Toyota Forklift 6HBW30 6HBE30 6HB40 6HBC30 6HBC40 6TB50 Service & Parts Manual SN 10011 and up

Service and Parts Manual

TOYOTA

Models 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50

Serial No. 1001 1 and Up

Date: 10/01/95

Service and Parts Manual Introduction

TOYOTA

PREFACE This manual presents factual material on the Toyota equipment you have purchased. The object is to insure safe operation and/or maintenance practices and procedures for this Toyota product.

MANUAL OVERVIEW This manual consists of both a Service Manual and a Parts Manual for the specific equipment listed on the cover.

The Table of Contents provides easy location of all subject matter within the manual.

Individual chapter indexes are located at the beginning of each chapter, following the reference tabs.

The section tabs allow a quick location identification for each section.

The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

DENOTES A SERIOUS HAZARD THAT COULD CAUSE INJURY OR DEATH TO THE OPERATOR OR OTHER PERSONNEL FROM A PARTICULAR ACTION OR CONDITION. A LESS SERIOUS HAZARD FROM AN ACTION OR CONDITION THAT ACAUTloNDENOTES COULD CAUSE MINOR INJURY TO THE OPERATOR OR MAINTENANCE PERSONNEL, OR CAUSE DAMAGE TO THE EQUIPMENT ITSELF. Denotes a particular statement pertaining to a particular procedure or explanation.

Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the page, opposite revised, added or deleted material. Revision lines indicate only current revisions with changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, the physical location of the material or complete page additions are not identified by revision lines.

Copyright 8 1995 by Toyota Industrial Equipment, a Division of Toyota Motor Sales, U.S.A., Inc. All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retreival or transfer, or recording without the written permission of the publisher.

Toyota lndustrial 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 lndustrial Equipment is not responsible for any errors that may appear in this manual.

Service and Parts Manual

Introdudion Example of Chapter and Page numbering system:

TOYOTA

Service and Parts Manual

Main Table of Contents

TOYOTA JWJ9

Subiect SECTION I: Service Manual

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i List of lllustratons

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Chapter 1: Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0

Chapter 2: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0

Chapter 3: Installation

Chapter 4: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Chapter 5: Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0

Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Chapter 7: Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Chapter 8: Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0

SECTION II: Parts Manual Introduction Chapter 1: Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Chapter 2: Brakes and Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Chapter 3: Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Chapter 4: Electrical

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Chapter 5: Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Chapter 6: Elevating Section/Attachment

. . . . . . . . . . . . . . . . . . . . . . . 600

Chapter 7: Special Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

Service and Parts Manual Table of Contents

TOYOTA

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Description Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Specifications Description Mechanical Drive Unit Handle Assembly Coast Control Drum Brake Hydraulic System General Pressure Relief Valve Flow Control Valve Lowering Solenoid Lift Cylinders Hydraulic Reservoir Breather Cap Hydraulic Pump Motor Hydraulic Pump Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Battery Drive Motor Contactors Lift Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Transistor Control (Motor Controller) Model 6HBW30 Models 6HBE30 and 6HBE40 Models 6HBC30 and 6HBC40 Model 6TB50

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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrometer Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Water To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Classes Of Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Instructions

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

Operational Checks Brake Fork/Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Reverse Switch Coast Control Receiving Inspection Guide

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Service and Parts Manual Table of Contents

TOYOTA

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motors Pump Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Transistor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview Advanced Transistor Control (AT) Current Limiting Low Voltage Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal Protection Runaway Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Static Return to Neutral Protection Plugging Controller Key Switch Input Controller Thumbwheel Throttle Inputs "Emergency Reverse" Plug Breaking Inhibit Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Plugged I N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Plugged IN/Key Switch Turned to ON or TURTLE Battery Plugged IN/Key Switch Turned ON/Deadman Switch Closed Directional/Speed Control Forward . . . . . . . . . . . . . . . . . . . . . . . .

Diredional/Speed Control-High Speed (FORWARD ONLY) Emergency Reverse Switch Plugging Turtle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift/Lower System Lift Lower

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication and Maintenance Daily or Every 8 Operating Hours. Whichever Occurs First . . . . . . . . . . .

Weekly or Every 5 0 Operating Hours. Whichever Occurs First Monthly or Every 200 Operating Hours. Whichever Occurs First . . . . . . . .

Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Semiannually or Every 1. 000 Hours. Whichever Occurs First Lubrication and Maintenance Guide Hydraulic System Oil Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Drive Unit Service Drive Housing Lubrication Drive Housing Vent Plug Drive Housing Steering Bearing Mechanical Drive Unit Assembly

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Service and Parts Manual Table of Contents

TOYOTA

Drive Unit Tooth Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Gear Case Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection After Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . .

Brake Adjustment (For all Models) . . . . . . . . . . . . . . . . . . . . . . .

Deadman Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Return Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . .

Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . .

After Every 200 Hours of Operation . . . . . . . . . . . . . . . . . . . . . .

Cushion Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . .

Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Replacement (Model 6HBE30 & 6HBC30) . . . . . . . . . . . . . . . .

Wheel Replacement (Model 6HBE40 & 6HBC40) . . . . . . . . . . . . . . . .

Pallet Entry Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . .

After Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . .

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork And Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . .

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowered Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . .

Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 8 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinders Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Leakage Wiper Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 200 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 1, 000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.15 5.16 5.16 5.17 5.20 5.20 5.20 5.21 5.22 5.22 5.24 5.24 5.24 5.24 5.24 5.26 5.26 5.26 5.26 5.26.1 5.27 5.27 5.27 5.27 5.27 5.28 5.28 5.29 5.29 5.30 5.30 5.31 5.32 5.34 5.34 5.35 5.35 5.35 5.37 5.37 5.37 5.37 5.37 5.37 5.39

Service and Parts Manual Table of Contents

TOYOTA

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Electrical Battery ElectrolyteLevel Specific Gravity Battery Exterior Battery Charging Battery Storage Motors Inspection Brushes Commutator Inspection Servicing High Mica Resurfacing Drive Motor General Data Drive Motor Inspection Drive Motor Removal Drive Motor Replacement Lift Motor General Data Inspection Removal Traction System Adjustments Potentiometer Adjustments Current Limit Setting Plug Current Adjustment Acceleration Adjustment Potentiometer Deadman Switch Adjustment Contactors Cleaning Inspection Tip Inspection Contactor Table Contactor Coil Replacement Replacement Of Contactor Tips, Insulation And/or Core And Rod Assembly .

