller, measure resistance in wiring harness between F1 and F2. If less than 1.0 ohm, replace motor controller.

Remove wires A1 and A2 a t motor. Measure resistance a t A1 and A2 of motor. If greater that 1.0 ohm, replace motor.

Bad wiring between motor controller and motor

With key switch OFF and battery disconnected, disconnect F1 and F2 from motor controller, check wiring between A1 (motor) to F1 (PMC), A2 (motor) to F2 (PMC).

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Travel

Table 5- 17.No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 1,2 Possible Cause

Action

Bad Motor Controller

Replace motor controller.

Table 5- 18.No Travel, Main Contactor Does Not Close.

Motor Controller Fault Code 3,4 Possible Cause

Action

Bad Motor Controller

With key switch OFF and battery disconnected, remove connector PMC from motor controller. Measure resistance in wiring harness between PMC-9 to PMC-17. If resistance is approximately 30 ohms, check wires for shorts to frame, B+, B-, or other conductors. If none found, replace motor controller.

Bad wiring between motor controller and main contactor

With key switch OFF and battery disconnected, remove PMC and check wiring between PMC-17 to M1-Y, PMC-9 to M1-X.

Bad main contactor coil

Disconnect and measure resistance of main contactor coil M1. If not approximately 3 0 ohms, replace coil.

Table 5- 19.No Travel, Main Contactor Does Close. Motor Controller Fault Code 2,1 Possible Cause

Action

Bad Motor Controller

With key switch OFF and battery disconnected, remove connector PMC from motor controller. Measure resistance between PMC-14 to PMC-16 while slowly rotating throttle in the two directions.

Resistance must increase from 0 to 6K ohms in each direction.

Check PMC-16 and PMC-14 for shorts to frame, B+, B-, or each other.

If none found replace motor controller.

Bad wiring between motor controller and throttle potentiometer

With key switch OFF and battery disconnected, remove PMC and check wiring between PMC, control handle, and throttle potentiometer VR.

Bad throttle potentiometer

With key switch OFF and battery disconnected, remove connector PMC from motor controller. Measure resistance between PMC-14 to PMC-16 while slowly rotating throttle in the two directions.

Resistance must increase from 0 to 6K ohms in each direction. If not, replace throttle potentiometer.

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Troubleshooting

Toyota Pallet Truck Service Manual Symptom Tables: Travel

Table 5-20.Slow Travel, Lift/Lower OK. No Fault Codes Possible Cause

Action

Battery problems

Replace battery with a fully charged good battery.

Motor controller programming changed

Verify programming using PMT. If changed, reset programming. See "Programmable Maintenance Tool" on page 5-13.

Truck not operating in high speed mode (M2 or M4)

Measure voltage at PMC-3. Check wiring between PMC connector and B+, and switch (if equipped).

Verify programming using PMT. If changed, reset programming. See "Programmable Maintenance Tool" on page 5-13.

Bad throttle potentiometer/wiring

With key switch OFF and battery disconnected, remove connector PMC from motor controller. Measure resistance between PMC-14 to PMC-16 while slowly rotating throttle in the two directions.

Resistance must increase from 0 to 6K ohms in each direction. If not, repair wiring or replace throttle potentiometer.

Bad motor controller

Jack and block truck. With key switch ON and handle in operating position, measure voltage at B+ of motor controller with throttle on in the two directions. Voltage must increase from 2V to B+ in each direction. If not, replace motor controller.

Binding drive wheel assembly

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Check drive wheel to see if it spins freely. If not, repair or replace.

Binding brake drum

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Turn the brake drum to see if it spins freely. If not, adjust, repair or replace.

Binding drive motor

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Turn the brake drum to see if it spins freely. Remove brake drum and check armature shaft. Remove motor and repair or replace drive unit or drive motor.

Bad drive motor (may test OK with no load, but fail under load) or worn brushes

Repair or replace drive motor or brushes.

Table 5-2 1.No Emergency Reverse, Travel/Lift/Lower OK. No Motor Controller Fauk Codes Possible Cause

Action

Bad Motor Controller

Jack and block truck. With key switch ON and handle in travel position, measure voltage at PMC-7 while pushing emergency reverse switch. If B+ is present, replace motor controller.

Bad wiring between motor controller and emergency reverse switch

With key switch OFF and battery disconnected, remove PMC and check wiring between PMC and switch SW7. Repair or replace as necessary.

Bad emergency reverse switch

With key switch OFF, battery disconnected, and PMC disconnected, check continuity of emergency reverse switch. Replace if necessary.

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Travel

Table 5-22.Slow Travel, Liftbower OK, Speed Limited to 15%. Motor Controller Fault Code 2,4 (Emergency Reverse Circuit Fault) Possible Cause

Action

Bad Motor Controller

With key switch OFF and battery disconnected, remove connector PMC from motor controller. Measure resistance between PMC-22 and PMC-7. If there is continuity, replace motor controller.

Bad wiring between motor controller and emergency reverse switch

With key switch OFF and battery disconnected, remove PMC and check wiring between PMC-22 and switch SW7. Repair or replace as necessary.

Table 5-23.No Rabbit Speed, Travel/Lift/Lower OK. No Fault Codes Possible Cause

Action

NOTE:Rabbit speed only works in the

NOTE: Rabbit speed (actual) is dependant on:

tractor-first (forward) direction. End rider models are equipped with "latched rabbit speed buttons. Press and release the button to enable rabbit speed. Rabbit speed is disabled by applying brake or returning the throttle to neutral.

M4 (mode) max speed setting B+ present a t PMC-10 (fonvard input) Throttle input (up to 100%) B+ present a t PMC-3 and PMC-4 (mode select 1 and 2) ~~i~~ motor armature

Motor controller programming changed

J a c k and block h c k . Verify programming using PMT. If changed, reset programming.

Verify inputs of B+ a t PMC-3 and PMC-4, and 100% throttle for rabbit speed.

Bad throttle potentiometer/motor controller

J a c k and block h c k . Verify inputs of B+ a t PMC-3 and PMC-4 and test for 100% throttle input when rabbit speed is requested. If not OK, replace throttle potentiometer. If OK, replace motor controller.

Bad Motor Controller

J a c k and block h c k . Verify "Arm P W using PMT in test mode while attempting full speed tractor first with rabbit switch closed. If not a t or near loo%, replace motor controller.

Bad wiring between motor controller and control handle or grab rail (end rider models)

With key switch OFF and battery disconnected, disconnect PMC and check wiring between PMC-3 and grab rail connections. Repair or replace wiring.

Check rabbit switch. Replace as necessary.

J a c k and block truck. With key switch ON and handle in operating position, rotate throttle to fonvard travel position. Check for B+ a t RLY1-7. If not present, check wiring between PMC-10 to RLY1-7. If B+ is present, check for B+ a t RLY2-A. Check wiring between RLY1-B to JPS-6.

Bad wiring between motor controller and control handle

With key switch OFF and battery disconnected, disconnect PMC and check wiring between PMC-3 and control handle connections. Repair or replace wiring.

Check RLY1 - 1.

Bad rabbit latch relay (RLY1)

Remove relay from truck. Apply 24Vdc to pins A(+)and B(-). Check continuity between pins 4 and 7. If no continuity, replace relay.

Bad rabbit latch relay wiring

Does rabbit speed work only while button is held down? Check wiring to RLY1.

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Troubleshooting

Toyota Pallet Truck Service Manual Symptom Tables: Travel

Possible Cause

Action

Bad motor

Jack and block truck. Verify "Arm P W using PMT in test mode while attempting full speed tractor first with rabbit switch closed. If at or near loo%, replace motor.

Table 5-24.No Travel. Motor Controller Fault Code 4,2 (Excessive Battery Voltage) Possible Cause

1 Battery problem

II

I ~ction I Verify the correct, fully-charged good battery is installed in truck.

I s battery charger plugged into truck?

Bad motor controller

Disconnect battery charger immediately.

1

I I s correct battery (24V) installed? Replace motor controller.

Table 5-25.Slow or No Travel. Motor Controller Fault Code 4,1 (Low Battery Voltage) Possible Cause

Action

Battery problem

Verify a correct, fully-charged good battery (24V) is installed in truck.

Bad battery terminals or quick disconnect plug

Repair or replace.

Bad motor controller

Use PMT to venfy battery voltage a t key switch input on test menu.

Compare voltage at PMC-1. Turn key switch OFF and disconnect battery connector. Check for continuity and wiring shorts between Bbat to Motor controller B- and key switch circuit wiring and fuses.

Repair or replace.

Measure voltage at PMC-1 wire with PMC disconnected. If 24V, replace motor controller.

Faulty wiring or connector

Jack and block truck. With key switch ON and battery connected, while attempting travel, measure voltage between A2, motor controller B+, B-,and: FU1-1, FU1-2, M1-1, M1-2 and MD-. If not 24V, repair or replace wiring.

Table 5-26.Slow or No Travel. Motor Controller Fauk Code 4,3 (Thermal Cutback) Possible Cause

11 Battery problem

1 Binding drive wheel assembly 1

I ~ction I Verify a correct, fully-charged good battery (24V) is installed in truck.

I Jack and block truck. Turn key switch OFF. Pull control handle down I to release brake. Check drive wheel to see if it spins freely. If not, repair or replace.

Binding brake drum

I

I

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Turn the brake drum to see if it spins freely. If not, adjust, repair or replace.

Binding drive motor

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Turn the brake drum to see if it spins freely. Remove brake drum and check armature shaft. Remove motor and repair or replace drive unit or drive motor.

Bad drive motor (may test OK with no load, but fail under load) or worn brushes

Repair or replace drive motor or brushes.

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Travel Possible Cause

Action

Truck overloaded or operated in extreme conditions

Operate and load truck within specifications.

Bad motor controller

Check mounting of motor controller. It must be mounted securely and in contact with the tmck frame (that acts a s a heatsink). If controller is mounted correctly, replace controller.

Faulty wiring or connector

Jack and block tmck. With key switch ON and battery connected, while attempting travel, measure voltage between A2, motor controller B+, B-,and: FU1-1, FU1-2, M1-1, M1-2 and MD-. If not 24V, repair or replace wiring.

Table 5-27.No Travel. Motor Controller Fault Code 2,2

- Static Return To Off (SRO)

Possible Cause

Action

Handle not positioned correctly

Move the handle to operating position before the throttle is rotated or jog switches are pressed (if equipped).

Bad motor controller

With key switch ON and battery connected, check for B+ voltage at PMC-10 and PMC-1 1. If not detected, replace motor controller.

If all other possible causes check out, replace motor controller.

Directional switches SW3 or SW4 shorted

Repair or replace.

Bad wiring between motor controller and handle assembly

[Motor controller is receiving direction command (B+ at PMC-10 and PMC- 1 1) before handle is lowered.] With key switch OFF and battery disconnected, check for continuity and wiring shorts between PMC- 10 and PMC- 11 and the control handle. Repair or replace.

Bad jog switches

With key switch OFF and battery disconnected, measure resistance of jog switches. Repair or replace.

Table 5-28.No Travel. Motor Controller Fault Code 2,3

- High Pedal Disable

Possible Cause

Action

Handle positioned correctly?

Move the handle to operating position before the throttle is rotated or jog switches are pressed (if equipped).

Bad throttle potentiometer

Test and adjust throttle potentiometer. See "Throttle Potentiometer" on page 6-37.

Bad motor controller

If all other possible causes check out, replace motor controller.

Table 5-29.Plugging Does Not Operate Correctly. Truck Travels OK in Forward and Reverse Possible Cause

Action

Bad motor brushes or motor

With key switch OFF and battery disconnected, check drive motor brushes and motor. See "Motor Brushes" on page 6-42. Repair or replace.

Bad motor controller

If all other possible causes check out, replace motor controller.

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Troubleshooting

Toyota Pallet Truck Service Manual Symptom Tables: Travel

Table 5-30.Truck Does Not Accelerate Correctly Possible Cause

Action

Battery problem

Verify a correct, fully-charged battery is installed in truck.

Motor controller programming not correct

Verify programming using PMT. Adjust "Acceleration Rate" programming to maximum.

Verify throttle input using PMT (in Test Mode).

Binding or mechanical problem

Jack and block truck. Turn key switch OFF. Pull control handle down to release brake. Check brake, wheel bearings, and load wheels.

Repair or replace.

Bad motor brushes or motor

With key switch OFF and battery disconnected, check drive motor brushes and motor. See "Motor Brushes" on page 6-42. Repair or replace.

Bad motor controller

If all other possible causes check out, replace motor controller.

Table 5-3 1.Jog Speed Does Not Activate. Lift and Travel OK. (Center Rider Models Only) Possible Cause

Action

Bad rabbit latch relay (RLY1)

Jack and block tmck. With battery connected and key switch ON, press jog button and check for B+ across RLY1. If B+ is present, test relay. If bad, replace RLY1.

Bad wiring between RLY1, DA1 and control handle assembly, including jog switches

With key switch OFF and battery disconnected, check wiring and jog switches for continuity/shorts. Repair or replace.

Table 5-32.Jog Speed Does Not Function. Lift and Travel OK. (End Rider Model w/Manual Coast) Possible Cause

Action

Bad coast module (DA1)

Jack and block truck. With battery connected and key switch ON, press jog button and check for B+ at PMC-10. If B+ is present, disconnect DA1 and measure voltage at DA1-6. If present, replace coast module DA1.

Bad wiring between DA1-2 and control handle

Jack and block truck. With battery connected and key switch ON, press jog button and check for B+ at PMC-10. If B+ is present, disconnect DA1 and measure voltage at DA1-1 while pressing each jog button. If present, turn key switch OFF and check for continuity and wiring shorts between DA1-2 and control handle.

Bad wiring between DA1-1 and jog buttons SW5 and SW6 (also rabbit switches SW16A and SW16B)

Jack and block truck. With battery connected and key switch ON, press jog button and check for B+ at PMC-10. If B+ is present, disconnect DA1 and measure voltage at DA1-1 while pressing each jog button. If NOT present, turn key switch OFF and check for continuity and wiring shorts between DA1-1 and switches.

Bad jog switches SW5 and SW6

With key switch OFF and battery disconnected, check wiring and jog switches for continuity and wiring shorts. Repair or replace.

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Toyota Pallet Truck Service Manual

Troubleshooting

Symptom Tables: Wiring System

Symptom Tables: Wiring System NOTE: Reference electrical schematics beginning on page A-9.

Table 5-33.Truck Functions par ti all^ Some Functions Do Not Work When Commanded Possible Cause

Action

Bad wiring in control handle

Visually inspect wiring in the handle and where the wiring leaves the handle and is over the brake. Repair or replace.

Bad wiring in hydraulic control area

Visually inspect wiring. Repair or replace.