ContactorDisassembly/Reassembly Checking Components Diodes Plug Diode Test Throttle Potentiometer Setting Example Turtle Speed Module (DA2) Test/Adjustment Replacenrent Emergency Reverse Module (DA1) Test Procedure Testing Other Electrical Components

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5.41 5.41 5.41 5.41 5.42 5.42 5.43 5.44 5.44 5.44 5.46 5.46 5.46 5.46 5.47 5.48 5.48 5.48 5.48 5.50 5.50 5.50 5.52 5.52 5.52 5.53 5.53 5.54 5.55 5.56 5.56 5.56 5.56 5.57 5.57 5.57 5.58 5.60 5.60 5.60 5.61 5.61 5.62 5.62 5.63 5.64 5.64 5.65

Service and Parts Manual Table of Contents

TOYOTA

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Replaceable Units (FRU) . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Does Not Run . Directional Contactors Do Not Close . . . . . . . . . . . . . .

Does Not Run . Directional Contactors Energize . . . . . . . . . . . . . . . . .

Runs In One Direction Only . Opposite Direction Contactor Does Not Energize Runs In One Direction Only . Directional Contactors Work Normally . . . . . .

Does Not Run In High Speed (Forward only) . . . . . . . . . . . . . . . . . .

Plugging Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . . . .

Does Not Accelerate Properly . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Reverse Module Does Not Activate When Button Is Depressed . . .

Emergency Reverse Module Checks OK. No Reverse Travel With S25 Depressed Lift/Lower Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forks Do Not Lift When Lift Button Is Pushed . . . . . . . . . . . . . . . . . .

Forks Do Not Lower When Lower Button Is Pushed . . . . . . . . . . . . . . .

6.0.0 6.1 6.2 6.3 6.4 6.4 6.6 6.7 6.8 6.9 6.10 6.10 6.1 1 6.12 6.13 6.13 6.14

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Torque Data for Bolts . . . . . . . . . . . . . . . . . . . . . . . . . .

Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decimal Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic (Cold Storage) . . . . . . . . . . . . . . . . . . . . . . . . .

7.0.0 7.1 7.2 7.3 7.4 7.5 7.6 7.10 7.11

Special Supplement Alphabetical Index

8.0

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Service and Parts Manual List of Illustrations

TOYOTA

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coast Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PressureReliefValve . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . .

Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Model 6HBW30 Electrical Wiring . . . . . . . . . . . . . . . . . . . .

Models 6HBE30 and 6HBE40 Electrical Wiring . . . . . . . . . . . . .

Models 6HBC30 and 6HBC40 Electrical Wiring . . . . . . . . . . . .

Model 6TB50 Electrical Wiring . . . . . . . . . . . . . . . . . . . . .

Battery Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Level Check . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluids Temperature Range . . . . . . . . . . . . . . . . . .

Checking Brake Actuation . . . . . . . . . . . . . . . . . . . . . . .

Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coast Control Operation . . . . . . . . . . . . . . . . . . . . . . . .

AT Control System (simplified) . . . . . . . . . . . . . . . . . . . . .

Motor Current Chart . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Controller Pinout Functions . . . . . . . . . . . . . . . . . . .

Travel Direction Reference . . . . . . . . . . . . . . . . . . . . . . .

Battery Plugged IN . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Plugged IN/Keyswitch Turned O N . . . . . . . . . . . . . . .

Battery Plugged IN/Keyswitch ON/Deadman Switch Closed . . . . . .

Directional/Speed Control Forward . . . . . . . . . . . . . . . . . .

Diredional/Speed Control High Speed (Forward) . . . . . . . . . . .

Emergency Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turtle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical - Hydraulic Circuits for Lift . . . . . . . . . . . . . . . . . .

Lift Switch Closed . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical . Hydraulic Circuits for Lower . . . . . . . . . . . . . . . .

Lower Switch Closed . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Points (6HBE30) . . . . . . . . . . . . . . . . . . . . . .

Component Identification and Location . . . . . . . . . . . . . . . .

Drive Assembly (Cutaway View) . . . . . . . . . . . . . . . . . . . .

Drive Gear Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Set Tooth Patterns . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Assembly Removal/lnstallation . . . . . . . . . . . . . . .

Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . .

Brake and Power Actuation Positions (6HBW30, 6HBE30 and 6HBE40) Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Return Spring Adjustment (6HBW30, 6HBE30 and 6HBE40) . .

Drive Motor Cutout Switch (6HBC30, 6HBC40 and 6TB50) . . . . . . .

Handle Assembly for 6HBW30. 6HBE30, 6HBE40 . . . . . . . . . . .

Handle Assembly for 6HBC30. 6HBC40 and 6TB50 . . . . . . . . . .

Cushion Drive Tire Replacement (typical) . . . . . . . . . . . . . . .

Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Wheels (6HBE40 and 6HBC40) . . . . . . . . . . . . . . . . . .

Pallet Entry Wheels (6HBE40 and 6HBC40) . . . . . . . . . . . . . .

Caster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.11 1.12 1.13 1.14 1.15 1.16 3.4 3.5 3.6 3.7 3.7 3.8 4.2 4.3 4.5 4.6 4.8 4.10 4.12 4.14 4.16 4.18 4.20 4.22 4.23 4.24 4.25 4.26 5.6 5.8 5.10 5.13 5.15 5.18 5.19 5.20 5.21 5.22 5.22 5.23 5.23 5.25 5.26 5.26.1 5.27 5.28 5.29

Service and Parts Manual List of Illustrations

TOYOTA

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . .

Linkage Detail and Lift Limit Switch . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Motor. Pump and Reservoir . . . . . . . . . . . . . . . . .

Checking Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Brush Location . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Mica Undercutting . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commutator Cutting Tool . . . . . . . . . . . . . . . . . . . . . . .

Drive Motor (Exploded View) . . . . . . . . . . . . . . . . . . . . . .

Lift Motor Assembly (Exploded View) . . . . . . . . . . . . . . . . . .

Potentiometer Location and Function . . . . . . . . . . . . . . . . . .

Deadman Switch Adjustment (6HBW30. 6HBE30 and 6HBE40) . . . .

Deadman Switch Adjustment (6HBC30. 6HBC40 and 6TB50) . . . . .

Typical Contactor Exploded View . . . . . . . . . . . . . . . . . . . .

Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turtle Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . .

Standard Torque Data for Bolts . . . . . . . . . . . . . . . . . . . .

Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . .

Schematic Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic for the Model 6HBW30 . . . . . . . . . . . . . .

Electrical Schematic for the Models 6HBE30 and 6HBE40 . . . . . . .

Electrical Schematic for the Models 6HBC30 and 6HBC40 . . . . . . .

Electrical Schematic for the Model 6TB50 . . . . . . . . . . . . . . .

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic for the Model 6HBW30 (Cold Storage) . . . . . .

Electrical Schematic for the Models 6HBE30 and 6HBE40 (Cold Storage) Electrical Schematic for the Models 6HBC30 and 6HBC40 (Cold Storage) Electrical Schematic for the Model 6TB50 (Cold Storage) . . . . . . .