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Troubleshooting

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Section 6. Component Procedures

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual List of Component Procedures

List of Component Procedures

Battery . . . . . . . . . . . . . . . . . . . . .6-8 to 6-10 Exterior Cleaning . . . . . . . . . . . . . . . . . 6-9 Maintenance-Free . . . . . . . . . . . . . . . 6-10 Storage . . . . . . . . . . . . . . . . . . . . . . .6-10 Testing. Charging. and Maintenance . . 6-9 With Gates and Rollers . . . . . . . . . . . . . 6-8 Without Gates and Rollers . . . . . . . . . . 6-8 Brake . . . . . . . . . . . . . . . . . . . . . .6-39 to 6-42 Brake Switch . . . . . . . . . . . . . . . . . . . . . .6-16

Cables. Power . . . . . . . . . . . . . . . . . . . . .6-1 1 Casters . . . . . . . . . . . . . . . . . . . . . . . . . .6-65 Coast Control Manual . . . . . . . . . . . . . . . . . . . . . . .6-21 Coast Module (DA1) . . . . . . . . . . . . . . . . . 6-23 Cold Storage Conditioning . . . . . . . . . . . . 6-90 Commutator . . . . . . . . . . . . . . . . . . . . . .6-43 Contactors . . . . . . . . . . . . . . . . . . . . . . . .6-30 Control Handle Models 7HBC30/40 a n d 7TB50. 3-Position . . . . . . . . . . . . . . . . . . . . . . . .6-34 Models 7HBW30 and 7HBE30/40 . . . 6-33 Models 7HBW30 and 7HBE30/40 Only Return Spring Adjustment . . . . . . 6-34 Control Handle Switches . . . . . . . . . . . . . 6-35 Cover Tractor . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Drive Unit Steering Bearing . . . . . . . . . . . . . . . . . 6-60

Emergency Reverse Check . . . . . . . . . . . . 6-29

Fork Height Adjustment . . . . . . . . 6-70 to 6-71 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Grab Rail Switches . . . . . . . . . . . . . . . . . 6-19

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Hydraulic Components General . . . . . . . . . . . . . . . . . . . . . . . 6-73 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 6-74 Hydraulic Pump . . . . . . . . . . . . . . . . . . . 6-86 Hydraulic Ram . . . . . . . . . . . . . . 6-78 to 6-81 Hydraulic Reservoir . . . . . . . . . . . . . . . . . 6-85 Hydraulic Solenoids . . . . . . . . . . . . . . . . 6-20 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . 6-84 Filter Screen . . . . . . . . . . . . . . . . . . . 6-85 Lift Motor . . . . . . . . . . . . . . . . . . . . . 6-88 Suction Tube . . . . . . . . . . . . . . . . . . . 6-85

Jog Speed Adjustment . . . . . . . . . . . . . . . 6-24

Key Switch . . . . . . . . . . . . . . . . . . . . . . . 6-15

Lift Cut-Out Switch . . . . . . . . . . . . . . . . . 6-18 Load Wheels . . . . . . . . . . . . . . . . . . . . . . 6-67 Model 7TB50 . . . . . . . . . . . . . . . . . . . 6-68

Maintenance-Free Batteries . . . . . . . . . . .

Manual Coast Trucks with Spring Preload Handle . .

Module. Coast (DA1). . . . . . . . . . . . . . . .

Motor Controller . . . . . . . . . . . . . . . . . . .

Motors . . . . . . . . . . . . . . . . . . . . . . . . . .

Brush Spring Tension . . . . . . . . . . . .

Brushes . . . . . . . . . . . . . . . . . . . . . .

Commutator . . . . . . . . . . . . . . . . . . .

Drive . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . .

Lift . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Nuts . . . . . . . . . . . . . . . . . .

00700-CL3 90.05. 1 5 March 2005

Toyota Pallet Truck Service Manual List of Component Procedures

Tests . . . . . . . . . . . . . . . . . . . . . . . . .6-46

Power Cables . . . . . . . . . . . . . . . . . . . . . .6-11

Relief Valve . . . . . . . . . . . . . . . . . . . . . . .6-76

Seals Hydraulic Cylinder . . . . . . . . . . . . . . . 6-81 Solenoids Hydraulic . . . . . . . . . . . . . . . . . . . . . .6-20 Steering Bearing. Inspect for excessive play . . .

6-60 Switches Brake . . . . . . . . . . . . . . . . . . . . . . . . .6-16 Control Handle . . . . . . . . . . . . . . . . . .6-35 Directional . . . . . . . . . . . . . . . . . . . . .6-36 Emergency Reverse Switch . . . . . . . . . 6-35 General . . . . . . . . . . . . . . . . . . . . . . .6-14 Grab Rail . . . . . . . . . . . . . . . . . . . . . .6-19 Horn. lift. Lower see Control Handle Switches Jog . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Key Switch . . . . . . . . . . . . . . . . . . . . .6-15 Lift Cut-Out . . . . . . . . . . . . . . . . . . . .6-18

Throttle Potentiometer . . . . . . . . . . 6.36. 6-37 Test/Adjustment . . . . . . . . . . . . . . . .6-37 Tractor Cover . . . . . . . . . . . . . . . . . . . . . . .6-7

Valve. Relief . . . . . . . . . . . . . . . . . . . . . . .6-76

Wheels Load . . . . . . . . . . . . . . . . . . . . . . . . . .6-67 Wiring Harness . . . . . . . . . . . . . . . . . . . .6-12

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1 5 March 2005

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Component Procedures

Component Locators

Component Locators Battery Connector

Motor Controller

Page 6-8

Page 6-28

Power Cables

I

Drive Unit

Drive Motor

Page 6-30

Page 6-53

Page 6-49

Inside Tractor, Model 7HBE30/40 Shown

00700-CL390-05, 1 5 March 2005

Page 6-39

Contactors

Page 6-1 1

Figure 6- 1 .

Brake

Wire Harness Page 6- 12

Component Procedures

Toyota Pallet Truck Service Manual Component Locators

rake Switch Page 6- 16

\ Hydraulic Reservoir Lift Limit Switch Page 6- 1 8 Figure 6-2.

Horn

Page 6-85

Page 6-27

Hydraulic Components

00700-CL3 90-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Tractor Cover

Tractor Cover Removal To take off the tractor cover, remove the two screws from the top of the cover and the two screws from the bottom of the cover. Lift the cover slightly outward and upward from the truck to avoid the handle assembly.

Installation To reinstall the cover, slide it back into the original position, and secure it with the two screws in the top of the cover and the two screws in the bottom of the cover.

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Battery

ACAUTION Before working on the battery, review Battery Safety, starting on Page 2-5.

Batteries may weigh more than 1,000 pounds (454 kg). Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting. Do not extend a battery more than 1 /3 of its length outside the battery compartment without being attached to a battery-moving device.

Trucks Equipped with Battery Gates and Rollers (optional) Removal 1. Drive the truck to the battery exchange location and as close to the battery replacement device as possible.

2. After the truck is stopped and the handle is returned to the full up (brake on) position, turn the key switch OFF. 3. Disconnect the battery connector located at the top of the tractor cover.

4. Position the battery replacement device in accordance with the manufacturer's recommendations.

5. Remove the battery gate located on the side of the truck next to the battery replacement device.

6. Roll the battery from the truck on the replacement device, making sure that the battery can not accidently come off the device.

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

2. Position the battery in the compartment.

Be sure the battery has no more than 1/2

in. (13 mm) of "free play" movement in the battery compartment.

3. Install the side gate. Move the lifting device from the area.

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

Inspection Inspect the optional battery gates for bending or cracks. Replace if necessary.

NOTE: The optional battery gate interlock will sound the horn when the gate is not installed and the key switch is turned ON.

Inspect the battery rollers in the truck and replacement device (if applicable)to ensure they can turn freely. Replace any damaged roller with a new one as required. Clean off electrolyte using a solution of 1 lb. (0.45 kg) of baking soda added to 1 /2 gal. (1.9 liters) of hot water.

Trucks Without Battery Gates and Rollers Removal 1. Drive the truck to the battery exchange location and as close to the battery lifting device a s possible.

2. After the truck is stopped and the handle is returned to the full up (brake on) position, turn the key switch OFF. 3. Disconnect the battery connector located at the top of the tractor cover.

4. Position the battery lifting device in accordance with the manufacturer's recommendations.

5. Position the battery hoist above the battery and attach to the battery manufacturer's designated lift points.

6. Remove the battery by lifting straight up.

7. Place the discharged battery on the charging stand.

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Toyota Pallet Truck Service Manual

Component Procedures

Battery

Installation 1. With a fully charged and tested battery on the hoist, position the battery above the battery compartment.

2. Lower the battery and position it in the compartment. Be sure the battery has no more than 1/2 in. (13 mm) of "free play" movement in the battery compartment.

3. Move the hoist from the area.

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

Battery Exterior Cleaning

Figure 6-3.

Battery Filler Plugs and Vent Holes

1. Read, understand, and follow procedures, recommendations and specifications in the battery and battery charger manufacturer's manuals.

2. Wear personal protective equipment. See "Battery Safety" on page 2-6.

3. Turn the key switch OFF and disconnect the battery connector. Remove the battery from the truck.

4. Inspect the battery cables to make sure they are not frayed or loose. Inspect the battery connector to ensure there is no foreign material inside the connector.

Make sure the filler plugs are tight and the vent holes in the filler plugs are open.See Figure 6-3.

00700-CL390-05, 1 5 March 2005

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

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

Do not clean the top of the battery with the soda solution while it is installed in the lift truck. Water can seep into the electrical components and cause serious damage.

6. 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 0.5 gal. (1.9 liters) of hot water.

7. 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.

8. Rinse the battery with clean water.

9. Dry the battery completely before reinstalling it.

10. Reinstall the battery in the lift truck, using a suitable battery moving device.

Reconnect the battery connector.

Testing, Charging, and Maintenance The most important element in battery service and prolonging battery life is correct charging.

For information on testing, charging, and maintaining your lift truck battery, consult the battery manufacturer's specifications and instruction manual.

Make sure you follow the correct method for each application, following the battery and battery charger manufacturer's instructions.

Component Procedures

Toyota Pallet Truck Service Manual Battery

ACAUTION The vent holes in the filler plugs must be open to permit 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.

ACAUTION 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.

Connectors must be checked for: Cracks Damage Worn contacts Repair or replace any bad components as required.

Maintenance-Free Batteries Your truck may be equipped with a maintenance-free battery. Please follow manufacturer's recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery must be kept clean and dry and may be washed to remove any accumulated foreign matter.

Storage Before you store a battery, make sure the electrolyte is at the correct 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.

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Power Cables

Power Cables Inspection Power cables must be checked for damage, including: Signs 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 as 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 must be crimped tightly and securely on the wire. Replace the lug if overheating is evident, and repair or replace faulty connectors as necessary.

00700-CL390-05, 1 5 March 2005

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Wiring Harness

Wiring Harness

all protective or securing attachments before moving the harness.

Terminology

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.

The term "connector JPx" 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 "Px." For example, connector JP2 is the mated connector in the control handle. 52 represents the jack connections. P2 represents the pin connections.

Inspection When working on the truck, use care around wiring harnesses: Do not pull on wires.

Carefully connect and disconnect all connections.

Do not pry connectors apart 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, and so on.

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.

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.

When replacing wires, follow these guidelines: Use the appropriate tools to remove and insert terminations a t each connector.

Remove damaged terminations and discard. Never reuse a termination from a wire.

Do not cut away a terminal lug and reuse the wire strands that were crimped into the original lug.

When stripping wire, use new wire strands for new terminations. Be sure to use a new wire with extra length to allow for cutting and stripping of the ends to install new terminations.

Use a new wire that is the same gauge (typically gauge 18 AWG), size, type, and color as the wire it is replacing.

Use a hand stripper capable of stripping by wire gage number. Use care not to nick or cut any of the wire strands. Discard and replace a wire with damaged strands.

Insert the wire strands the proper length into termination before crimping.

During troubleshooting and repairs, it may be necessary to unmate a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note the location of the wire and

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Fuses

Fuses

Figure 6-4.

Fuse location

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

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 RX1 scale and measure the resistance across the fuse. The resistance must be less than one ohm.

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Component Procedures

Component Procedures

Toyota Pallet Truck 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 an ohmmeter set to a low resistance scale to measure the resistance across the switch. In a closed position, the switch must be less than one ohm. In an open position, the switch must show a resistance greater than 10 megohms.

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Toyota Pallet Truck Service Manual Key Switch

Key Switch Toyota pallet trucks are equipped with a two-position key switch (SWl),which energizes all truck operations except the horn. The horn can be sounded when the key switch is OFF.

Inspection 1. With the battery plugged in and key switch ON, battery voltage B+ must be present on the two terminals of the switch.

2. Disconnect the battery; test the key switch with an ohmmeter after removing the wires from the switch terminals.

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

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

2. Remove the tractor cover.

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

4. Remove the key switch.

5. Disconnect wires from the bottom of the key switch.

Installation 1. Connect the wires to the terminals.

2. Install the new key switch and tighten the locking nut.

3 . Reconnect the battery connector and

check key switch operation.

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

5. Install tractor cover.

6. Reconnect the battery connector.

00700-CL390-05, 1 5 March 2005

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Brake Switch

Brake Switch

Figure 6-5.

Make sure the switch does not bottom out when fully compressed.

Brake Switch, 7HBW30 and Model 7HBE30 or Model 7HBE40

Adjustment

Figure 6-6.

Brake Switch, 7HBC30 or 7HBC40 and 7TB50).

The brake switch (SW2)is located near the brake adjusting rod, above the drive motor. See Figure 6-5.

NOTE: The bracket may need to be bent to fully engage the switch.

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

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

2. Remove the tractor cover.

7. Replace the tractor cover. Reconnect the battery connector.

3. Reconnect the battery connector and turn the key switch ON. 4. Using the nuts on the barrel of the brake switch, adjust the switch so that power is disconnected when: For 7HBW30 and Model 7HBE30 or Model 7HBE40 models, the handle is approx. 10" from fully raised or fully lowered. See Figure 6-5.

For Model 7HBC30, Model 7HBC40 and 7TB50, the parking brake is ON. See Figure 6-6.

5. Test operate the truck.

Removal 1. Lower the forks completely.

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

3. Remove the tractor cover.

4. Disconnect the wires on the brake switch.

5. Remove the jam nut holding the brake switch on the mounting bracket.

6. Remove the brake switch.

Installation 1. Mount the brake switch to the mounting bracket.

2. Connect the wires to the brake switch.

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

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Brake Switch

5. Adjust switch if necessary. See "Brake Switch" on page 6-16.

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

7. Install the tractor cover.

8. Reconnect the battery connector.

00700-CL390-05, 1 5 March 2005

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Lift Cut-Out Switch

Lift Cut-Out Switch When the forks are fully raised, the lift cut-out switch (SW10)shuts off power to the lift contactor (M3),which turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure 6-7.

Figure 6-7.

neutral position. Lower, then raise, the forks until they reach their fully-raised position. The lift cut-out switch must cut power off to the pump when the lift rams reach 1/2 to 1 in. (13 to 25.4 mm) before their upper limit.

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

7. Install the tractor cover.

Lift Cut-Out Switch and Adjustment Screw

Adjustment 1. Remove the tractor cover.

2. Raise the forks until they reach their fully raised position. If the lift cut-out switch does not shut the pump down when the lift rams reach their upper limit, the relief valve on the hydraulic pump will make a high-pitched squeal, indicating that the relief valve is opening. See "Adjusting Hydraulic Pump Relief Valve Pressure" on page 6-76.

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

4. Reposition the lift cut-out adjustment screw up or down to operate the switch (cut power off)when lift is 1/2 to 1 in.

(13 to 25.4 mm) before the fully-raised position.

5. Reconnect the battery and turn the key switch ON. Leave the control handle in the

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Toyota Pallet Truck Service Manual

Component Procedures

Grab Rail Switches

Grab Rail Switches Models 7HBE30/40 Only

Remove the tractor cover.

Disconnect the grab rail switch wire harness connector (JP-4) located above the hydraulic pump/motor assembly.

Pull wire harness through the grab rail.

4. To replace individual switches, remove the switch module mounting screws. Use no larger than a 25-watt soldering iron and unsolder the wires to the bad switch.

Installation 1. If the individual switch is being replaced, resolder the wires to the new switch body.

Figure 6-8.

2. If the complete switch module is being replaced, insert the wire harness through the grab rail. Reconnect connector (JP-4).

Grab Rail Switch Removal, left Side

Removal 1. Remove the lift/lower button by inserting a narrow blade screwdriver between the lift/lower button and rabbit button.

Carefully pry up and sideways to release the plastic tab. This will raise one edge slightly. See Figure 6-8.

2. Repeat procedure for the opposite side of the lift/lower button then remove the button. See Figure 6-9. After the lift/lower button is removed, the switch module mounting screws are visible.

Figure 6-9.

Grab rail Switch Removal, Right Side

3. To replace the complete switch module:

Remove switch module mounting screws.

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3. Apply thread-locking compound LoctiteB 425 to the mounting screws. Reinstall the switch module.

NOTE: Use only LoctiteB425 thread-locking compound. Other types will deteriorate the plastic housing.

4. Reinstall the lift/lower button by lining up the guides and pushing down until it locks into place.

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Solenoids

Hydraulic Solenoids

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. lb. (35 Nm).

4. Install the solenoid coil on 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.

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

8. Install any covers that were removed.

Lift Motor Solenoid

/

Lower

Solenoid/Valve

Figure 6- 10.

Hydraulic Solenoids

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 nut 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 must be completely clean and free from any nicks or damage.

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Component Procedures

Toyota Pallet Truck Service Manual Manual Coast

Manual Coast Trucks With Spring-Loaded Control Handle

4. Remove the handle retainer spring

between the coast actuator handle and coast shaft.

Coast Spring

Coast Shaft

Locking Nut

7HBW30,7HBE30/40 (Optional)

Figure 6- 1 1.

Coast Interlock Switches

Coast Rod

Adjustment Adjust the preload on the manual coast spring until the pull rod will not permit the control handle to return to a full vertical (brake applied) position when released from any position.

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

2. Remove the tractor cover.

3. Place the manual coast actuator handle in the OFF position. See Figure 6- 11 on page 6-2 1.

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Figure 6- 12.

Manual Coast Assembly, Installed

5. Remove the lock nut and washer holding the bottom of the coast actuator handle to the actuator body. Remove the bolt then carefully remove the handle.

6. Remove the lock nut and washer on the end of the coast rod. See Figure 6- 12 on page 6-21.

7. Remove the control handle. See "Control Handle" on page 6-33.

8. Remove the set screw securing the coast shaft, then carefully remove the coast shaft and actuator assembly from the drive unit.

9. Disassemble by removing the large jam nut on the coast spring sleeve. Remove the spring and spring sleeve.

Component Procedures

Toyota Pallet Truck Service Manual Manual Coast

Installation 1. Reinstall the coast shaft and actuator assembly. Secure with set screw. Apply thread-locking compound (P/N 00590-0 1931-7 1) to the set screw.

2. If the coast spring retainer has been removed, reinstall and secure each shoulder bolt with thread-locking compound (P/N 00590-01931-71).

3. Reinstall the control handle, inserting the coast rod through the actuator assembly.

See "Control Handle" on page 6-33.

4. Secure the coast rod with the lock nut and washer. Adjust until the 0.81 in. (20.57 mm) dimension is correct. See Figure 6-12 on page 6-21.

5. After the lock nut is adjusted correctly, secure the jam nut with thread-locking compound (Loctite #290).

6. Reinstall the coast actuator handle and handle spring.

7. Reconnect the battery and test the operation of the truck.

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Toyota Pallet Truck Service Manual

Component Procedures

Coast Module (DA1)

Coast Module (DAI ) Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the two socket head cap screws from the underside handle cover. Remove this cover to expose the coast module (DA1).See Figure 6-13.

Table 6- 1.

DA 1 Test Measurements

Positive (+) Lead

Negative (-) Lead

Ohmmeter Diode Test Reading Function

pin DA1-1

pin DA1-2

2 megohms Less than

1.0 ohm pin DA1-1

pin DA1-3

2 megohms Less than

1.0 ohm pin DA1-2

pin DA1-1

greater than 10 megohms

Open

pin DA1-3

pin DA1-1

greater than 10 megohms

Open

pin DA1-4

pin DA1-5

less than 1.0 ohm

----

Testing 1. Remove the coast module from the truck.

See procedure above.

Figure 6-1 3: Control Handle (Shown DisassembledJ

3. Disconnect the wire harness from the coast module.

4. Remove the coast module.

Table 6- 1.

DA 1 Test Measurements

NOTE: Disconnect and remove DA1 to test correctly.

2. Use an Digital Voltmeter (DVM)to verify measurements. See Table 6-1.

3. Apply 24 VDC (f2 volts) across pin 1 (+) and pin 6 (-). The resistance between pins 4 and 5 must change as the coast module potentiometer (VR1) is rotated.

See Table 6-2.

Table 6-2.

DA 1 Potentiometer Reading

4. If you do not obtain the indicated readings, replace the coast module.

Installation 5. Mount the coast module in the handle.

6. Reconnect the wire harness.

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Component Procedures

Toyota Pallet Truck Service Manual Coast Module (DA1)

7. Reconnect the battery connector.

8. Turn the key switch ON and verify coast operation.

9. Adjust the coast speed a s necessary. See "Jog Speed Adjustment" on page 6-24.

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

11. Install the handle cover using the six socket head cap screws.

Jog Speed Adjustment Adjusting the VR1 potentiometer on the coast module, in effect, adjusts the jog speed. The higher you set the resistance, the faster the speed. You can not adjust the speed faster than 3.5 mph (5.6 kph) on an empty truck.

Prior to installation, use a setting of 4,500 ohms.

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Toyota Pallet Truck Service Manual

Component Procedures

Gauges

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

Toyota pallet trucks are available with one of three optional gauge packages: hour meter, battery discharge meter, hour meter/battery discharge combination meter, and combination meter with lift cut-out.

Hour Meter

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

3 . Connect the wires to the correct terminals.

4. Reconnect the battery connector and test operation.

5. Install the tractor cover.

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

Combination Hour/Battery Discharge Meter

Inspection

The Toyota pallet truck may be equipped with a low battery lift cut-out feature as part of the battery discharge/hour meter package. This feature prevents the forks from being raised when the battery reaches a programmable level of discharge. This feature maintains a minimum (reserve)level of battery charge to enable the truck to return to the battery area for charging or replacement of the battery.

If the numbers do not illuminate when the battery is plugged in, use a voltmeter to check for B+ at pin 1 on the rear 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 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 switch).

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

Removal

Low Battery Lift Cut-out (optional)

Adjustment

With the optional lift cut-out feature, two adjustments are present on the rear of the meter. One setting, labeled "discharge," programs the battery discharge level that the forks will be prevented from raising and is adjustable from "K" to "P." The other setting, labeled "reset," programs the battery level that the meter will reset its memory and indicate a fully charged battery.

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

Hour Meter

2. Remove the tractor cover.

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

3 . Remove the wires from the rear of the

gauge and make careful note of their orientation.

4. Remove the two mounting nuts and slide off the mounting bracket.

5. Remove the gauge by lifting through the top of the tractor frame.

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Battery Discharge Meter The battery discharge meter measures the battery state-of-charge when the key switch is turned ON.

Component Procedures

Toyota Pallet Truck Service Manual Gauges

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 start flashing when the battery is almost fully discharged.

3 . Plug the connector in the meter.

4. Reconnect the battery connector and test

operation.

5. Install the tractor cover.

Inspection If the displays do not illuminate when the key switch is ON, use the voltmeter to check for B+ at pin 6 on connector P9 (with respect to pin 2, B-). If the voltage is not present, use the schematic in the Appendix and trace B+ and Bto the source (battery through the key switch).

If the meter does not log hours, verify that B+ is present on P9-6 when the brake switch is closed (handle is in drive position). If the voltage is not present, use the schematic in the Appendix and trace B+ to the source brake switch.

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

ACAUTION If the battery is replaced with a battery that is not fully charged, the display may provide incorrect 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 connector from the rear of the meter.

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

5. Remove the meter by lifting through the top of the tractor frame.

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

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

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Toyota Pallet Truck Service Manual

Component Procedures

Horn

Installation NOTE: The horn can be sounded with the key switch in the OFF position.

NOTE: The optional battery gate interlock will sound the horn when the gate is not installed and the key switch is turned ON.

Figure 6- 14.

Horn location

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 6-14.

4. Remove the horn mounting bolt.

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1. Attach the horn to the tractor frame and tighten the mounting bolt.

2. Attach the two wires.

3. Reconnect the battery connector and test operation.

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

5. Install the tractor cover.

6. Reconnect the battery connector.

Component Procedures

Toyota Pallet Truck Service Manual Motor Controller

Motor Controller

and putting undue strain on internal connections.

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

Figure 6- 16.

Removing the Motor Controller

Removal Figure 6- 15. Motor Controller Connections

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.

3. Remove any dirt or corrosion from the bus

bar area. Wipe the controller with a moist rag. Permit it to dry before connecting the battery.

4. Make sure the bus bars are tight. Use two wrenches to avoid stressing the bus bars

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

2. Remove the tractor cover.

3. Push the locking tab and disconnect the

PMC connector (control wires) from the motor controller.

4. Disconnect the cables from the Mterminal on the motor controller. Use two wrenches to avoid stressing the bus bars.

See Figure 6-15.

5. Disconnect the bus bars (terminals B+ and B-) on the motor controller. Use two wrenches to avoid stressing the bus bars.

See Figure 6-15.

6. Remove the four hex head cap screws securing the motor controller to the truck frame, and pull the controller out. See Figure 6-16.

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Toyota Pallet Truck Service Manual

Component Procedures

Motor Controller

Installation 1. Secure the motor controller to the truck frame with the four previously removed hex head cap screws. See See Figure 6- 16 on page 6-28.

2. Connect the bus bar on the motor controller terminal B+.

Make sure the bus bar is tight. Use two wrenches to avoid stressing the bus bar.

3. Connect the power cables to the B- and Mterminals on the motor controller. Use two wrenches to avoid stressing the terminals.

See Figure 6- 15 on page 6-28.

4. Connect the drive motor field cables to the F1 and F2 terminals on the motor controller.

NOTE: Torque motor terminal bolts to 10.3 to 11.0 ft. lb. (14 to 15.5 Nm).

5. Connect the PMC connector (controlwires) to the motor controller.

6. Connect the battery connector and turn the key switch ON. 7. Test the operation of the truck.

8. Disconnect the battery connector and turn the key switch OFF.

9. Install the tractor cover.

10. Connect the battery connector.

Programming The motor controller is programmed to factory default settings. You can change certain parameters using the Programmable Maintenance Tool (see "Program Mode" on page 5-13.). You can also copy or "clone" the parameters and options from one motor controller to another (see "Functions Mode" on page 5-17.)

Emergency Reverse Check A wire connected directly between the motor controller and the emergency reverse switch detects a broken wire.

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The emergency reverse check output wire periodically pulses the emergency reverse circuit to check for continuity. If there is no continuity, the motor controller limits the vehicle to 15% speed and indicates Fault Code 2,2. See "Fault Codes" on page 5-11.

Toyota Pallet Truck Service Manual

Component Procedures

Contactors

Contactors Tip Inspection

Figure 6- 17. Severely Pitted Contactor lips

When you inspect contactor tips, follow these guidelines (see Figure 6-17): 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

ACAUTION When repairing contactors, use only Toyota authorized contactor kits.

Figure 6- 18.

Disconnecting Main Contactor

Main Contactor Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires on the X and Y terminals. Note the location for the correct installation later. See Figure 6-18.

discoloration or minor irregularities. This practice produces a surface more susceptible to sticking.

If a cone and crater appear, remove the cone with a file; Do not use sandpaper or emery cloth.

Figure 6- 19.

Removing Contactor Assembly

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Toyota Pallet Truck Service Manual

Component Procedures

Contactors

4. Remove the bolts holding the bus bar and cable to the contactor. Note location for reassembly later. See Figure 6- 18.

5. Remove the lock washer.

5. Remove the two screws holding the contactor to the frame. See Figure 6-19.

Tip Removal

1. Remove the contactor assembly. See "Removal" on page 6-30.

Figure 6-22.

Removing Fixed Contacts

6. Extract the fixed contact from inside the top cover molding. See Figure 6-22.

7. Remove the normally-closed fxed contact

Figure 6-20.

Removing Top Cover

from the top cover assembly. This will let the moving contacts lift up on one side and expose the return springs.

2. Remove the two top cover screws and remove the top cover molding from the magnet frame assembly. Do not lose the return spring. See Figure 6-20.

3. Lift out the moving contact assembly from the magnet frame assembly.

Figure 6-23.

Installing the Fixed Contacts

Tip Installation

1. Install the fxed contacts through the holes in the top cover molding. Make sure the hexagons are properly seated. See Figure 6-23.

Figure 6-2 1 .

Removing Brass Lock Nuts

4. Remove the brass lock nut on each main terminal. See Figure 6-2 1.

00700-CL390-05, 1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Contactors

2. Install the lock washer and M 8 brass lock nut. Torque to 70 to 84 in. lb.

(8 to 9.5 Nm).

ACAUTION

4. Connect one lead of the ohmmeter to the X terminal of the contactor. Connect the other lead to the Y terminal of the contactor.

5. The reading must be 40 to 48 ohms.

Do not over-torque the contactor hardware.

Screws

Return Spring

Magnet Frame Assembly

f b \Vh

r

I

Moving Contact Assembly

Figure 6-25. Installing the Main Contactor

Installation Figure 6-24. Main Contactor Components

3 . Insert the moving contact assembly into

the coil and frame.

4. With the moving contact assembly located in the magnet frame assembly, place the return spring on the moving contact insulator. Make sure the return spring is seated.

5. Arrange the coil with the terminals toward you, and fit the top cover assembly over the moving contact assembly and tighten the top cover screws to 19 to 24 in. lb. (2.1 to 2.7 Nm).

6. Test coil resistance.

1. Secure the contactor to the frame with the two screws removed previously. See Figure 6-25.

2. Secure the bus bar and cable to the contactor with the nuts.

NOTE: Torque contactor terminals to 5.9 to 6.6 ft. lb. (8 to 9.5 Nm).

3 . Connect the wires to the X and Y

terminals. See Figure 6-25.

4. Install the tractor cover.

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

Coil Resistance

NOTE: If the contactor is already removed from the truck, skip 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.

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Component Procedures

Toyota Pallet Truck Service Manual Control Handle

Control Handle Models 7HBW30 and 7HBE30/40 Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

ACAUTION Note the position of cable tie straps holding harnesses and cables. When reassembling, attach new cable tie straps in the same locations.

Figure 6-27.

Loosening Jam Nut

6. Loosen the jam (top) and adjusting (bottom)nuts on the handle return spring until the tension is relieved. See Figure 6-27.

Figure 6-26. Control Handle Harnesses

3. If installed, remove the manual coast lever and disconnect the pull rod.

4. Remove the handle cover to access the handle harnesses. See Figure 6-26.

5. Disconnect the control handle harness at JP5, JP6, and JP2. See Figure 6-26. Cut the cable tie straps holding the harness to the frame.

Figure 6-28.

Detaching Handle Return Spring

ACAUTION Before removing the nut in the next step, make sure you are not under the handle. When the nut is removed, the handle will fall down.

7. Remove the cable tie straps holding the motor cables to the weldment. Remove the nut holding the bottom of the handle return spring seat weldment. See Figure 6-28. Remove the bolt.

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Toyota Pallet Truck Service Manual

Component Procedures

Control Handle 8. Remove the remaining four socket head

cap screws holding the handle assembly to the drive unit.

9. Carefully remove the handle.

Installation 1. Secure the handle assembly to the drive unit using the six socket head cap screws you removed earlier (after inserting the manual coast pull rod into actuator assembly). Do not tighten until the last screw is in position.

2. Thread the handle harnesses through the handle base and leave disconnected.

3. Put the washer on the spring rod, then the spring on the push rod.

4. Install the mounting bolt. Install locking nut on the bolt and secure.

5. Raise the handle and adjust the handle return spring. See "Return Spring Adjustment" on page 6-34.

6. Connect the handle harness connectors.

7. Install the handle cover.

8. Install the cable tie straps on the handle harness and drive motor cables, in their original locations.

9. Connect the battery connector and turn the key switch ON. 10. Test the operation of the truck.

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

12. Install the tractor cover.

13. Reconnect the battery connector.

Return Spring Adjustment Adjust the preload so that the handle will return to full vertical position when released from any position.

1. Loosen the jam (top) nut.

2. Tighten the adjusting (lower) nut until the control handle returns to the vertical position when released from any position.

(Do not overtighten).

Models 7 H B C 3 0 / 4 0 and 7TB50 3-Position Handle Design Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

ACAUTION Note the position of cable tie straps holding harnesses and cables. When reassembling, attach new cable tie straps in the same locations.