Service and Parts Manual Special Service Tools

viii

TOYOTA

Service and Parts Manual Chapter 1 Description Index

TOYOTA PAGE

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.3

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coast Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 1.4 1.5 1.6 1.6

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HydraulicReservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 1.7 1.7 1.7 1.7 1.8 1.8 1.8 1.8 1.8 1.8 1.9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contadors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advanced Transistor Control (Motor Controller) . . . . . . . . . . . . . . . . . . . . . .

1.1 0 1.10 1.10 1.11 1.12 1.12

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model6HBW30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Models 6HBE30 and 6HBE40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Models 6HBC30 and 6HBC40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 6TB5O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.13 1.13 1.14 1.15 1.16

Service and Parts Manual Overview Overview

TOYOTA

A pallet vehicle is a mobile, self-propelled machine. It is used to lift and carry material within its rated capacity in and around manufacturing plants, warehouses, loading platforms, docks, railroad cars, and highway trailers. It is usually associated with manufacturing or warehousing. It is not intended for such uses as earth moving, snow removal or over the road hauling. Any unintended use may seriously affect operational safety, reliability, and longevity.

include five models for transporting skids and Toyota pallet vehicles (Figure 1.l) pallets with up to nine inches of under clearance without use of skid adapters.

The Model 6HBW30 units are 6,000 Ib. (2,724 Kg) capacity, low lift, short haul, pallet vehicles. These models are designed for use with all pallet types and for positioning equipment and materials in work areas.

The 6HBE30 and 6HBC30 units are 6,000 Ib. (2,724 Kg) capacity rider versions and are designed for transporting and/or order picking operations where loads are transported over longer distances than applicable for 6HBW30 Models. The 6HBE30 has a riding platform at the front of the power unit and a second set of controls mounted on the hand rail. The 6HBC30 has a riding platform between the battery and the forks. Both units allow a maximum travel speed of approximately 7.5 MPH (12.7 Km/hr) (when riding only).

The 6HBE40 and the 6HBC40 are similiar to the 6HBE30 and the 6HBC30 except they are designed to handle 8,000 Ib. (3,632 Kg) loads.

In addition to pallet vehicles, the 6TB5O model Toyota is a rider-type tow tractor designed to tow loads up to 10,000 Ibs. (4,540 Kg) within warehouses and storage centers.

THE OPERATOR MUST NOT RIDE ON THE MODEL 6HBW30.

ACAUT~ON

Service and Parts Manual Overview Model ldentification

Figure 1.1

Vehicle Model ldentification

TOYOTA

Service and Parts Marlual Overview Vehicle Specifications

TOYOTA

This vehicle is rated by load weight.

Review the specification plate located on the compartment cover for the vehicle's capacity.

TOTAL WEIGHT OF LOAD MUST INCLUDE PALLET, CONTAINER, OR DEVICE HOLDING LOAD AND OPERATOR (ON RIDER MODELS).

Maximum speeds attainable vary with vehicle weight, rolling resistance, and condition of battery.

Draw Bar pull - Maximum = 700 Ibs (317 kg) Draw Bar pull - Normal = 200 Ibs (90 kg) Maximum Capacity = 10,000 Ibs (4540 kg) load trailing Maximum turtle speed is 3.5 mph (5.6 Km/hr)

Figure 1.2

Description

Vehicle Specifications

The description of the vehicle components will be broken down into three main sections:

Mechanical Hydraulic Electrical

Service and Parts Manual Mechanical

TOYOTA

Mechanical Drive Unit (See Figure 1.3)

The drive unit incorporates a double reduction gear train using helical and beveled gears bathed in oil for quiet, efficient high torque operation.

The first reduction employs helical gears, and is accomplished through a drive pinion (28) located on the motor armature shaft that mates with a gear (27) mounted on pinion shaft.

The pinion shaft (6) employs spiral bevel pinion gears that mate with the bevel gear (1 2) mounted on the axle (1 7). Spiral bevel gears are used in the second reduction for quiet, efficient, high torque operation. The heavy-duty high torque drive axle is supported by two tapered roller bearings (1 4 , 3 1 ).

The drive housing (21) is supported in the frame by a large ball bearing assembly (20). The major advantage of this mounting is to keep steer effort to a minimum.

Figure 1.3

Drive Unit

1.4

Service and Parts Manual Mechanical Handle Assembly (See Figure 1.4)

TOYOTA

The operator controls the speeds forward and reverse using the twist grip handles or thumb actuated butterfly levers on each side of the handle. The twist grips/butterfly controls return to neutral when hand pressure is released.

The lift, lower and horn buttons are centrally located to facilitate operation using either hand. A wraparound guard offers protection to the operator's hands, and prevents damage to the controls from minor impacts.

An Emergency Reverse switch (Models 6HBW30, 6HBE30 and 6HBE40 only) located on the top of the handle head assembly will reverse the direction of the vehicle should the switch be activated. Forward travel is prevented until the control handle assembly is raised to the vertical position. (See page 3.7)

/Twist

Grip Handle

Hand Guard

DirectionaI/Speed Control

Butterfly Control

Figure 1.4

Handle Assembly

Service and Parts Manual Mechanical Coast Control (See Figure 1.5)

TOYOTA

The Models 6HBE30 and 6HBE40 are equipped with a coast control (optional on Model 6HBW30) that allows the vehicle to coast without the automatic brake being applied.

Coast

Activated

Figure 1.5

Drum Brake

Deactivated

Coast Control

The brake drum is mounted on the armature shaft of the drive motor. The brake stops the vehicle by stopping the revolution of the armature shaft. A switch in the brake assembly is activated at the same time to interrupt electrical power to the drive motor.

Service and Parts Manual Hydraulic System

TOYOTA

Hydraulic System General

The hydraulic system provides the means by which the lift operation is controlled.

Included in the system is a motor driven, gear type, fixed displacement pump that supplies hydraulic oil to the lift cylinders.

From the pump the hydraulic oil passes under pressure through a check valve (Figure 1.7). The check valve is used to prevent the oil from being pushed back into the pump. Also, the adjustable pressure relief valve (Figure 1.6) is used to protect the motor, pump, and cylinders from excessive pressure. The hydraulic oil is filtered by the inlet filter screen located in the reservoir. The reservoir provides an adequate supply of hydraulic oil to the pump plus an ample reserve.

Pressure Relief Valve

The pressure relief valve (Figure 1.6), which is installed in the adapter housing, is connected in parallel with the high pressure outlet of the pump.

The high pressure oil exerts a force on the ball which is held closed by the force of the spring. When the force exerted by the oil exceeds that of the spring, the ball will unseat (crack), allowing the oil to be diverted back to the reservoir. This action is a safety feature which protects all of the components in the hydraulic system from excessive pressure.

To Reservoir Threaded Hex Cap

r

ReliefAdjust Screw

Figure 1.6

~\\\\\''' Spring

Pressure Relief Valve

Flow Control VaIve

The flow control valve is used to control the lowering speed of the forks. The flow control valve (non-adjustable) is preset at 2 GPM and is pressure compensated resulting in uniform lowering speeds regardless of load. (See page 1.9)

Lowering Solenoid

The lowering solenoid is a normally closed directional valve with electrical solenoid actuation. The electrical actuation is accomplished by depressing the lower button on the handle or on the hand rail. (See page 1.9)

Service and Parts Manual Hydraulic System

TOYOTA

Lift Cylinders

The lift cylinders lift the forks. (See page 1.9)

Hydraulic Reservoir

The hydraulic reservoir is located in the right side of the drive compartment and is mounted as an integral part of the hydraulic unit. Capacity of the reservoir is 1.5 quarts (1.41 liters). (See page 1.9)

Breather Cap

The breather cap, located on the side of the reservoir, allows air to enter or exit the reservoir to compensate for changes of oil level during operation of the hydraulic system. The air that enters the system is filtered to prevent any large amount of contaminants from entering the system.

Hydraulic Pump Motor

The hydraulic pump motor is a 24 Volt series wound unit utilizing Class F insulation.

(See page 1.9)

Hydraulic Pump

Hydraulic pressure is provided by a fixed displacement gear pump. The pump is coupled to the series wound hydraulic pump motor. The pump has a single inlet and discharge port piped directly from the reservoir to the lift cylinders to eliminate line loss. (See page 1.9) The internal parts of the pump are machined to a high degree of accuracy. If the pump is in need of repair which requires complete disassembly, it is recommended that the pump be sent to your local Toyota Dealer for repairs. Include your purchase order and full information about the breakdown.

Check Valve

The check valve (Figure 1.7) is used for directional control in the hydraulic system.

As a directional control, it has a free-flow and a no-flow direction. Flow through the seat will push the ball away and permit free flow. Spring pressure pushes the ball against the seat, and pressure build-up forces it to seal the passage so the flow is blocked. (See page 1.9)

BIYL

HOSE

Figure 1.7

Check Valve

1.8

Service and Parts Manual

TOYOTA

Hydraulic System Hydraulic Compo. nents

Hydraulic Pump Motor #

Pump Motor Solenoid

Return Line

Fill Plug

-

Hydraulic Pump

Reservoir

Lowering Solenoid

Lifi Cylinders

Figure 1.8

Hydraulic Components

1.9

Service and Parts Manual Electrical System Electrical System

TOYOTA

The electrical system is comprised of: a battery drive motor lift motor contactors handle or auxiliary switches control assemblies cables and wires

Battery

The 24 volt battery is located in the compartment behind the steering mechanism, The battery supplies all electrical power for the traction and lift systems.

Batteries are rated in ampere hours over a set period of time and should be of proper size for the particular work intended. Extending the work beyond the capacity of the battery, such as discharging it below a specific gravity of 1.150, may shorten its life. Overcharging the battery by using too high a rate of charge, causing it to gas vigorously after it has nearly reached full charge, will also shorten its life. The battery should always be recharged immediately following a complete discharge.

The battery should never be allowed to remain in a discharged condition.

EXTREME CAUTION SHOULD BE EXERCISED TO ASSURE THAT THE POLARITY OF ACAUT~ON THE VEHICLE IS NOT REVERSED WHEN THE BATTERY IS INSTALLED OR WHEN THE BATTERY CONNECTORS ARE CHANGED. PRIOR TO REMOVING THE BAITERY OR BATTERY CONNECTORS, THE CABLES SHOULD BE CAREFULLY MARKED AS TO POSITIVE AND NEGATIVE POLARITY. IF IN DOUBT, CHECK THE POLARITY USING A VOLTMETER. Drive Motor

The drive motor, connected directly to the drive unit, is a fan cooled series wound four pole construction. The pre-lubricated sealed drive motor bearings do not require lubrication.

The brush rigging is designed to maintain constant brush pressure regardless of brush length. A coil spring for each of the four brushes is situated and fastened so that correct pressure is maintained.

Service and Parts Manual Electrical System Contactors

TOYOTA

The forward and reverse contactors are included in a dual unit with two contacts actuated by each coil (forward or reverse). Each set of contactors is a single pole, double throw design. Drive motor direction of rotation is determined by which set of contacts is actuated.

The field weaken contactor is single pole, single throw design with normally open tips.

Contactors are magnetic type, designed for maximum interchangeability of parts.

Points are silver alloy and are easily replaced. The f and R contactors have suppressors connected in parallel with their coils to protect the solid state circuits from high transient voltages produced when coils de-energize.

Model 6HBW30 Figure 1.9

Models 6HBE30, 6HBE40t6HBC30, 6HBC40 and 6TB50 Contactor Panel

Service and Parts Manual Electrical System

TOYOTA

Lift Limit Switch

The amount of upper lift is limited by the LIFT LIMIT switch (S24). It is located to the left of the hydraulic pump motor above the horn. The switch, normally closed, is connected in series with the pump motor solenoid. When the forks are raised to their upper limit, the actuator tab on the cylinder plate actuates the switch. This opens the switch and de-energizes the lift solenoid which in turn removes power from the lift motor.

Advanced Transistor Control (Motor Controller)

The AT Control System is used on this vehicle. This system electronically controls drive motor power and can be smoothly varied from full OFF to full ON without speed steps or increments. The heart of this control system is the Advanced Transistor Control Power Module.

The AT Power Module is basically a high-power semiconductor switch. An array of MOSFET power transistors are connected in parallel and control the current in the motor windings.

Figure 1.10 Motor Controller 1.12

Service and Parts Manual Electrical System

Module Emergency Reverse Module (DA1)

Figure 1.1 1

I Motor Drive

Model 6HBW30 Electrical Wiring

TOYOTA

Load Holding Solenoid

Service and Parts Manual Electrical System

Figure 1 . 1 2 Models 6HBE30 and 6HBE40 Electrical Wiring

TOYOTA

Service and Parts Manual Electrical System Models 6HBC30 and 6HBC40

TOYOTA

I.

Weaken

tch

Control Module

Load Holding Solenoid

Figure 1.1 3 Models 6HBC30 and 6HBC40 Electrical Wiring

Service and Parts Manual

TOYOTA

Electrical System Model 6TB50

/

Control Module

I Turtle Module (DA2)

Figure 1.1 4 Model 6TB50 Electrical Wiring

Drive Motor

Service and Parts Manual

O~eratinaInstructions

For Operating Instructions, refer to the Operatof s Manual located on the vehicle.