3. Remove the handle cover to access the handle harnesses.

4. Disconnect the control handle harness at JP5, JP6, and JP2. Cut the cable tie straps

holding the harness to the frame.

5. Remove the six socket head cap screws holding the handle assembly to the drive unit.

6. Carefully remove the handle assembly.

Installation 1. Secure the handle assembly to the drive unit using the six socket head cap screws you removed earlier. Do not tighten until the last screw is in place.

2. Thread the handle harnesses through the handle base.

3. Connect the handle harness connectors.

4. Install the handle cover.

5. Install the cable tie straps on the handle harness and drive motor cables, in their original locations.

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

7. Test the operation of the truck.

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

9. Install the tractor cover.

10. Reconnect the battery connector.

3. Tighten the jam (top) nut into place after the handle is adjusted.

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Toyota Pallet Truck Service Manual

Component Procedures

Control Handle Switches

Control Handle Switches

NOTE: YOU can access the emergency reverse switch also. (On 7HBW30 and 7HBE30

4. To access the switch mounting nuts and washers, remove the screws that hold the switch bracket to the cover.

@ Directional 8 p4 & Switches

8

Figure 6-29. Control Handle Cover Assembly

NOTE: Model 7HBC30/40 and 7TB50 control handles are provided in a fxed-position design with the brake levers located within the handle recesses.

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

2. From the underside, remove the four socket head cap screws from the handle cover assembly. See Figure 6-29.

Figure 6-3 1 .

Control Handle (Shown Disassembled)

5. To remove the two directional switches, remove the throttle potentiometer bracket covering these switches. See Figure 6-31.

6. Identify wire placement.

7. Using no larger than a 25-watt soldering iron, unsolder the wires to the switch.

8. Remove the mounting nut and washer, noting the position of the washer.

9. Remove the handle yoke covers to access the jog switches. See Figure 6-30.

10. Disconnect the switch wire connectors and remove any wire ties.

11. Remove the jog switches from the mounting location.

Installation 1. Identify wire placement.

Figure 6-30. Control Handle (All Covers Removed)

3. For access to the horn, lift, lower, and bypass switches, lay open the cover containing the switches. See Figure 6-30.

00700-CL390-05, 1 5 March 2005

2. For the horn, lift, lower switches, attach each switch to the mounting bracket with a washer and mounting nut.

3. Using no larger than a 25-watt soldering iron, solder wires to the switch body.

4. Attach the mounting bracket to the handle cover with the screws removed previously.

6-35

Component Procedures

Toyota Pallet Truck Service Manual Control Handle Switches

5. Mount the jog switch assembly in the handle. Secure the assembly with the two screws removed previously in the Removal instructions.

6. Reattach the wire connectors and secure with wire ties.

7. Install the two directional switches, then install the throttle potentiometer bracket covering these switches.

8. Reattach the handle cover assembly.

9. To adjust directional switch settings, loosen the switch mounting bracket screws and move the bracket to position the switches. See Figure 6-33.

10. Check directional travel by rotating the control assembly handle slowly in both directions. Verify that the throttle potentiometer is centered in position. The amount of rotation should be the same in both directions, before the drive motor starts turning. See "Test/Adjustment" on page 6-37.

1 1 . Reattach the control handle yoke covers.

12. Reconnect the battery connector and turn the key switch ON. Test the control handle switch functions.

13. Return the truck to service.

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Toyota Pallet Truck Service Manual

Component Procedures

Throttle Potentiometer

Throttle Potentiometer

Loosen the nut on the potentiometer shaft.

See Figure 6-33..

The throttle potentiometer is a two-wire resistive throttle that connects the pot wiper pin (PMC-16) and the pot low pin (PMC-14). Zero speed corresponds to 0 ohm and full speed corresponds to 6,500 ohms.

Test/Ad justment 1. Turn the key switch OFF and disconnect the battery connector.

2. Jack and block the truck (see "Jacking Safety" on page 2-11).

3. Remove the arm cover plate from the

underside of the handle/arm assembly by removing the three mounting screws.

4. Disconnect handle harness connector JP6 at the bottom end of the handle prior to adjustment. This will ensure that feedback from other circuitry in the truck will not change the ohmmeter readings.

5. Remove the four screws from the underside of the switch cover assembly.

Remove the cover to access the throttle potentiometer. See Figure 6-32.

Figure 6-33: Throttle Potentiometer

7. Connect the ohmmeter to pins VR-2 and VR-4. Measure the potentiometer

resistance while rotating the potentiometer body until the ohmmeter reads as close to '0' ohms as possible. Retighten the potentiometer shaft nut.

8. Engage the potentiometer gear with the Actuator Cam Assembly Gear.

9. 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 the two directions. Record the maximum resistance value in the two directions. In either direction, the resistance value must be 6,500 + 500 ohms. In addition, the difference between the two readings must be 300 ohms or less.

Figure 6-32: Control Handle Switch Cover

6. To electrically center the potentiometer,

place the throttle in the neutral position.

10. To determine the ideal potentiometer

position, add the previously recorded readings and divide that result in half.

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Component Procedures

Toyota Pallet Truck Service Manual Throttle Potentiometer

(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 + 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 potentiometer from moving in the bracket.

12. Reconnect handle harness connector JP6 at the bottom end of the handle.

13. Reattach the switch cover assembly to the control handle with the four screws previously removed.

14. Reconnect the battery connector.

15. Test the operation of the truck.

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

17. Install the tractor cover.

18. Reconnect the battery connector.

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Toyota Pallet Truck Service Manual

Component Procedures

Brake

2. Remove the tractor cover.

3. Remove the control handle.

Brake Models 7HBW30 and 7HBE30/40

ACAUTION Permit the brake to cool completely before servicing.

ACAUTION Do not stick any obiects in the drive motor fan.

4. Remove the 3/4-16 nut holding the brake drum to the armature shaft.

5. Loosen the set screw holding the spring screw in place and back out the spring screw.

6. Remove brake rod.

7. Remove the clevis pin holding the 1 lever to the spring assembly.

Springs

Figure 6-34. Brake Adjustment

Adjustment 1. Move the handle down to a 45" angle.

2. Loosen lock nuts on each side of the brake rod. See Figure 6-34.

3. Adjust the brake nut until the brake is fully off.

Bolts

Figure 6-35. Brake Shoes and Springs

8. Remove the brake drum. It may be necessary to use a puller.

9. Remove the shoe springs. See Figure 6-35.

4. Tighten the lock nuts on the two sides of the brake rod.

10. Remove the brake shoes. See Figure 6-35.

5. Adjust the spring screw if necessary. See Figure 6-34. The compressed length of spring when brakes are on (handle vertical) must be 1.94 in. (49 mm).

12. Remove the brake assembly.

NOTE: Stopping distance must be measured with a rated load. The vehicle must stop within approximately 6 ft. (1.83 m).

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

00700-CL390-05, 1 5 March 2005

11. Remove the five bolts holding the brake assembly to the drive motor assembly.

Installation 1. Install the brake using the five mounting bolts to the drive motor assembly. Apply thread-locking compound (P/N 00590-0 1931-71) to the mounting bolts. Torque bolts to 13 ft. lb. (17.6 Nm).

Component Procedures

Toyota Pallet Truck Service Manual Brake

2. Install the clevis pin holding the lever to the spring assembly using a new cotter pin.

3. Install the brake shoes.

4. Install the shoe springs.

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

2. Remove the tractor cover.

6. Install the control handle.

3. Disconnect the brake cable at the brake end by removing the spring and clevis pin.

See Figure 6-36.

7. Adjust the brake. See "Brake" on page 6-39.

4. Remove the brake cable from the cable mount.

8. Test operate the truck.

5. Disconnect the handle harness (JP6).

6. Remove the control handle by removing the six screws under the handle mount.

5. Install brake drum using the 3/4-16 nut.

Models 7HBC30/40 and 7TB50 (With Fixed-Position Handle)

Nut

Figure 6-37.

Figure 6-36.

Brake Adjustment

Brake Drum With Control Handle Removed

7. Remove the 3/4-16 nut holding the brake drum to the armature shaft. See Figure 6-37.

Adjustment 1. Loosen the adjusting nut on the brake adjustment. See Figure 6-36.

2. Squeeze one of the brake handles approx.

75% closed.

3. While holding the brake in position, turn the brake adjusting nut until the brake contacts the brake drum. See Figure 6-36.

4. Tighten the lock nut securely against the bracket. See Figure 6-36.

5. Release the brake handle.

6. Test the brake.

NOTE: Use a maximum rated load when you measure the stopping distance. The truck must stop within approx. 6 ft.

(1.83 meters).

Figure 6-38.

Brake Puller

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Toyota Pallet Truck Service Manual

Component Procedures

Brake

8. Remove the brake drum. It may be necessary to use a puller. See Figure 6-38.

5. Install the control handle. See "Control Handle" on page 6-33.

6. Connect the handle electrical harness (JP6).

7. Insert the brake cable into the cable mount. See Figure 6-41.

Figure 6-39.

Brake Shoes and Springs

9. Remove the shoe springs. See Figure 6-39.

10. Remove the brake shoes.

11. Remove the five bolts holding the brake assembly to the drive motor assembly.

Figure 6-4 1 .

Brake Cable and Related Components

8. Connect the brake cable clevis to the brake arm using the clevis pin and brake arm return spring.

12. Remove the brake assembly.

Nut

9. Adjust the brake. See "Brake" on page 6-39.

10. Install the tractor covers.

11. Connect the battery connector and turn the key switch ON. 12. Test the operation of the truck.

Figure 6-40.

Brake Drum With Control Handle Removed

Installation 1. Secure the brake assembly to the drive motor assembly using the five mounting bolts. See Figure 6-39.

2. Install the brake shoes.

3. Install the shoe springs.

4. Install the brake drum using the 3/4-16 nut. See Figure 6-40.

00700-CL390-05,1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Motors, General

you must take this into account when considering brush replacement.

Motors, General

2. Check brush spring tension. See "Motor Brush Spring Tension" on page 6-43.

-

Figure 6-42.

BRUSH

Motor Brush, Typical Location

Motor Brushes Conduct a partial inspection of the 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 up and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment.

Inspection 1. Inspect the brushes for wear and for correct contact with the commutator. See Figure 6-42. Record the level of wear on the brushes. This history will give you an indication of whether a brush must be changed or if it can wait until the next inspection. Refer to page 6-43 for acceptable brush length and general motor information.

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore,

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 as 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.

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 replacement 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, 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 until they seat against the sandpaper.

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Component Procedures

Toyota Pallet Truck Service Manual Motors, General

4. Rotate the armature until the face of the brushes are contoured to match the curve of the commutator.

scale directly to the spring. See Figure 6-43.

5. Remove the sandpaper.

12. Attach a 5 lb. (2.27 kg) spring scale to the leather loop.

6. Blow any dust out of the motor with clean, compressed air at a maximum of 30 psi (207 kPa).

13. While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates.

Motor Brush Spring Tension

14. When the paper strip starts to move freely, the spring scale will read the spring brush tension.

15. Refer to table below for correct spring tension.

Scale

Minimum Brush Length

Motor Drive Motor

0.62 in.

(15.7 mm)

Spring Tension

40 to 6 5 oz.

(1120 to 1820 gm)

16. Repeat steps 3 thru 9 for the remaining brushes. If tension is not within the range given for cmy brush, replace the complete set of springs.

Commutator

P u l l Paper i n Direction o f Rotation

Figure 6-43. Motor Brush Spring Tension lnspection

NORMAL UNDERCUT

High Mica

Inspection 7. Turn the key switch OFF, and disconnect the battery connector.

8. Remove the tractor cover.

HIGH MICA

9. Slide the brush up slightly in its holder.

10. Insert a paper strip between the brush face and the commutator.

11. 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

00700-CL390-05,1 5 March 2005

Figure 6-44. Mica Undercutting

Inspection Inspect the commutator for surface condition and high mica. Most armatures have the mica

Component Procedures

Toyota Pallet Truck Service Manual Motors, General

undercut. If the armature on your motor does not, do not attempt to cut it.

The commutator must be smooth and clean to provide m&mum 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.

Table 6-3.

Good commutation will be indicated by a dark brown polished commutator and an evenly polished brush wearing surface.

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, remove the motor for servicing

Commutator Surfaces

satisfactory results for long periods of time. This condition can appear in alternating bars a s shown or every 3rd or 4th bar, etc. This is related to the winding design of the armature. Difficulty is caused by split windings crossing in the same

by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

Commutator Machining

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Toyota Pallet Truck Service Manual Motors, General Table 6-3.

Commutator Surfaces

Condition-Exa Commutator

corrective action should have been taken.

coil, riser bars, or equalizer connections.

not corrected, will result in scored commutator.

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

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Motors, General

undercutting requires special equipment at a motor rebuilding facility.

Electric Motor Tests Motor Types

Terminal Stud Flat Motor Cable Securing Nut

j *c

Shunt-Wound or Series-Wound Motors Shunt-Wound Motor

Liber

Stud

Nut

Series-Wound Motor Figure 6-45. Motor Terminal Nuts

Terminal Nuts When 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 nut to avoid twisting the stud. Check these torques each time you check motor brushes.

Figure 6-46.

Motor Circuits

See Figure 6-46.

Table 6-4.

Terminal N u t Torques

A shunt-wound motor, such as the drive motor, has four external connections: two armature (A) and two field (F).

A series-wound motor, such as the lift motor, has only two external connections because the armature and field windings are connected internally.

NOTE: Shunt-wound and series-wound motors for European markets may have the field connections labeled (E)instead of (F).

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:

Bad brushes or brush springs

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Toyota Pallet Truck Service Manual

Component Procedures

Motors, General

A broken wire in the field or armature winding A loose or bad connection See Figure 6-46.

1. Isolate the motor from the truck circuit by removing the power cables. Use two Table 6-5.

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. See Table 6-5.

Motor Resistance Measurements

3. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor.

lead to an unpainted surface of the motor housing. Set the ohmmeter to the highest scale.

4. If an open circuit is found in a series-wound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

If the ohmmeter reads resistance of less than 100,000 ohms, the motor is grounded. Clean, repair or replace the motor as necessary.

Grounded Motor Test In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused 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 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 megohmmeter or a digital ohmmeter to a motor terminal and the other

00700-CL390-05, 1 5 March 2005

Short-circuited Winding A short-circuited winding is one in which the insulation on the field or armature has broken down at two or more points. The breakdown creates a low resistance path, permitting 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 an 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 operating faster than normal overheating blowing a power fuse severe burning or discoloring on one or two commutator segments every 90" of rotation

Component Procedures

Toyota Pallet Truck Service Manual Motors, General

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 at a motor rebuilding facility.

Short-circuited Armature A short-circuit in the armature will cause heating, which will probably result in burning of:

armature coil brush wires commutator segments Visual inspection may reveal this condition.

Positive determination of a short-circuited armature requires special equipment at a motor rebuilding facility.

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Toyota Pallet Truck Service Manual

Component Procedures

Drive Motor

Drive Motor

rotate the drive unit for access to all seven mounting plate bolts. Remove the bolts.

ACAUTION

Removal 1. Turn key switch OFF and disconnect the

battery connector.

2. Remove the tractor cover.

Due to the weight of the drive motor and the attached components, it is recommended that you use a hoist to lift the motor from the truck.

3. Remove the control handle assembly.

4. Remove the brake assembly from the top of the drive motor as described on page 6-39.

Drive Motor Mounting Bolts (7)

5. Unscrew the brake switch wires. See "Brake Switch on page 6-16.

Pinion Gear Figure 6-47.

Drive Unit Mounting Plate Bolts

6. Remove the four hex head nuts and drive motor power cables. Use two wrenches to avoid twisting the motor stud.

7. Remove the hex head bolts securing the mounting plate to the main case of the drive unit. See Figure 6-47. Use a steel jack handle in the control handle frame to

Figure 6-48.