TOYOTA

Service and Pads Mtinual Cha~ter3 Installation Index

TOYOTA

SUBJECT Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrometer Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Water to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 3.2 3.2 3.3

Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Classes of Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Checking the Hydraulic System

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork/Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coast Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 3.7 3.7 3.8 3.8

Break-Inperiod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 3.9 3.9 3.9 3.9

Service and Parts Manual Visual Inspection Visual Inspection

TOYOTA

Whenever a vehicle is received, it should be checked for any damage which may have occurred in transit. Check all screws, nuts, and bolts which may have come loose and require tightening. Use the following checklist during the visual inspection.

All defects must be corrected before putting the vehicle into operation.

Checking the Battery

1. Check the polarity of the battery before installing it. The positive (+) side is connected to the main fuse on the contactor assembly. Also, check the polarity of the cables and the connector to see that they agree.

EXTREME CAUTION SHOULD BE EXERCISED TO ASSURE THAT THE POLARITY TO

VEHICLE IS NOT REVERSED WHEN THE BAT~ERYIS INSTALLED OR WHEN THE ACAUTIONTHE BATTERY CONNECTORS ARE CHANGED. PRIOR TO REMOVING THE CABLES FROM THE BAllERY CONNECTORS, THE CABLES SHOULD BE CAREFULLY MARKED AS TO POSITIVE AND NEGATIVE POLARITY. IF IN DOUBT, CHECK THE POLARITY USING A VOLTMETER.

2. The battery must fit snugly in the battery compartment. Do not use a battery with more than 1h"(12.7 mm) length or width clearance.

3. Maintain the water level in the battery about Add only distilled water after charging.

(Continued on next page)

(15.9 mm) above the baffles.

Service and Parts Manual Visual Inspection

TOYOTA

Checking the Battery (Cont'd) A fully charged battery will have a specific gravity reading of 1.265 or higher with electrolyte at 80°F (26.6OC). Refer to the following chart.

Battery specific gravity readings with electrolyte at 80°F are:

Hydrometer Use

The hydrometer measures the specific gravity of the electrolyte. The specific gravity varies directly with the state-of-charge of a lead acid battery.

Test Procedure

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

2. Leaving the hydrometer within the cell, determine the specific gravity of the cell.

(See Chart Above.)

3. If there is not enough electrolyte to get a hydrometer reading: Add just enough distilled water to cover the battery plates.

Charge the battery, then take readings.

4. The specific gravity reading for each cell should be taken and recorded on the battery chart.

No amount of charging will increase battery capacity or raise the specific gravity above its fully charged level (1.280 to 1.300).

Add distilled water to the cell after the charging process. Consult your battery manual for further information.

Adding Water To Battery

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

Guidelines Use only battery manufacturer's approved or distilled water.

Add distilled water after hydrometer and voltmeter readings are taken.

Add distilled water after charging to reduce overfilling.

Always have plates entirely covered.

Keep outside of battery case clean and dry.

Service and Parts Manual Visual h S ~ e d i 0 n

TOYOTA

Checking the Battery (Cont'd) NEVER ALLOW THE PLATES TO BECOME EXPOSED DUE TO LOW ELECTROLYTE LEVEL. DO NOT OVERFILL. THE LIQUID WILL EXPAND AND SPILL OVER WHEN THE BATTERY IS PUT INTO USE AND WARMS UP.

A CAUTION

THE ELECTROLYTE IN THE BAllERY IS A SULFURIC ACID AND WATER SOLUTION; THEREFORE, EXTREME CARE SHOULD BE EXERCISED WHEN WORKING AROUND THE BAlTERY. SHOULD ANY OF THE ELECTROLYTE COME IN CONTACT WlTH YOUR CLOTHING OR SKIN, FLUSH THE AREA IMMEDIATELY WlTH COLD WATER. SHOULD THE SOLUTION GET O N YOUR FACE OR IN YOUR EYES, FLUSH THE AREA WlTH COLD WATER AND GET MEDICAL HELP IMMEDIATELY.

Voltage Check

Take a voltage check on each cell after performing the hydrometer test. Connect the leads of a Simpson Volt/Ohmmeter (VOM) or equivalent to the positive and negative terminals of each cell.

1. Touch the voltmeter leads to the positive and negative terminals of each cell.

There should be a reading of at least two volts for each fully charged cell and a variance of no more than 0.2 volts between cells.

2. Record the voltage reading for each cell on the battery maintenance chart.

VOM readings will vary with the state of charge and should be approximately:

Service and Parts Manual Visual Inspection Connecting the Battery

TOYOTA

The quick disconnect running and charging connector is located on the left side of the drive module. To disconnect the power supply, pull up on the battery connector.

To reconnect, push the battery connector down. Check connectors for any foreign material or damage before using the vehicle (Figure 3.1).

Make sure that the battery cables stay within the confines of the vehicle.

ALWAYS DISCONNECT THE BAITERY CONNECTOR WHEN PERFORMING MAINTENANCE ON THE VEHICLE OR WHEN THE VEHICLE IS NOT IN USE.

Battery Connector

Service and Parts Manual

TOYOTA

Visual ~ ~ ~ ~ e d i o n Lubrication

Make sure the vehicle has been properly lubricated. Refer to the Maintenance Chapter for proper checking and oil changing procedures.

Checking the Hydraulic System

To check the hydraulic oil level, lower the forks and remove the one-piece cover.

Remove the Breather Cap (Figure 3.2). The oil should be within 1/4" (6.35 mm) of the fill hole.

Also check all hoses and fittings for leaks; repair if necessary.

Outlc Port

4

I

-eather Cap

Pump Adapter

Relief Valve Adjustment

Reservoir

Fill Eilbow

Figure 3.2 Hydraulic Oil Level Check

Service and Parts Manual

TOYOTA

Visual Inspection Cold Storage Conditioning

If the vehicle is to be used in a cold storage application, it will be equipped with Class I and Class II cold storage option components when delivered from the factory, EXCEPT FOR the oil in the hydraulic reservoir and the drive unit.

WHEN THE VEHICLE IS READY TO BE INSTALLED IN A COLD STORAGE ENVIRONMENT, THE OIL IN THE HYDRAULIC SYSTEM AND THE DRIVE UNIT MUST BE CHANGED IN ACCORDANCE WITH THE FOLLOWING ITEMS. Classes Of Cold Storage

There are two classes of cold storage application in Toyota terminology. Those classes are: (See Figure 3.3)

1. Class I: Applies to vehicles operating in an: Environment where temperatures fluctuate from +20°F (-7°C) to +70"F (21"C) in a continuous duty cycle.

Application where the vehicle goes in and out of the freezer for short periods of time.

2. Class II: Applies to vehicles operating: In and out of an environment where temperatures fluctuate from +40° (4°C) to -40°F (-40°C).

Continuously at -20°F (-29°C).

Refer to: Lubrication Equivalency Chart in Chapter 7.

Figure 3.3 to ensure the proper oil selection for a particular temperature range.

Recommended Drive Unit Oils

Recommended Hydraulic Oils

49- ---

-

50°F (10°C) to 120" (Standard)

30" F (- 1"C) and Above

5---7

30" F (-1"C) and Below

Figure 3.3

Hydraulic Fluids Temperature Range

3.6

to 70" (21°C)

Service and Parts Manual

TOYOTA

Visual tnspection Operational Checks

The brake is applied only when the handle is in the positions shown in figure 3.4.

Check the brake for proper operation and make sure it is not dragging in the Brake Released position. (Refer to Step 10 of Receiving Inspection Guide on page 3.8).

Brake

Brake Released

Brake Applied

Figure 3.4

Checking Brake Actuation

Fork/Lift Linkage

Check to make certain the forks are level and that the linkage pivot points are lubricated.

Emergency Reverse Switch

Check operation of the Emergency Reverse switch. (See Figure 3.5.)

1. Make sure that when the Emergency Reverse switch is activated: the vehicle travels in the reverse direction (forks first). forward travel is locked out until reset by turning the keyswitch off or moving the control handle to the brake applied position. (See figure 3.4.)

-

-

Emergency Reverse Switch

Figure 3.5

Control Handle

Service and Parts Manual

TOYOTA

Visual Inspection Coast Control

Check for proper operation of the Coast Control. (See Figure 3.6.)

Activated

Figure 3.6

Receiving Inspection Guide

Deactivated

Coast Control Operation

Check and correct or report the following where applicable.

1. lnspect for correct polarity of the battery connector.

2. Make sure that the electrolyte in the battery is at the proper level.

3. Check the specific gravity of the electrolyte; it should be 1.265 or higher when the battery is fully charged.

4. lnspect all electrical connections for loose or disconnected wires, cables, or terminals.

5. lnspect the control wires and cables for grounds.

6. Make sure that all grease fittings are intact. Lubricate all fittings. Refer to Lubrication Chart in Chapter 7.

7. Check the oil level in the drive gear housing.

8. Check the oil level in the hydraulic reservoir.

9. Check the forward and reverse operation of the steering control hcndle.

10. Check the operation of the brake. The brake should have sufficient force to stop the vehicle securely and should not drag during travel. The power to the drive motor should cut out when the brake is applied.

1 1. Check the lifting and lowering operation of the forks. The load wheels should raise the forks equally on both sides. The hydraulic pump should stop when the forks have reached their upper limit. If it does not, the lift limit switch rr~ustbe adjusted.

12. Check for hydraulic leaks.

13. Check operation of Emergency Reverse Switch.

14. Operate the horn.

Service and Parts Manual ~ r e a k - Period ~n

TOYOTA

Break-In Period Introduction

As with any new piece of equipment, a break-in period is required. The manner in which the vehicle is treated in the first few days of operation may have a direct impact on the overall performance of the vehicle, as well as the life span of individual components. Take time to review the following suggestions and comments on operating a new industrial vehicle or a vehicle with new components.

Motors

The brushes in the motors will not fully seat on the commutators for approximately 1 70 hours. Accelerate/decelerate the vehicle in a smooth progressive fashion. Avoid jackrabbit starts and stops.

Pump

The lift pump gears or vanes need time to wear-in properly. If possible operate the lift system starting with a light load and progressively increasing the weight over an hour or two. Intermix load weights so as not to overheat the hydraulic system. Seals in the lift cylinders, when new, cause extra drag thus making the hydraulic system work harder.

Battery

The break-in period for a new battery is 170 hrs of operation. During this period, the charging/discharging cycles of the battery will "form" the battery plates within the individual cells. Abusing or improperly charging/discharging a new industrial battery can be a costly mistake.

Applying a little common sense to the operation of a new industrial vehicle will ensure a long, productive life.

Service and Parts Manual Chapter 4 Theory of Operation Index

TOYOTA

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

Advanced Transistor Control Setion Overview System Overview Advanced Transistor Control (AT) Current Limiting Low Voltage Cutback Thermal Protection Runaway Protection Static Return to Neutral Protection Plugging Controller Keyswitch Input Controller Thumbwheel Throttle Inputs "Emergency Reverse" Plug Breaking Inhibit . . . . . . . . . . . . . . . . . . . . . . .

Control Module Battery Plugged IN Battery Plugged IN/Keyswitch Turned to ON or TURTLE Battery Plugged IN/Keyswitch Turned ON/Deadman Switch Closed Diredional/Speed Control Forward Diredional/Speed Control-High Speed (FORWARD ONLY) Emergency Reverse Switch Plugging Turtle Speed

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

Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25

Service and Parts Manual Advanced Transistor Control

TOYOTA

Advanced Transistor Control Section Overview

This section will provide a better understanding of the advanced transistor control used on Models 6HBW3OI6HBE30, 6HBE40,6HBC30t 6HBC40 and 6TB50.

Because of the many interlocking controls, a specific condition will be presented for each operational mode. The condition and mode will be illustrated on the applicable schematic sheet or sheets as necessary.

The schematics in this chapter are for Theory of Operation explanation only and are not for actual vehicle troubleshooting or maintenance. Refer to Chapter 7 Appendix for actual vehicle schematics.

Circled numbers explanations.

0 ,@ etc. in the illustrations are keyed to the corresponding

The following operational modes will be covered in this section:

Travel System Battery Plugged In Key switch ON Brake Switch Closed Directional/Speed Control Forward High Speed (Rabbit Speed) Turtle Speed Emergency Reverse Plugging

Lift/Lower System Key switch ON Lift Switch Closed Hydraulic Action Lift Switch Open Lower Switch Closed

Service and Parts Manual

TOYOTA

Advanced Transistor Control System Overview

The "Advanced Transistor" (AT) stepless speed control is used on all Toyota vehicles.

The Model 6HBE30 will be used for the example in this chapter. Other models may differ slightly.

Advanced Transistor Control (AT)

The AT Control System is used on the Models 6HBW30, 6HBE30, 6HBE40, 6HBC30, 6HBC40 and 6TB50 vehicles. This system electronically controls drive motor power and can be smoothly varied from full OFF to full ON without speed steps or increments. The heart of this control system is the Advanced Transistor Control Power Module.

The AT Power Module is basically a high-power semiconductor switch. An array of

MOSFET power transistors are connected in parallel and control the current through the motor windings.