Drive Unit, Pinion Gear

8. Lift out the drive motor, control handle frame, and drive unit mounting plate.

9. Remove pinion gear lock nut and pinion gear. Remove the seven mounting bolts securing the motor to the drive unit mounting plate. See Figure 6-48.

10. Remove the bolts mounting the control handle frame to the drive motor. Separate the motor from the handle frame.

Installation 1. Position the control handle frame on

brush end of drive motor and attach with four hex head cap screws. Apply thread-locking compound (P/N

00700-CL390-05, 1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Drive Motor

00590-0 1931-71) and torque to 25 to 30 ft. lb. (35 to 42 Nm). See Figure 6-49.

3. Install pinion gear and lock nut on armature shaft. Torque to 50 ft. lb.

(67.8 Nm).

4. Using a gasket scraper, remove any gasket material from the mating surfaces of the drive unit mounting plate and main case.

5. Apply a coating of gasket compound (P/N 00590-00438-71) to the drive unit case and drive unit mounting plate.

6. With a suitable hoist, position the assembled motor and mounting plate on the drive unit. Install hex head cap screws and torque to 50 ft. lb. (67.8 Nm).

Figure 6-49.

Decal on Mounting Plate

When installing the hex head bolts that secure the mounting plate, torque the hex bolts to the specified 25 to 30 ft. Ib. (35 to 42 Nm). Failure to torque these bolts properly may cause the braking and steering to fail. See the decal above and on the mounting plate on the truck.

7. Attach power cables with four hex head bolts. Torque to 100 to 120 in. lb. (11.2 to 13.6 Nm). Use a second wrench on the stud terminal securing nut to avoid twisting the motor stud. See "Terminal Nuts" on page 6-46.

8. Reattach the brake switch and wires.

9. Reattach brake and brake linkage and adjust as described on Page 6-39.

10. Install control handle.

11. Connect wiring harness connectors and install new cable tie straps in original locations from which they were removed.

12. Before testing operation, move handle from extreme left to right and back several times. Check for any wire and cable interference. Repair or adjust as necessary.

13. Reconnect battery connector.

14. Test operation.

15. Disconnect battery and install tractor cover.

Figure 6-50.

Oil Seal Washer Location

2. Position the drive unit mounting plate on the opposite end of motor and secure with seven hex head cap screws. Note: Longer cap screws are used at two locations [A].

Install oil seal washers at four locations [B].Torque to 120 to 150 in. lb. (13.5 to 16.9 Nm).

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Toyota Pallet Truck Service Manual

Component Procedures

Drive Motor

Drive Motor Data Lubrication

None required. Sealed ball bearings are used at the two ends of the motor.

Armature Test

These armatures have standard winding connections and can be tested on a growler using a metal strip or hacksaw blade to locate shorted windings.

Commutator

Replace the armature when the commutator has worn to the minimum diameter of 2.9 in. (73.0 mm).

Brush Replacement

Replace brushes when they have worn to the minimum length of 9/ 16 in. (14 mm).

Spring Tension

Check that the spring tension of new brushes is 20 oz. (568 grams).

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Component Procedures

Toyota Pallet Truck Service Manual

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Component Procedures

Drive Unit

Drive Unit Removal 1. Lower the forks. Turn the key switch OFF and disconnect the battery connector.

Remove the tractor cover.

2. Remove the drive unit fill plug (Figure 6-51) and drain plug (Figure 6-53).

Permit the gear oil to drain.

Use extreme care when 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 2-8.

Figure 6-53.

Figure 6-5 1 .

Drive Unit Fill Plug

Drive Unit Drain Plug

4. Remove the control handle assembly.

5. Unscrew the brake switch wires. See "Brake Switch on page 6-16.

6. Remove the four hex head nuts holding the drive motor power cables. Use two wrenches to avoid twisting the motor stud.

7. Remove the control handle assembly. See "Control Handle" on page 6-33.

8. Remove the brake assembly from the top of the drive motor as described on page 6-39.

Figure 6-52. Jacking Tractor

3. Jack the truck and block the frame. See Figure 6-52.

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Component Procedures

Toyota Pallet Truck Service Manual Drive Unit

9. Unscrew the brake switch wires. See "Brake Switch on page 6-16.

Figure 6-54.

14. Remove the hex head bolts securing the drive unit plate to the main case. See Figure 6-54.

Drive Unit Mounting

10. Remove the four hex head nuts holding the drive unit to the main case cover. See Figure 6-54.

11. Remove the socket head cap screws which secure the drive unit to the frame. See Figure 6-54.

12. Secure hoisting straps through the control handle frame. Remove the drive unit, drive motor, and control handle frame using a hoist with at least one-ton capacity.

13. To separate the drive unit from the drive motor, you must first separate the drive unit plate from the drive unit main case.

Figure 6-55.

Drive Unit mounting to Drive Motor

15. Remove the pinion gear nut and pinion gear from the underside of the drive unit plate. Remove seven hex head bolts mounting the motor to the drive unit plate.

See Figure 6-55.

Disassembly 1. Remove the six hex head cap screws 1291 which secure the cover plate [4]to the main case [3]of the drive unit for access to the gear assembly. Refer to Figure 6-56 for numbers in [brackets].

2. Remove the lock nut [24]from the wheel drive shaft [8].Use a suitable press to remove the wheel shaft assembly from the case.

3. Remove the spiral gear and bearing assembly.

4. Remove the lock nut 1221 from the helical gear [I].Use a suitable press to remove the pinion shaft assembly from the case.

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Toyota Pallet Truck Service Manual Drive Unit

5. Remove the helical gear and bearing assembly from the case.

LEGEND: 1. Helical Gear and Pinion Set 19. Shim 3.5 OD 2. Spiral Gear and Pinion Set 20. Shim 3.5 OD 3. Main Case

21. Shim 3.5 OD

4. Cover Plate

22. Lock Nut, 3/4-16

5. Bearing Filler Plug

Ring Set--Kit

6. Hex Plug

Lock Nut, 1 3/8-18

7. Ball (341, 1 / 2 dia.

Ball (351, 9/16" dia.

8. Drive Wheel Shaft

N/A

9. Ring

Seal--Oil

10. Pipe Plug

Vent Plug

11. Bearing Cup/Cone

Hex Head Cap Screw

12. Bearing Cup/Cone

N/A

13. Bearing Cup/Cone

Flat Washer

14. Shim 2.0 OD

Grease Fitting

15. Shim 2.0 OD

Grease Fitting

16. Shim 2.0 OD 17. Shim 2.0 OD

Spirol Pin 35. N./A

18. Shim 3.5 OD

Figure 6-56.

Drive Unit, Exploded View

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Drive Unit

Assembly NOTE:

Refer to Figure 6-56 for numbers in [brackets].

1. To determine the correct shim pack 114-171: a. Press the bearing cone [ l l ]on the pinion shaft 121. b. Place the pinion, bearing cone, and matching bearing cup on a flat surface to check the total length of the bearing assembly and pinion head. c. Locate the Mounting Distance [MD] stamped on the housing. d. Locate the Setting Distance [SD] etched on the pinion head. e. Subtract the total length of the pinion head assembly and Setting Distance from the Mounting Distance. This will be your required shim pack [14- 171.

MD - (Length + SD) = shim 2. Place the shim pack 114-171 in the case [3] and draw the bearing cup into position.

3. Place the case [3]in a fabricated assembly base and press the remaining bearing cup [1 11 into the case.

4. Insert the pinion shaft [2]through the bottom of the case [3]and position it in place.

10. Prevent the helical gear [ l ]from turning by inserting a 1/8 in. bolt through the pipe plug hole [28].Engage the bolt with gear teeth.

11. Place the spiral gear [2]into position.

Check the backlash while you press the gear down into the bearing cup [ 121. The required backlash is 0.003 to 0.005 in.

(0.076 to 0.127 mm).

12. Add to or subtract from the shim pack [18-2 11 to achieve the correct backlash.

Check the tooth pattern. See "Tooth Pattern of Drive Unit" on page 6-57.

13. Press the bearing cup [13]in the case.

Place the bearing cone in the cup, and press the seal [27]into the case.

14. Insert the wheel drive shaft [8]through the seal and bearing while you align the spline of the shaft with the spiral gear [2].Press the shaft through until it is seated.

15. Install the lock nut 1241 and torque to 55 ft. lb. (77 Nm) and obtain a setting of 0.000 to 0.001 in. (0.000 to 0.025 mm) preload. Clean and apply LoctiteB 271 thread-locking compound before assembly.

16. Place the complete drive wheel assembly on the wheel drive shaft.

6. Place the helical gear [ l ]on the spline of the pinion shaft 121.

17. Install cover plate (with '7'"visible). Apply sealant (85 gram tube P/N 00590-04851-71 or 300 ml cartridge P/N 00590-04852-71) in continuous bead around all holes and perimeters of mating parts. Use six hex head cap screws [29] and lock washers [26].Torque to 18 ft. lb.

(25.2 Nm).

7. Install and tighten the lock nut [22]to adjust the end play of the pinion shaft (0.000 to 0.002 in.) (0.000 to 0.050 mm).

18. Install the hex plug 161, pipe plug [lo],and vent plug 1281 into the unit using anti-seize compound (Loctite #565).

5. Press the bearing cone [ l11 into place in the main case 131. Permit approx. 0.005 in.

(0.127 mm) end play.

8. Press the bearing cone 1121 on the spiral gear 121.

9. Place the shim 118-211 (approx. 0.020 to 0.030 in.) (0.508 to 0.762 mm) in the bearing cup bore and then insert the bearing cup [ 121 in place. The cup must be a slip fit. Tap it in place with a soft face hammer.

19. Install the drive motor.

Checking the Gears 1. Clean the pinion and spiral gear [2].Apply a small amount of red lead on the teeth of the pinion gear.

2. Rotate gear several times to right and left.

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Toyota Pallet Truck Service Manual

Component Procedures

Drive Unit 3. Check the tooth contact pattern on the spiral and pinion gear. See 'Tooth Pattern of Drive Unit" on page 6-57.

TOOTH PATTERN ON RING GEAR CONCAVE FLANK DRI WEN CONCAVE FLANK

CONVEX FLANK

Tooth Pattern of Drive Unit Mount the gear sets according to the instructions in this chapter. Adjust the shim packs to the correct tolerances. Adjust incorrect tooth patterns as shown in the chart below; the degree of change depends on the position of the patterns on the teeth.

CORRECT PATTERN

BY CHANGING THE SHIMS IN THE DIRECTION SHOWN

BY THE ARROWS

DRI VI NG CONVEX FLfiNK

No Adjustment Needed J

\d 'l

IDEAL PATTERN

PATTERN AT TIP

PATTERN AT ROOT

TOE PATTERN

H E E L PATTERN

Figure 6-57.

Drive Unit Gear Tooth Pattern

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Component Procedures

Toyota Pallet Truck Service Manual Drive Unit

Installation

ACAUTION

8. Install the six socket head screws in the steering bearing. Apply thread-locking compound to the screws and torque them to 80 ft. lb. (108 Nm). See Figure 6-59.

Be sure the key switch is OFF, and the battery connector disconnected before you begin.

Figure 6-59.

Drive Unit Mounting

ACAUTION Figure 6-58.

Drive Unit Mounting to Drive Motor

1. Position the drive unit mounting plate on the opposite end of motor and secure with seven hex head screws. Torque to 120 to 150 in. lb. (13.5 to 16.9 Nm).

See Figure 6-58.

2. Install pinion gear and lock nut on armature shaft and toraue to 50 ft. lb.

(67.8 Nm). See Figure 6159.

Do not remove the hoist until the cap screws are in place and torqued to 80 ft. Ib. (1 08 Nm).

9. Remove the hoist and install the brake. e See "Brake" on ~ a e 6-39.

A

-

10. Mount the control handle.

11. Connect the wiring harness.

3. Using a gasket scraper, remove any gasket material from the mating surfaces of the drive unit mounting plate and the main case.

4. Apply a generous coating of gasket compound (P/N 00590-00438-71) to the drive unit case and the drive unit mounting plate.

5. With a suitable hoist, position the assembled motor and mounting plate on the drive unit. Install hex head screws and torque to 50 ft. lb. (67.8 Nm).

See Figure 6-59.

Figure 6-60.

6. Using the hoist, lift the drive unit, drive motor, and control handle frame into place on the truck frame.

12. Connect the drive motor cables. Torque 100 to 120 in. lb. (11.2 to 13.6 Nm). Usc second wrench on the stud terminal

Drive Unit Drain Plug

7. Align the drive unit to the truck frame.

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Toyota Pallet Truck Service Manual

Component Procedures

Drive Unit

securing nut to avoid twisting the motor studs.

13. Attach the brake switch wires. See "Brake Switch" on page 6- 16.

Drive Housing Lubrication Gear Oil Level

14. Install drain plug. See Figure 6-60. Make sure the drive unit is filled to the correct level with gear oil. Install fill plug. See Figure 6-61.

15. Reconnect the battery connector and turn the key switch ON. 16. Check the controls for correct operation.

-igure 6-62.

Drive Unit Level Plug

1. Remove the level plug. See Figure 6-62.

2. Check oil level. When truck is level, the oil must be up to the bottom of the level plug opening.

3. If necessary, add the specified oil through the plug opening, but do not overfill.

4. Install the level plug securely.

Figure 6-6 1 .

Drive Unit Fill Plug and Vent Plug

Drive Unit Vent Plug Make sure the drive unit vent plug is clean and open to keep pressure from building up in the housing. Extra pressure could force lubricant out of the shaft seals. See Figure 6-61.

Cleaning 1. Remove the vent plug from the top cover of the drive housing. See Figure 6-61.

2. Wash it in a suitable cleaning solvent.

3. Dry it with compressed air to make Sure it is not clogged.

Figure 6-63.

4. Install the vent plug and tighten it

Changing Gear Oil

securely.

Drive Unit Drain plug

1. Remove the drain plug from the bottom of the gear housing cover and permit the oil to drain. See Figure 6-63.

2. Remove and clean the vent plug. See "Cleaning" on page 6-59.

00700-CL390-05, 1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Drive Unit

3. After the oil has drained completely, flush the housing with a suitable solvent and permit it to drain.

4. Install the drain plug. See Figure 6-63.

5. Fill the drive housing with the specified gear oil through the pipe plug opening in the top cover of the transmission. The drive housing will hold 2.9 qts. (2.75 liters) of gear oil. Do not overfill.

Drive Housing Steering Bearing Inspection

Figure 6-64.

Dial Indicator on Deck Plate

Figure 6-65.

Indicator Point on Transmission Cover (A]

The fit of steering (radial) bearings in the drive unit transmission is such that some play is expected. However, as the bearing rings wear, the play may increase. If the play is permitted to become extreme, it will become quite noticeable in the drive unit.

If worn rings are suspected as the cause of excessive play in the drive unit, inspect the drive housing to determine if the bearing rings must be replaced: 1. Jack the tractor of the truck up just enough to permit the drive tire to clear the floor.

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 2-8.

2. Place a magnetic base dial indicator on the deck plate (see Figure 6-64) and position the indicator point on top of the transmission top cover (see Figure 6-65 and Figure 6-66).

Figure 6-66.

Indicator Point on Transmission Cover (BJ

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Toyota Pallet Truck Service Manual

Component Procedures

Drive Unit

3. Adjust the dial indicator to zero then lower the truck to the floor.

4. Note the new indicator reading. If the reading is 0.060 in. (1.5 mm) or less the radial rings do not have to be replaced. ~f the reading exceeds 0.060 in. (1.5 mm) the rings must be replaced. If the reading is between 0.050 and 0.060 in. (1.27 and 1.5 mm) the bearing rings must be checked during future scheduled maintenance visits.

9. Replace the gear oil and replace the fill plug.

Drive Wheel Removal

NOTE: For numbers in [brackets] in the

following instructions, see "Drive Unit, Exploded View" on page 6-55.

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

2. Remove the drive unit fill plug and drain plug and permit gear oil to drain. See Figure 6-6 1 and Figure 6-63.

3. Remove the drive unit as described on page 6-53.

4. Remove the spirol pin 1341 and bearing filler plug [5] (Figure 6-56). Remove 34 (qty)1/2 in. steel ball bearings [7]and 35 (qty)9/16 in. steel ball bearings 1251 through the filler plug opening. Separate the ring from the main case, then remove the ring set 1231.

Installation 5. Install the bearing four-piece ring set 1231.

6. Insert 34 (qty) 1 /2 in. steel ball bearings [7]and 35 (qty)9/ 16 in. steel ball bearings [25]through the filler plug opening.

Alternate 1 /2 in. and 9/ 16 in. steel balls during installation.

7. Use a hoist to replace the drive unit. See "Installation" on page 6-58.

ACAUTION Do not remove the hoist until the cap screws are in place and torqued to 80 ft. Ib. (108 Nm).

8. Replace the drain plug.

00700-CL390-05, 1 5 March 2005

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

2. Turn the control handle all the way to the left.

Use extreme care when 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 2-8.

3. Jack and block the truck under the tractor frame. See Figure 6-67.

Component Procedures

Toyota Pallet Truck Service Manual Drive Unit

ACAUTION 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.

Figure 6-68.

Drive Wheel a n d Tire

4. Remove drive wheel mounting bolts. See

Figure 6-68.

5. Remove the drive wheel.

Cushion Tire Replacement Any misalignment of the tire and hub while the tire is being pressed on 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

2. Place a circular ram on the press table.

See Figure 6-69. The length of the ram must be longer than the width of the old tire to permit 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 correct 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 on the wheel. The chamfered edge must always be the leading edge when a tire is pressed on the hub.

5. Center the hub assembly on top of the ram and make sure they mate squarely.

RAM

'

PRESS TABLE

Figure 6-69.

Cushion Tire Replacement

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 on the hub and the old tire off of the wheel. Operate the press slowly for the first few inches of travel because this is the critical step of the operation. If the tire begins to cock, stop the press immediately and realign the

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Toyota Pallet Truck Service Manual Drive Unit

tire. A sharp jar with a soft-headed mallet will usually realign the tire on the hub.

NOTE: If the new tire does not press on with a minimum of 5 tons (68,947 kPa) pressure, 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 drive wheel mounting bolts to 100 ft. lb. (135 Nm).

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual

Component Procedures

Casters

Casters

Figure 6-7 1 . Caster Assembly, Disassembled

3 . Remove the four bolts and washers from the mounting plate. See Figure 6-70.

Figure 6-70.

Removing Caster

Removal 1. Turn the key switch OFF and disconnect

the battery.

Disassembly 1. Remove the caster assembly if required.

2. Disassemble the caster assembly by removing the hex head lock nuts from the two mounting bolts and the larger lock nut from the axle shaft. See Figure 6-71.

3 . Remove the wheel and shims.

Use extreme care when 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. See "Jacking Safety" on page

4. Align the new wheel with the shims on

each side and insert on the axle shaft.

5. Reassemble caster, making sure that the outer mounting bolt spacer is installed before tightening the hex head lock nuts.

2-8.

2. Jack and block the tractor.

The casters are very heavy. Do not place hands under the casters when removing the four bolts.

Figure 6-72. Caster Assembly, Assembled

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Component Procedures

Toyota Pallet Truck Service Manual Casters

Assembly 1. Align the shims on each side of the wheel carrier and insert on the axle shaft.

2. Reassemble caster, making sure that the outer mounting bolt spacer is installed before tightening the hex head lock nuts.

See Figure 6-72.

Figure 6-73.

Securing Caster to Tractor

Installation 3. Fasten the caster assembly to the frame with the four bolts and washers. Do not tighten the bolts yet.

4. Insert the height adjusting shims between the caster assembly and frame. Adjust caster height so that each is flush with the drive tire (or 1/8 in. (3.175 mm) above drive tire). See Figure 6-73.

5. Do not adjust casters higher than 1/8 in.

(3.175 mm) above drive tire or caster may not track correctly. The two casters must contact the floor at all times when testing the truck.

6. Securely tighten the four mounting bolts.

7. Lubricate through the grease fittings.

8. Remove the block and jack.

9. Check truck stability in a forks-trailing direction only with a full-size battery.

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Component Procedures

Toyota Pallet Truck Service Manual Load Wheels

Load Wheels

5. If the bearings are to be reused, insert a

Replacement

6. Install the bearings in the load wheel with the shields facing out.

1. Lift the forks to maximum height and

brass drift pin into each end of the load wheel and knock the bearings out.

block them. See "Jacking Safety" on page 2-8.

Figure 6-76.

Figure 6-74.

Removing Tension Pin

2. With a hammer and pin punch, drive out the tension pin. See Figure 6-74.

Removed Load Wheel and Components

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 load wheel and washers with the holes in the load arm casting.

9. Drive the axle through the load arm casting, load wheel and washers. Make sure the pin hole in the axle aligns with the housing.

10. Install the tension pin.

11. Lubricate the grease fittings.

Figure 6-75.

Removing Axle From Load Arm Casting

3. Drive the axle out of the load arm casting with a hammer and brass drift pin. See Figure 6-75.

4. Push the load wheel out. Note the location of the washers and pin. See Figure 6-76.

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Component Procedures

Toyota Pallet Truck Service Manual Load Wheels Model 7TB50

Load Wheels Model 7TB50

5. Slide the load wheel onto the axle, install the thrust washer then secure with the snap ring.

NOTE: Verify that the snap ring is properly

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

seated into the snap ring groove.

6. Remove the blocking and return the truck to service.

Use extreme care when 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 -8.

2. Jack and block the operator compartment.

See "Jacking Safety" on page 2-8.

3. Remove the load wheels by first removing the external snap ring and thrust washer from the each end of the load axle.

4. Remove the wheel assembly.

5. Support the load axle on blocks to prevent it from dropping a s the fasteners are removed.

6. Remove the four bolts securing the axle to the operator compartment.

7. Remove the load axle from underneath the operator compartment.

Installation 1. Inspect the load wheel axle and snap ring groove for wear. If either area shows signs of wear, replace the axle.

2. Position the load axle under the operator compartment supported on blocks.

3. Apply thread-locking compound (P/N 00590-0 1931-71) to the bolts previously removed, then secure the load axle to the operator compartment. Torque bolts to 30 ft. lb. (40.7 Nm).

4. Inspect the load wheels for wear or damage prior to installation.

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Component Procedures

Toyota Pallet Truck Service Manual Pallet Entry Sliders

Pallet Entry Sliders

Wheel Replacement (Single Pallet) (Optional)

Slider Replacement

1. Raise the forks and block them in the raised position. See "Jacking Safety" on page 2-8.

2. Remove the locknut and bolt from sides of the entry roller bracket. See Figure 6-78.

Use extreme care when the truck is jacked up. Keep hands and feet clear from the 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 truck.

For details, see "Jacking Safety" on page -8.

3 . Replace the roller(s).

4. Insert the bolt through the entry roller bracket and roller. Secure with the locknut.

Figure 6-78:

Figure 6-77.

Replacing Pallet Entry Slider

6000 Ib. Models (Single Pallet) 1. Raise the forks and block them in the raised position. See "Jacking Safety" on page 2-8.

2. Remove the two lock nuts and bolts from the bottom of the entry slider bracket. See Figure 6-77.

3 . Replace the slider.

4. Insert the two 1/4-20 bolts through the entry slider bracket and slider. Secure each bolt with a lock nut. See Figure 6-77

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Pallet Entry Wheel Replacement

Component Procedures

Toyota Pallet Truck Service Manual Fork Height Adjustment

Fork Height Adjustment Upper Bell Crank Adjustment Adjust the lowered fork height at the upper bell crank to make sure that trucks with long-john forks enter and exit pallets correctly: 1. Lower the forks completely. Measure the fork height at the load wheel and in front of the battery compartment. Record the dimensions. Fork height at the load wheel must be between 3-1 /4 in. and 3-5/ 16 in.

(83-84 mm). Fork height at the battery compartment must be set between 3-1 /2 in. and 3-5/8 in. (89-93 mm).

4. Release lift pressure and loosen the bolts until the shim stacks will slide between the lift cylinder clevis and the cylinder support plate.

5. Remove the bolts from one side at a time and insert the shim stack. Replace and tighten the bolts in one side before removing bolts from the other side to insert the other shim stack.

6. Raise the forks and remove blocks. Check fork height to validate the correct slope.

7. Torque bolts to 75 ft. lb. (102 Nm).

8. Readjust the trail fork acentric pin to permit the fork to lower fully at the load wheel.

Lower Bell Crank Adjustment

Figure 6-79.

Location of shim stacks

2. Subtract the battery compartment dimension from the load wheel dimension.

If this answer is negative, add the desired down slope (1/8 in. to 1 /4 in.) to the result to determine the shim stack height to put the forks to the desired slope. If the answer is positive, within the desired slope, leave it alone. If the answer is positive but not within the desired slope, add a 1/8 in. shim to put the forks to the desired slope. See Figure 6-79.

3. Raise the forks. Place blocks under the forks at the battery compartment and the fork tips. Lower the forks until the forks are resting on the blocks. Loosen the bolts that fasten the lift cylinder clevis to the cylinder support plate.

6-70

Figure 6-80.

Fork Height Adjustment at lower Bell Crank

Adjust the lowered fork height for new load wheels at the lower bell crank (Figure 6-80).

1. Lower the forks completely and measure the fork height at the load wheel and in front of the battery compartment. Record the dimension(s).

The fork height at the load wheel must be between 3-1 /4 in. and 3-5/ 16 in.

(83-84 mm). The fork height a t the battery compartment must be between 3-1 /2 in. and 3-5/8 in. (89-93 mm).

2. Remove the hex head bolt that captivates the fork height adjustment eccentric pin.

3. Slide the eccentric pin out 1/2 in. (13 mm). Use a slide hammer to loosen the eccentric pin if necessary.

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Toyota Pallet Truck Service Manual Fork Height Adjustment

4. Rotate the eccentric pin to adjust the fork height. The indicator mark on the pin is the standard setting for the pin.

5. Slide in the eccentric pin and replace the hex head bolt.

6. Raise and lower the forks a few times then measure the fork height at the battery compartment and load wheels. Continue to adjust the eccentric pins until the fork height measurements are correct (see step 1).

7. Adjust the two forks evenly so the forks hit the lower stops at the same time.

To adjust the lowered fork height for worn load wheels: 1. Lower the forks completely. Measure the distance from the floor to the top of the fork at the load wheel. The lowered fork height must be between 3-1 /4 in. and 3-5/ 16 in. (83 to 84 mm).

2. Remove the hex head bolt. See Figure 6-80. Slide the eccentric pin out 1/2 in. (13 mm) and rotate as necessary to adjust the fork height. The indicator mark on the pin is the standard setting for the pin.

3. Make sure that the two wheels are adjusted to share the load equally.

4. Slide in the eccentric pin and replace the hex head bolt.

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual

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Toyota Pallet Truck Service Manual Hydraulic Components

Hydraulic Components General Guidelines To prolong the life of your Toyota pallet truck, adhere to the following guidelines: Keep all fittings and connections tight to prevent leaks. Be careful not to tighten brass fittings too much 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.

When you remove a fitting with a pipe thread, use a sealing compound on the outside of the threads before you reinstall the fitting. (Do not use ~eflon@ tape.) Make sure all parts are clean.

When you install a hose assembly, make sure it isn't 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.

Keep hose clamps tight to prevent hoses from chafing and to avoid leaks.

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Fluid

Hydraulic Fluid Fluid Level To prevent air from entering the lines, the reservoir must be filled and visible to the bottom of the fill plug elbow with the forks fully lowered. Add the specified fluid if necessary.

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

Store and handle hydraulic fluid with extreme care to prevent moisture and foreign matter from entering the hydraulic system.

1. Lower the forks.

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

3. Remove the tractor cover.

Figure 6-82.

Hydraulic Connections

4. Remove one of the lift cylinder hoses from

the fitting at the hydraulic pump. See Figure 6-82.

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.

Hydraulic Unit

Fluid will be under pressure and may spray or splash. Point hose away from body and hold firmly in waste fluid container.

Changing Fluid

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

Contaminated hydraulic fluid is the major cause of hydraulic system failures. Any service equipment, such as containers, funnels and hand pumps, must be kept clean at all times.

Cover them when not in use.

7. Operate the hydraulic pump by pressing

Figure 6-8 1 .

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 connect the lift cylinder hose.

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Toyota Pallet Truck Service Manual Hydraulic Fluid

10. Remove the vent plug and fill the reservoir to the bottom of the filler port with the recommended hydraulic fluid. See "Lubrication Equivalency Chart" on page A-2. Replace vent plug.

11. Connect the battery connector and turn the key switch ON. 12. Raise and lower the forks several times to purge air from the system.

13. Return the forks to the lowest position and recheck the fluid level. Add fluid if necessary.

14. Install the tractor cover.

15. Dispose of waste fluid properly.

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Adjusting Hydraulic Pump Relief Valve Pressure

Adjusting Hydraulic Pump Relief Valve Pressure

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 the relief valve is opening.

5. If the relief valve opens at a lower or higher FEMALE RUN TEE 7/16-20 JIC X 1/8" NPT

RELIEF VALVE

pressure than the specified pressure, adjust the relief valve.

Relief Valve Adjustment 1. Remove the lock nut covering the relief valve adjustment screw.

TO UFT CYLINDERS

~ \, J RESERVOIR

Figure 6-83.

Checking Relief Valve Pressure

The hydraulic system is protected by a relief valve located in the adapter body. See Figure 6-83. The relief valve is set by the manufacturer to open at a specified pressure.

Relief Valve Seitings Table 6-6.

Truck Pressure levels

2. As you depress the lift button, turn the adjusting screw inward to increase the pressure setting or outward to decrease the pressure setting.

3. Monitor the pressure gauge indicator.

After the relief valve is properly set, release the lift button.

4. Reinstall the hex cap.

5. Check the relief valve setting.

6. Lower the forks completely. Turn the key switch OFF. 7. Remove the pressure gauge. Replace the elbow.

8. Turn the key switch ON. Raise the forks.

Inspect all hoses and fittings for leaks.

9. Adjust the lift-limit switch to shut down the pump when the forks reach their upper limit. See "Lift Cut-Out Switch" on page 6- 18.

Removal 1. Clean the surface around the valve.

Check Setting 1. Adjust the lift-limit switch so the switch will not shut the pump down when the forks reach their upper limit.

2. Retract the lift cylinders completely.

Remove the 90" elbow. Install a female tee with a 1/8 in. NPT 0 to 3,000 psi (0 to 20684 kPa) pressure gauge in place of the elbow. See Figure 6-83.

3. Turn the key switch ON. Leave the control handle in the neutral (vertical)position.

2. Disconnect the wires from the terminals on the coil, then loosen and remove the nut. Remove the coil.

3. Using a wrench on the flat surface, loosen and remove the tube subassembly unit.

Remove, inspect, and clean or replace the strainer as required.

Installation 1. Inspect and clean the valve cavity as required.

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Toyota Pallet Truck Service Manual Adjusting Hydraulic Pump Relief Valve Pressure

Do not bend or apply pressure to center stud or hold cartridge body any place but on the flat sides of the subassembly.

2. Confirm that the O-ring and ~ e f l o n @ ring are in position. Apply a small amount of clean grease on the two rings. Verify that the strainer is in position.

3 . Hand screw the subassembly in position and tighten to a maximum of 35 ft. lb.

(49 Nm).

4. Assemble the coil on the spool assembly.

Tighten the nut to a maximum of 5 ft. lb.

(7 Nm).

5. Reconnect the wires to the terminals on the coil.

Check Valve Removal and Installation 1. Remove the check valve from the adapter.

2. Remove the 1/2-20 hex plug from the valve body.

3 . Inspect the ball for pitting or scoring.

Inspect the valve seat for scoring.