The transistors are connected in series with the battery and the motor. When the transistors are on, the current through the motor builds up, storing energy in the motor's magnetic field. When the transistors turn off, the stored energy causes the motor current to continue to flow through the internal freewheel diode. The transistors are turned on and off at the rate of up to 15,000 times per second by the internal control circuitry. The ratio of on and off times is varied by the input from the throttle potentiometer. This technique is called pulse width modulation.

I

------CONTRUER ----B+ 1 B+

- I +

24 UoLT T BATTERVl

THROTTLE POTENTIMIETER

FILTER

I -1CRPS

-I I

=

I I

CONTROL CIRCUITRY

I I I

C - -----A

----------,I

:-El---

--- + CURRENT PATH

DURING TRANSISTOR ON T I M

I

Figure 4.1

AT Control System (simplified)

4.2

[) CURRENT PATH MJRING T R R N S I S l _ OFF T I E

I

Service and Parts Manual Advanced Transistor Control

TOYOTA

Advanced Transistor Control (AT) (Cont'd.)

As shown in Figure 4.2, the motor current ramps up and down as the power FET's turn on and off. The average current (which determines the motor torque) is being controlled by the ratio of the on and off times. In this way, smooth, stepless control of the power delivered to the motor is achieved with very low power loss in the control components.

Current Limiting

The AT controller limits motor current to a preset maximum. This current limit protects the controller from damage. Damage would result if the current were limited only by motor demand. The current limit also reduces stress placed on the motor, drive train, motor controller, and battery. Motor, battery efficiency and service life are improved by eliminating high current surges during vehicle operation.

I

T I K

CURRENT P A T H D U R I N G T W S I S T O R ON T I C K

t)CURRENT M T H WRINGTRANSISTOROFF TIME

Figure 4.2 Low Voltage Cutback

Motor Current Chart

The AT controller prevents operation at very low battery voltages. The control circuitry requires a minimum voltage to function properly. Performance is gradually reduced if the battery voltage falls below approximately 16 volts. By reducing the output to the motor, battery voltage can recover. A balance is achieved where the battery is allowed to supply as much current as it can without falling below 16 volts.

Service and Parts Manual Advanced Transistor Control

TOYOTA

Advanced Transistor Control (AT) (Cont'd.)

Thermal Protection

When internal temperature of the motor controller exceeds 165°F (73"C), and the controller is overloaded, current limit will be gradually reduced in a linear fashion. This will generally allow continued vehicle operation, but at a reduced performance level.

When the controller cools down, full current limit and performance will automatically return. This action is not damaging to the controller; however, if thermal cutback occurs often, the vehicle may not be suited for the particular application.

Runaway Protection

The AT controller has a feature which shuts off the output in the event of an open circuit fault in the throttle system or the control module which could otherwise result in uncontrolled operation. The throttle configuration is a 13,000 ohm pot going from zero ohms in neutral (when referencing the pot wiper to the fixed center tip of the pot), to 5000 ohms for full O n in either direction. Broken pot wiring, connections or pots which fail open would normally give a full ON signal. The AT controller detects any throttle inputs of more than 7000 ohms as a fault and shuts off the output, preventing a runaway condition. The controller will return to normal operation when the fault is repaired.

Static Return to ~ aProtection l Neut~

The AT controller has circuitry to sense a "high" (non-zero) throttle at the time the keyswitch is turned on and inhibits the output until the throttle is released and re-applied. This safety feature prevents the vehicle from being turned on with the throttle engaged, requiring the operator to start smoothly from zero throttle. It also protects against sudden starts caused by problems in the throttle linkage (e.g., bent parts, broken return spring, etc.), which might give a partial or full throttle signal to the controller even with the throttle released.

Plugging

When the series wound drive motor field is reversed while the vehicle is moving, a form of electrical braking called "plugging" occurs which may be used to slow the vehicle down. When the motor is reversed, with the throttle engaged (by reversing the field connections) the armature acts as a generator. Current from the armature flows through a "plugging diode" built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plugging torque proportionately based on throttle position. The vehicle slows smoothly to a stop, then automatically accelerates in the other direction. The plugging current is factory set. Do not attempt to adjust it.

Service and Parts Manual Advanced Transistor Control

TOYOTA

Advanced Transistor Control (AT) (Cont'd.)

Controller Keyswitch Input

The controller keyswitch input (PMC2-1) is used to turn the controller on and off. The controller's main power connections (B+ and B- busses) are kept "live" at all times.

Most of the internal circuitry is powered down when the keyswitch is turned off.

PMC2-1 is turned on by the brake switch connecting it to the battery B+.

Controller Thumbwheel Throttle Inputs

The throtile inputs (PMC1-1 and PMCl-2) are used to input speed selection to the controller.

The throttle input must go from zero ohms at neutral to 5000 ohms in each direction (actual values may vary, but they must be equalized +/- 100 ohms). Actual start point is approximately 300 ohms, and full on is achieved at 4.3k ohms.

"Emergency Reverse1' Plug Breaking Inhibit

In normal operation, when reversing vehicle direction, the controller goes through a "plugging" mode. A variable pulse rate (throttle controlled) is input to the drive motor (the field connection is also reversed), initiating a gradual decrease in speed to zero, then reversing direction.

An "emergency reverse" condition requires a quicker response. PMC2-3, when connected to B+ through the Emergency Reverse switch, allows a higher current limit during a plug. This causes the controller to bypass the normal plugging mode of operation and immediately ramp up to full speed in the reverse direction as long as the Emergency Reverse switch is activated. The Emergency Reverse Module is deactived during an emergency reverse condition. This places a resistor in parallel with the throttle pot. This action commands a maximum forks-first travel speed command to the motor controller.

Plug Current Adjust

Current Limit Adjust

Acceleration Adjust

(Cover Removed)

Figure 4.3 Motor Controller Pinout Functions

Service and Parts Manual Advanced Transistor Control Control Module

TOYOTA

This module has four basic functions:

1. The throttle control section controls the directional contactors by monitoring relative direction change of the wiper in the throttle potentiometer with respect to either end of the potentiometer.

2. The field weaken management circuit controls the field weaken contactor and is activated only when all the following conditions are met.

A. The vehicle is not plugging.

B. Emergency reverse is not activated.

C. The throttle control must be 90% ON. (Minimum potentiometer setting approximately 4.3k ohms)

D. The direction of travel must coincide with the manual wire selection. That allows field weakening in that particular direction.

3. The emergency reverse circuitry controls the override of the directional travel control. This control is common to the Models 6HBW30, 6HBE30 and 6HBE40 only.

4. Controls the hour meter.

Forward (Tractor-first)

Service and Parts Manual Advanced Transistor Control Battery Plugged

IN

TOYOTA

When a properly charged battery is connected to the vehicle, battery potential (B+) goes to: (see Figure 4.5).