4. Reassemble and bleed the pressure line of all air.

To bleed the line, loosen (do not remove or loosen too much) the outlet pressure port fitting and turn the lift motor ON until oil seeps out through the fitting.

5. Turn the lift motor OFF and retighten the outlet pressure port fitting.

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Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Ram

Hydraulic Ram

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

Inspection

3. Using a suitable device, remove battery.

See Page 6-8.

Slight fluid leakage at the seals indicates the hydraulic cylinder seal and/or O-rings are becoming worn. When leakage becomes excessive, disassemble and inspect the complete assembly. Replace any worn or broken components.

Removal Removal of the hydraulic ram(s) requires disconnecting the fork section from the truck.

Be sure to follow the correct jacking and blocking procedures when separating the truck section and fork section.

Use extreme care when 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 2-8.

4. Remove the tractor cover.

5. Jack up and block the truck at the drive wheel end to gain access to the bottom of the truck.

6. Place a jack between the forks under the battery compartment. Jack up and block the fork section to gain access to the lower bell cranks. See Figure 6-84.

7. Lift the fork section to maximum height and block the fork section under the battery compartment.

Figure 6-85.

Removing Lower Bell Crank Pins

8. Remove the lower bell crank pin covers,

then remove the two bell crank pins. Insert a 1/4 in. fine-thread bolt into the pin and connect to a slide hammer to remove stubborn pins if necessary. See Figure 6-85.

Figure 6-84.

Blocking Fork Section For Ram Removal

1. Lower the forks completely.

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Toyota Pallet Truck Service Manual

Component Procedures

Hydraulic Ram

gain access to the hydraulic rams. See Figure 6-87.

In the next steps, the tractor and frame will separate. Use the jack to stabilize the truck.

Figure 6-88.

Figure 6-86.

Disconnecting Upper Clevis Brackets

9. Remove the four hex head cap screws located at the top of the battery compartment housing to disconnect the hydraulic ram clevis from the fork section. see Figure 6-86.

Figure 6-87.

Hydraulic Ram Area, Forks Removed

10. At this time the two sections are disconnected. Move the fork section to

Hydraulic line Connection

11. Remove the hydraulic line from the bottom of the selected hydraulic cylinder. See Figure 6-88.

NOTE: Be prepared to catch hydraulic fluid under each hydraulic cylinder in a suitable container.

Figure 6-89.

Vent Hose Connection

12. Remove the vent line from the top of the cylinder. Remove the vent hose fitting from the lift ram housing. See Figure 6-89.

13. Remove the lower hydraulic ram pin cover then remove the pin and spacer. See Figure 6-90.

14. Remove the upper hydraulic ram pin that secures the ram to the clevis. The pins are

00700-CL390-05, 1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Ram

held in place by the channel on the battery compartment and will remove easily with the fork section disconnected from the truck section. See Figure 6-90.

15. Push the piston completely into the cylinder.

3. Put sealant on the threads of the hose fitting. (Do not use ~ e f l o n @ tape.)

Figure 6-9 1 .

Figure 6-90.

Hydraulic Ram Removal/lnstallation

16. Lift the ram up and out of the tractor frame.

17. Inspect the clevis, pin and associated parts fro wear and/or damage. Replace a s necessary. If they are in good condition, retain them for later installation.

Installation 1. Position the hydraulic ram into the tractor

frame and install the upper hydraulic ram pin to secure the ram to the clevis.

2. Install the lower hydraulic ram pin, placing the ram spacer on the pin before the hydraulic ram then complete installation and secure with the pin cover.

Hydraulic line Connection (Installed)

4. Install the hose fitting (if removed) in the bottom of the hydraulic ram. See Figure 6-91.

5. Connect and secure the hydraulic line at the bottom of the hydraulic cylinder.

6. Install the vent hose fitting if removed. See Figure 6-92.

7. Connect and secure the vent line at the top of the cylinder.

8. Slide the fork section back into position until the clevis makes contact with the mounting plate on the fork frame. Secure each clevis with the four hex head cap screws (two for each ram).

00700-CL390-05, 1 5 March 2005

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Ram

9. Insert the two bell crank pins into the lower bell cranks and fork section then secure with the pin covers.

20. Install the tractor cover.

Figure 6-93.

Figure 6-92.

Hydraulic Vent Hose Connection (Installed)

10. Jack the fork frame between the forks and remove the block(s)under the battery compartment.

11. Lower the fork frame.

12. Jack the tractor end to remove the blocks then lower the tractor end.

13. Using a suitable lifting device, install the battery.

NOTE: Do not connect the battery connector at this time.

Removing Outer Spiral lock Ring

Hydraulic Cylinder Seals Disassembly 1. Remove the lift ram from the truck. See "Hydraulic Ram" on page 6-78.

2. Extend the piston fully from the cylinder.

See Figure 6-93.

3. Remove the outer lock ring. See Figure 6-93.

4. Push the piston back inside the tube at least 3/4 in. (19 mm).

Check the hydraulic reservoir fluid level. If necessary, add fluid; fill to the bottom of the breather cap elbow. See "Lubrication Equivalency Chart" on page A-2.

Connect the battery connector and turn the key switch ON. Lift and lower the forks several times.

Re-check the hydraulic reservoir fluid level. If necessary, add fluid; fill to the bottom of the breather cap elbow.

Lower the forks completely.

Turn the key switch OFF and disconnect the battery connector.

00700-CL390-05, 1 5 March 2005

Figure 6-94.

Removing the Spacer

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Ram

5. Remove the spacer. See Figure 6-94.

Figure 6-95.

8. Carefully pull the rod and head assembly from the cylinder. See Figure 6-96.

Removing Lock Ring from Cylinder Figure 6-97.

6. Remove the head lock ring from inside the cylinder. To make removal easier, push the head assembly into the tube. See Figure 6-95.

7. Remove the sharp ridge from the back corner of the head lock ring groove if necessary.

Remove the Piston Jam Nut

9. Remove the piston jam nut and spin off the piston. See Figure 6-97.

10. Slide the head assembly off the rod at the piston end of the rod.

( Outer Lock Ring IHead Assembly Pi

BmHHMHHHHHHmAHNmHHmHHHHAHM

Figure 6-98.

Figure 6-96.

Rod and Head Assembly Out of Cylinder

Piston Rod Components

11. Remove the old seals and clean the metallic parts thoroughly. See Figure 6-98.

Assembly 1. Lubricate new seals with applicable hydraulic fluid and slide the lock ring, spacer and head lock ring on the rod a t the piston end of the rod.

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

Component Procedures

Hydraulic Ram

2. Slide the head assembly and sleeve on the rod at the piston end of the rod.

3. Install the piston and the piston jam nut on the rod. See Figure 6-99.

5. Install the head lock ring, then pull the rod out to properly seat the head assembly into the head lock ring. See Figure 6-100.

Figure 6- 10 1. Installing the Outer Lock Ring Figure 6-99. Securing Piston Jam Nut

4. Carefully push the rod and head assembly

into the tube. Make sure that the head assembly is installed past the head lock ring groove.

Figure 6- 100. Installing the Head Lock Ring

00700-CL390-05, 1 5 March 2005

6. Install the spacer and outer lock ring. See Figure 6-101.

Component Procedures

Toyota Pallet Truck Service Manual Hydraulic Unit

Hydraulic Unit Draining and cleaning the hydraulic reservoir is important to control the accumulation of condensation and contamination, which 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.

Figure 6-102. Hydraulic Unit

4. Using a suitable lifting device, remove the battery to gain access to the hydraulic unit mounting bolts. See "Battery" on page 6-8.

5. Remove the bolts that secure the hydraulic unit 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 previously removed cap screws.

2. Install the hydraulic lines on the hydraulic unit.

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 only until the fluid is visible at the bottom of the vent plug elbow. See Figure 6-102. Use up to 1.5 quarts (1.4 liters).

Install the vent plug.

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

Connect all wires and cables to the pump motor. The lift motor stud terminal securing nut (top nut) must be torqued to 60 to 84 in. lb. (6.8 to 9.5 Nm) and the motor cable securing nut (bottom nut) to 84 to 108 in. lb. (9.5 to 12.2 Nm). The solenoid stud terminal securing nut (top nut) must be torqued to 35 in. lb. (3.9 Nm).

Connect the battery.

Raise and lower the forks, and check all hoses and fittings for leaks.

9. Lower the forks.

Removal 1. Lower the forks completely.

2. Disconnect the battery. Remove and tag all wires and cables connected to the pump motor. See Figure 6-102.

3. Remove and tag the hydraulic lines from the hydraulic unit.

00700-CL390-05,1 5 March 2005

Toyota Pallet Truck Service Manual

Component Procedures

Hydraulic Unit

10. Check the hydraulic fluid level in the reservoir.

13. Remove the reservoir and properly dispose of the old hydraulic fluid. See Figure 6- 104.

14. After the fluid has drained, flush the inside of the reservoir with a suitable cleaning solvent.

15. Dry the inside of the reservoir with clean, dry compressed air.

Installation 16. Inspect the reservoir O-ring for defects and replace if necessary.

17. Lubricate the O-ring (with applicable hydraulic fluid) and install the O-ring.

See Figure 6-104.

Figure 6- 103. Adapter Cap Screws

Hydraulic Reservoir NOTE: If your truck is supplied with a Haldex ~arnes@ hydraulic unit, the hydraulic reservoir may be constructed of metal or plastic. Refer to the replacement parts manual for the correct part if a replacement is needed.

18. Carefully install the reservoir on the adapter housing and secure with four cap screws. Torque the cap screws to 20 to 25 in. lb. (2.2 to 2.8 Nm).

19. Install the hydraulic unit in the truck. See "Installation" on page 6-84.

Filter Screen

'Spring clip

Removal 11. Remove the hydraulic unit from truck. See "Removal" on page 6-84.

12. Remove the four cap screws that connect the hydraulic reservoir to the adapter housing. See Figure 6-103.

/

Suction Tube

Pump Housing

Figure 6- 105. Pump Housing Components

Filter Screen and Suction Tube 1. Remove the reservoir. See "Hydraulic Reservoir" on page 6-85.

2. With pump assembly inverted, push the spring clip toward the pump housing. See Figure 6-105.

3. Grasp the suction tube with the filter screen and pull out of pump housing.

Figure 6- 104. Removed Reservoir

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

Component Procedures

Hydraulic Unit

4. Clean the filter screen at the bottom of the suction tube with suitable solvent. See Figure 6-106.

5. Install the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-85.

5. From the pump side, blow dry with clean, dry compressed air.

Figure 6- 107. Pump and Adapter Body

Hydraulic Pump Figure 6- 106. Cleaning Filter Screen

Installation 1. Inspect the filter screen and tube for defects and replace if necessary.

Removal 1. Remove the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-85.

2. Lubricate the pump end of the suction tube with hydraulic fluid.

2. With the pump assembly inverted, push spring clip toward the pump housing. See Figure 6- 105.

3. Push the spring clip toward the pump housing. Insert the suction tube through the spring clip and into the pump housing until it stops. See Figure 6-106.

3. Grasp the suction tube with the filter screen and pull out of the pump housing.

See Figure 6-105.

4. If necessary, rotate the suction tube so

4. Remove the eight screws that secure the pump to the adapter body.

that the filter screen is toward the center line of the pump.

Figure 6- 108. Pump Drive Coupling

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Hydraulic Unit

5. Separate the pump from the adapter body.

See Figure 6- 107.

6. Set aside the pump drive coupling to be reused.

Installation 7. Stand the motor assembly on end, with the adapter body facing up.

8. Lubricate the three O-rings and place them between the pump and adapter body.

9. Insert the pump shaft coupling on the end of the motor armature shaft. Fill the coupling cavity with lubricant (P/N 00590-04836-7 1). See Figure 6- 108.

Figure 6- 109. Installing Pump in Adapter

10. Place the pump on the adapter body while lining up the shaft with the coupling. See Figure 6- 109. Rotate if necessary.

11. Secure the pump with the eight screws and torque to 10 to 12 ft. lb. (13.6 to 16.3 Nm).

12. Install the reservoir. See "Hydraulic Reservoir" on page 6-85.

00700-CL390-05, 1 5 March 2005

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual Lift Motor

Lift Motor

2. Remove the two bolts from the end plate that attach the motor to the adapter housing. See Figure 6-110.

General Data Lubrication

None required. Sealed bearings are used a t the two ends of the motor.

Armature Test

These armatures have standard winding connections and can be tested on a growler using a metal strip or hacksaw blade to locate shorted windings.

Commutator

Replace the armature when commutator has worn to the minimum diameter of 1.5 in. (38.1 mm).

Brush Replacement

Replace brushes when they have worn to the minimum length of 1/2 in. (13 mm).

Spring Tension

Check that spring tension of new brushes is 32 to 40 oz. (908.8 to 1136 gm).

Figure 6- 1 1 1 . Separated Reservoir and Motor

3. Separate the motor from the adapter housing. See Figure 6-111.

4. Remove the solenoid from the side of the motor housing to be reused.

Installation

Figure 6- 1 10. Bolts Securing Motor To Adapter

Brush Inspection See "Motors, General" on page 6-42.

Removal 1. Remove the hydraulic unit from the truck.

See "Hydraulic Unit" on page 6-84.

Figure 6- 1 12. Coupling Cavity

1. Stand the pump assembly on end, with the adapter body facing upwards.

2. Set aside the pump drive coupling to be reused. See Figure 6- 111.

NOTE: The coupling is the mechanical connection between the pump shaft and

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

Component Procedures

Lift Motor the electric motor armature shaft. It may have been removed with the motor.

3. Insert the pump drive coupling on the end of the pump shaft. Fill the coupling cavity with lubricant (P/N 00590-04836-7 1). See Figure 6-112.

4. Rotate the pump or motor shaft to make sure the motor shaft fits correctly into the coupling.

Figure 6- 1 13. Indexing Pin

5. Install the new motor on the adapter housing. Rotate further if necessary until the motor contacts the adapter body.

NOTE: An indexing pin on the end of the motor housing fits into a hole in the adapter body. This ensures the motor mounting screws align with the threaded holes in the adapter body. See Figure 6-113.

Figure 6- 1 14. Securing the Motor and Adapter Body

00700-CL390-05, 1 5 March 2005

6. Insert the screws into the motor end plate, through the motor and into the adapter body. See Figure 6-114.

7. Make sure the motor is mating flush with the adapter body and torque screws to 6.3 to 7.4 ft. lb. (8.5 to 10 Nm).

8. Install the solenoid. Torque the mounting screws to 60 to 69 in. lb. (6.8 to 7.9 Nm).

9. Install the hydraulic unit. See "Hydraulic Unit" on page 6-84.

Component Procedures

Toyota Pallet Truck Service Manual Cold Storage Conditioning

Cold Storage Conditioning New Toyota pallet trucks to be used in a cold storage environment are equipped at the factory with cold storage components for cooler and freezer applications exceptforfluids i n the hydraulic reservoir.

ACAUTION When a truck is to be installed in a cold storage environment, change the fluid in the hydraulic reservoir according to the following items.

See "Lubrication Equivalency Chart" on page A-2. for recommended fluids in the hydraulic reservoir and the drive unit.

00700-CL390-05,1 5 March 2005

Toyota Pallet Truck Service Manual

Section A. Appendix

00700-CL390-05, 1 5 March 2005

Appendix

Appendix

Toyota Pallet Truck Service Manual Lubrication Equivalency Chart

Lubrication Equivalency Chart

( + l o "C to +49 "C)

0590-04934-71 (1 quart/0.9 liter) 0590-04840-71 (5 gal./ 18.9 liter)

Exxon Nuto H 4 6 Forsythe AWTH21 5 IS046 Mobil DTE-1 B NOCO NOCOLUBE AW46 Texaco Cygnus 4 6 or HD 4 6

Mobil Aero HFA Texaco Aircraft Hydraulic Fluid 1 5

Shell Tellus T Oil 32

0590-04842-71 Mobil423 or 424 NOCO Torque TDH

Citgo HEP2 (above 30" F only) Exxon RONEX MP or UNIREX N2 Gulf Gulfcrown Grease No. 2 Mobil Grease 77 Phillips Philube 1B and RB Grease Shell Alvania Grease EP2

Table A- 1 .

(10 cartridges per case) 0590-04845-71 (5 ga1./18.9 liter)

Lubrication Equivalency Chart

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual

Appendix

Torque Chart - Standard (Ferrous)

Torque Chart (Ferrous)

- Standard

ft-lbs

ft-lbs

ft-lbs

ft-lbs

ft-lbs

ft-lbs

5/ 16-18

11

8

17

13

25

18

1 1/2-6 1 1/2-12

870 980

650 730

1940 2200

1460 1640

3160 3560

2360 2660

Table A-2.

Torque Chart - Standard "Note: Use "oiled" values for bolts with thread-locking compound

00700-CL390-05, 1 5 March 2005

Appendix

Toyota Pallet Truck Service Manual Torque Chart - Metric

-

Torque Chart Metric

Table A-3.

Torque Chart - Ferrous Metric "Note: Use "oiled" values for bolts with thread-locking compound

Torque Chart - Non-Ferrous Metric Table A-4. *Note: Use "oiled" values for bolts with thread-locking compound

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Decimal Equivalent Chart

Decimal Equivalent Chart

Table A-5.

Decimal Equivalent Chart

00700-CL390-05, 1 5 March 2005

Appendix

Appendix

Toyota Pallet Truck Service Manual Decimal Equivalent Chart

Table A-5.

Decimal Equivalent Chart

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Standard/Metric Conversions

Standard/Metric Conversions

00700-CL390-05, 1 5 March 2005

Appendix

Appendix

Toyota Pallet Truck Service Manual Standard/Metric Conversions

00700-CL390-05, 1 5 March 2005

Toyota Pallet Truck Service Manual Electrical Schematics

Electrical Schematics

00700-CL390-05, 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

METER OPTIONS CONNECTOR

FU3 2 B+ BAJTERY JP10-10HOUR ENABLE

BAnERY GATE INTERLOCK

HOUR METER OPTION

METER OPTIONS CONNECTORS

COMPONENT LEGEND Dl D3

DIODE RLYl COIL SUPPRESSION DIODE HORN FEEDBACK

DAI MODULE FOR SPEED CONTROL DA2 MODULE FOR HORN SUPPRESSION DA3 MODULE FOR METER/MODE CONTROL FU1 FUSE FOR PUMP CIRCUIT 150 AMPS FU2 FUSE FOR DRIVE CIRCUIT 250 AMPS FU3 FUSE FOR CONTROL CIRCUIT 15 AMPS

M D MOTOR DRIVE MP MOTOR PUMP PMCl CONNECTOR O N MOTOR CONTROLLER PMC-PROG CONNECTOR O N CONTROLLER FOR PROGRAMMER RLYl RELAY FOR WCH/SPEED FUNCTIONS (OPT.) RLY2 RELAY FOR COAST INTERLOCK (OPT.) R2

SOL1 SOLENOID LOWER

ID1 INDICATOR DIODE FAULT CODE

SW1 SW2 SW3 SW4

JPI CONNECTOR BY KEY FOR ID1 JP2 CONNECTOR IN HANDLE FOR FUNCTIONS JP3 CONNECTOR IN HANDLE FOR TRAVEL FUNCTIONS JP4 CONNECTOR FOR RAIL FUNCTIONS (7HBE30/40 ONLY) IP6 CONNECTOR IN HANDLE FOR TRAVEL FUNCTIONS P- COhhECTOR h nAhD.E FOR O G S A TCnES (OPT P9 TERM hA. COhhECT O h S FOR METERS (OPT .PI0 COhhECTOR FOR 1RA.E. COhF G-RAT O h S .P: I SP. CE h nAhD.E FOR TnR0Tl.E PS3 SP. CE BY COhTRO..ER FOR RE. ERSE TRA. E. PS-l SP. CE BY COhTRO..ER FOR FORAARD TRA. E. .P:5 SP. CE BI. RA. COhhECTOR FOR MODE COhTRO. .P:' SP-CE h nAhD.E FOR O G SA TCn BhEG .P:8 SP. CE h nAhD.E FOR O G S GhA. JPSIO SPLICE IN HANDLE FOR JOG SWITCH FEED M1 M2

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KEY SWITCH BRAKE SWITCH TRACTOR FIRST SWITCH FORKS FIRST SWITCH

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HTRl HEATER IN CONTROL HANDLE

THROnLE POTENTIOMETER

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00700-CL390-05 1 5 March 2005

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00700-CL390-05 1 5 March 2005

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Check Valve

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Mo1 4Control Valve 2.0 GPM

Figure A- 1 0: Hydraulic Schematic

00700-CL390-05 1 5 March 2005

Toyota Pallet Truck Service Manual

lndex

.

Section I Index Battery . . . . . . . . . . . . . . . . . . 6-8 to 6-10 Exterior Cleaning . . . . . . . . . . . . . . 6-9 Gates And Rollers . . . . . . . . . . . . . 6-8 Maintenance Free . . . . . . . . . . . . 6-10 Storage . . . . . . . . . . . . . . . . . . . .6-10 Testing. Charging. and Maintenance 6-9 Without Gates and Rollers . . . . . . . 6-8 Bearing. Steering . . . . . . . . . . . . . . . . 6-60 Brake . . . . . . . . . . . . . . . . . . . . . . . .6-39 Brake Switch . . . . . . . . . . . . . . ..5-6. 6-16 Brushes . . . . . . . . . . . . . . . . . . . . . .6-42

Cables. Power . . . . . . . . . . . . . . . . . . 6-11 Casters . . . . . . . . . . . . . . . . . . . . . . .6-65 Coast Control Manual . . . . . . . . . . . . . . . . . . . . 6-21 Coast Mode. Manual . . . . . . . . . . . . . . 3-8 Coast Module (DA1) . . . . . . . . . . . . . . 6-23 Cold Storage . . . . . . . . . . . . . . . . . . . 6-90 Commutator . . . . . . . . . . . . . . . . . . . 6-43 Component Locators . . . . . . . . . . . . . . 6-5 Contactors Tip Inspection . . . . . . . . . . . . . . . 6-30 Control Handle Models 7HBC30/40 and 7TB50.

3-Position . . . . . . . . . . . . . . . 6-34 Models 7HBW30 and 7HBE30/40 Only . . . . . . . . . . . . . . . . . . . . . . . .6-33 Return Spring Adjustment . . . 6-34 Control Handle Switches . . . . . . . . . . 6-35 Conversions. Standard/Metric . . . . . . . A-7 Covers. Tractor . . . . . . . . . . . . . . . . . . 6-7 Cushion Tire . . . . . . . . . . . . . . . . . . . 6-62

Decimal Equivalent Chart . . . . . . . . . . A-5 Definitions . . . . . . . . . . . . . . . . . . . . .5-6 Acceleration Rate . . . . . . . . . . . . . . 5-6 Definitions. Troubleshooting . . . . . . . . 5-6 Directional/Speed Control . . . . . . . . . . 3-7

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Drive Unit . . . . . . . . . . . . . . . . . . . . . .6.53 Housing Lubrication . . . . . . . . . . .6.59 Steering Bearing . . . . . . . . . . . . . . 6.60 Tooth Pattern . . . . . . . . . . . . . . . .6.57 Vent Plug . . . . . . . . . . . . . . . . . . .6.59 Drive Wheel . . . . . . . . . . . . . . . . . . . .6.61

Electrical Connectors . . . . . . . . . . . . . 5-10 Electrical Schematics . . . . . . . . . . . . . . A-9 Emergency Reverse . . . . . . . . . . . . . . . .3.8 Emergency Reverse Check . . . . . . . . .6.29 Equivalent Chart. Decimal . . . . . . . . . .A-5

Fault Codes . . . . . . . . . . . . . . . . . . . .5. 11 Filter Screen . . . . . . . . . . . . . . . . . . . .6-85 Fork Height Adjustment . . . . . 6.70 to 6-71 . 13 Fuses . . . . . . . . . . . . . . . . . . . . . . . . 6.

Gauges . . . . . . . . . . . . . . . . . .6.25 to 6-26 Combination Hour/Battery Discharge Meter (2) . . . . . . . . . . . . . . . . .6.25 Hour Meter . . . . . . . . . . . . . . . . . .6.25 Gear Oil Changing . . . . . . . . . . . . . . . . . . .6.59 .

Level . . . . . . . . . . . . . . . . . . . . . . 6.59 General System Data . . . . . . . . . . . . . .3.4 Grab Rail Switches . . . . . . . . . . . . . . .6. 19

Harness Inspection . . . . . . . . . . . . . . . . . . .6. 11 Repair . . . . . . . . . . . . . . . . . . . . . .6. 12 Horn . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 .

Hydraulic Fluid . . . . . . . . . . . . . . . . .6.74 Hydraulic Pump . . . . . . . . . . . . . . . . .6.86 Hydraulic Ram . . . . . . . . . . . . . . . . . .6.78 Hydraulic Reservoir . . . . . . . . . . . . . .6.85 Hydraulic Solenoids . . . . . . . . . . . . . .6.20 Hydraulic Unit . . . . . . . . . . . . . . . . . .6.84

Toyota Pallet Truck Service Manual

Index

Jog Speed Adjustment

. . . . . . . . . . . .6.24

Key Switch . . . . . . . . . . . . . . . . . . . . .6. 15

Lift Cut-Out Switch . . . . . . . . . . . . . . .6. 1 8 Load Wheels . . . . . . . . . . . . . . . . . . . .6.67 Model 7TB50 . . . . . . . . . . . . . . . . .6.68 Lubrication Equivalency Chart . . . . . . .A.2 Lubrication Points . . . . . . . . . . . . . . . .4.6

Maintenance General Truck Operation . . . . . . . . .4.2 .

Guidelines . . . . . . . . . . . . . . . . . . . 4.2 Lubrication Points . . . . . . . . . . . . . .4.6 Manual Coast Trucks with Spring Preload Handle 6-21 Manual Coast Mode . . . . . . . . . . . . . . 3 . .8 Map. Navigating the Manual . . . . . . . . .1.2 Metric Conversions . . . . . . . . . . . . . . . .A.7 Module. Coast (DAl) . . . . . . . . . . . . . .6.23 Motor Controller . . . . . . . . . . . . . . . . .6.28 Motors Brush Spring Tension . . . . . . . . . .6.43 .

Brushes . . . . . . . . . . . . . . . . . . . 6.42 .

Drive . . . . . . . . . . . . . . . . . . . . . . 6.49 .

General . . . . . . . . . . . . . . . . . . . . 6-42 .

Lift . . . . . . . . . . . . . . . . . . . . . . . 6-88 .

Tests . . . . . . . . . . . . . . . . . . . . . . 6.46

Operating Modes Program . . . . . . . . . . . . . . . . . . . .5. 1 3 Operation Directional/Speed Control . . . . . . . .3.7 Emergency Reverse . . . . . . . . . . . . .3.8 .

Lift/Lower . . . . . . . . . . . . . . . . . . . 3.7 Motor Controller . . . . . . . . . . . . . . .3.9 Strip Curtain Bypass . . . . . . . . . . . .3.8

Planned Maintenance . . . . . . . . . . . . . . 4-1 Power Cables . . . . . . . . . . . . . . . . . . .6-11 Program Mode . . . . . . . . . . . . . . . . . .5-13 Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . . . . . ..3.6. 5-13

Relief Valve . . . . . . . . . . . . . . . . . . . .6-76 Reverse . . . . . . . . . . . . . . . . . . . . . . . .3-8 Reverse. Emergency . . . . . . . . . . . . . . . 3-8

Safety Battery . . . . . . . . . . . . . . . . . . . . . .2-5 Definitions . . . . . . . . . . . . . . . . . . .2-2 General . . . . . . . . . . . . . . . . . . . . .2-3 Jacking . . . . . . . . . . . . . . . . . . . . . 2-8 Scheduled Maintenance Annually . . . . . . . . . . . . . . . . . . . .4-5 Daily or Every Eight Hours . . . . . . . 4-3 Every Two Months . . . . . . . . . . . . .4-4 Schematics Electrical . . . . . . . . . . . . . . . . . . . .A-9 Seals Hydraulic Cylinder . . . . . . . . . . . . 6-81 Sliders Pallet Entry Pallet Entry Wheels/Sliders . . 6-69 Solenoids Hydraulic . . . . . . . . . . . . . . . . . . .6-20 Special Tools . . . . . . . . . . . . . . . . . . . .3-6 Speed Control . . . . . . . . . . . . . . . . . . .3-7 Steering Bearing. Drive Unit . . . . . . . . 6-60 Strip Curtain Bypass . . . . . . . . . . . . . . 3-8 Suction Tube . . . . . . . . . . . . . . . . . . .6-85 Switch. Brake . . . . . . . . . . . . . . . . . . .5-6 Switches Brake . . . . . . . . . . . . . . . . . . . . . .6-16 Control Handle . . . . . . . . . . . . . . .6-35 General . . . . . . . . . . . . . . . . . . . .6-14 Grab Rail . . . . . . . . . . . . . . . . . . .6-19 Key . . . . . . . . . . . . . . . . . . . . . . . .6-15 Lift Cut-Out . . . . . . . . . . . . . . . . .6-18 Symptom Tables Lift/Lower System . . . . . . . . . . . . 5-25 Travel (Forward/Reverse) System . 5-28 Wiring System . . . . . . . . . . . . . . .5-35

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Toyota Pallet Truck Service Manual

Systems Overview . . . . . . . . . . . 3- 1 to 3-9

Tenninal Nuts . . . . . . . . . . . . . . . . . . 6-46 Theory of Operation . . . . . . . . . . 3-7 to 3-9 Coast Mode . . . . . . . . . . . . . . . . . . 3-8 Directional/Speed Control . . . . . . . 3-7 Emergency Reverse . . . . . . . . . . . . 3-8 Forward . . . . . . . . . . . . . . . . . . . . .3-7 Lift . . . . . . . . . . . . . . . . . . . . . . . .3-7 Lift/Lower . . . . . . . . . . . . . . . . . . .3-7 Lower . . . . . . . . . . . . . . . . . . . . . .3-7 Motor Controller . . . . . . . . . . . . . . 3-9 Reverse . . . . . . . . . . . . . . . . . . . . .3-8 Strip Curtain bypass . . . . . . . . . . . 3-8 Throttle Potentiometer . . . . . . . . . . . . 6-37 Torque Chart Metric . . . . . . . . . . . . . . . . . . . . . .A-4 Standard . . . . . . . . . . . . . . . . . . . .A-2 Tractor Cover . . . . . . . . . . . . . . . . . . . 6-7 Troubleshooting . . . . . . . . . . . . . . . . . 5-1 Definitions . . . . . . . . . . . . . . . . . . . 5-6 Electrical Connectors . . . . . . . . . . 5-10 Electrical Guidelines . . . . . . . . . . . 5-3 Fault Codes . . . . . . . . . . . . . . . . . 5-11 Flowcharts . . . . . . . . . . . . . . . . . . 5-21 Hydraulic Guidelines . . . . . . . . . . . 5-5 Symptom Tables . . . . 5.25. 5.28. 5-35 Truck Model Identification . . . . . . . . . . 3-2

Vehicle Specifications

. . . . . . . . . . . . . 3-3

Wheel. Drive . . . . . . . . . . . . . . . . . . . 6-61 Wheels Load . . . . . . . . . . . . . . . . . . . . . .6-67 Pallet Entry . . . . . . . . . . . . . . . . . 6-69 Wiring Inspection . . . . . . . . . . . . . . . . . . 6-11 Repair . . . . . . . . . . . . . . . . . . . . . 6-12 Wiring Harness . . . . . . . . . . . . . . . . . 6-12

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Index

Index

Toyota Pallet Truck Service Manual

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00700-CL390-05 1 5 March 2005