1. Positive side of keyswitch.

2. Positive side of horn button.

3. Positive side of the open pump contactor tips.

4. B+ on the motor controller 5. Through the motor controller plug diode at A2 and to the positive side of the open directional contactors.

Service and Parts Manual Advanced Transistor Control

TOYOTA

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Tracina Leaend $gxg&B= Positive B+ (DC)

-

'

............ ..................... - Negative B- (DC) ...........

--- Circuits Signal Voltage Traced Earlier = =

Figure 4.5

Battery Plugged IN

4.8

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control Battery Plugged IN/ Keyswitch Turned To ON or TURTLE

TOYOTA

When keyswitch is turned ON, battery potential (B+) goes to: (see Figure 4.6)

1. Positive side of the hour meter.

2. Positive side of battery discharge indicator.

3. Positive side of lift/lower switches.

4. Handle heaters (if equipped).

5. Positive side of deadman switch.

6. PMC2-1 on the motor controller.

7. P1 -N on the control module.

Service and Parts Manual Advanced Transistor Control

TOYOTA

NOTES:

Tracina I eaend -

1 . All boxes labeled LurtIe Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. AJl boxes labeled Motor Controlla are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

--.----. ..................... ..........= Negative B- (DC)

= Positive B+ (DC)

-- --= Signal Voltage Circuits Traced Earlier

=

Figure 4.6

Battery Plugged IN/Keyswitch Turned ON

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control Battery Plugged IN/ Keyswitch Turned ON/Deadman switch Closed

TOYOTA

With the deadman switch closed (control handle moved beyond 10" of vertical) B+ is also available to: (See Figure 4.7)

1. The hourmeter which is now activated and is recording hours of operation.

2. Positive side of field weaken switch.

3. Through the forward and reverse contactor coils to P I -A and P I -H on the control module.

4. Through emergency reverse switch and normally closed contacts.

The forward and reverse contactors will not be energized until the twistgrip/butterfly control (diredional/speed control) is rotated. This activates internal switching circuitry in the control module to complete the negative circuit to the contactor coils.

5. Emergency reverse module pin 2.

Releasing the control handle will open the deadman switch which will disrupt power to the above circuits.

Service and Parts Manual Advanced Transistor Control

TOYOTA

NOTES: 1. All boxes labeled Turtle Mod& are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Tracina Leaend = Positive B+ (DC) --...................... .......... - Negative E (DC)

---=

Figure 4.7

Battery Plugged IN/Keyswitch ON/Deadman Switch Closed

4.1 2

Signal Voltage = Circuits Traced Earlier

NOTE: This schematic is far Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control Directional/Speed Control Forward

TOYOTA

As the twist grip/butterfly control (diredional/speed control) is rotated in the forward direction from neutral the following occurs: (Refer to Figure 4.8) 1. The first few degrees of control handle movement closes the forward directional contactor.

The resistance of throttle potentiometer (diredionalhpeed control pot) is varied as the twist grip/butterfly lever is rotated. When the lever is in the neutral position, the resistance is zero ohms between the wiper and the center tap VR4. As the lever is rotated in either direction, resistance increases to a maximum of approximately 5.OK ohms.

2. The throttle potentiometer in the control handle: controls throttle input to the motor controller (VR-2 input to PMC1-1). determines direction (VR1, VR2, and VR3).

VR-1 input to the control module at P I -L with output from the control module at P1-K to the motor controller at PMC1-2.

VR-3 input to the control module at P I -J with output from the control module at P I -K to the motor controller at PMC1-2.

Service and Parts Manual Advanced Transistor Control

TOYOTA

KEY

SWITCH

DEADMAN

SWITCH

NOTES:

Tracina Leaend

1 . All boxes labeled Turtle are physically contained in a single module and are split ovt on this diagram for functional clarity only.

2. All boxes labeled Motor Controller:are physically contained in a single module and are split out on this diagram for functional clarity only.

3.All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

-.. EX = Negative E ..........

L (DC)

= Positive B+ (DC)

- -fi

Figure 4.8

Diredional/Speed Control Forward

= Signal Voltage = Circuits Traced Earlier

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control DirectionaVSpeed Control-High Speed (FORWARD

TOYOTA

As the twist grip/butterfly lever is rotated to full speed forward the following occurs: (except during a plugging condition) (Refer to Figure 4.9)

ONLY) 1. With the directional/speed control fully rotated, the power FET transistors in the motor controller are energized to 90% ON. 2. If the field weaken switch is pushed while operating at full speed with the power FET transistor 90% ON, the field weaken coil is energized. A field weaken resistor is then put in parallel with the drive motor field winding. This will reduce the current flow through the winding thus weakening the electromagnetic field. With the field weakened, the armature will rotate at a higher speed, but will have lower torque.

The control module controls this circuit and will allow the drive motor to run at a higher speed in FORWARD only. (See step 3 below.)

3. Forward enable (PI -E on Control Module) is at negative potential in order for field weakening to engage.

When operating with the field weaken contactor energized, the motor current is monitored by the AT control system. If motor current is above the preset limit, high speed will be prevented. Or, if while operating in high speed, the motor current raises to above the current limit, the field weaken contactor will drop out.

Service and Parts Manual Advanced Transistor Control

TOYOTA

KM SWITCH

DEADMAN

SWITCH

NOTES:

1. All boxes labeled Iurtle Modulp are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Contr* are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

-

-. Positive B+ (DC) ............ ....................... - Negative E L(DC)

_

---

.--._m

= Signol Voltage

= Circuits Traced Earlier

Figure 4.9

Diredional/Speed Control High Speed (Forward)

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control Emergency Reverse Switch

TOYOTA

If the vehicle direction of travel is quickly reversed by the emergency reverse switch, the AT control system will provide a rapid deceleration and an immediate acceleration in the reverse (forks first) direction.

When traveling in the forward direction, if the emergency reverse switch is activated: (See Figure 4.10)

1. The forward contador coil is de-energized.

2. The emergency reverse switch goes into N/O position which applies B+ to PMC2-5 of the motor controller. This allows a higher plugging current limit.

3. The reverse contactor coil is energized.

4. A full reverse signal is sent to the motor controller regardless of throttle input, and remains in that condition until the belly button is released.

Once the emergency reverse switch is activated, the control module locks out the forward contactor by opening the negative circuit (internally) at P I -A. To reset the vehicle for normal travel, the handle must either be set to the full vertical or full horizontal position. Turning the keyswitch OFF and then ON will also reset the control module.

Upon engagement of the emergency reverse switch (also called the belly button switch), battery voltage is removed from P I -C of the control module. The reverse contactor coil energizes and immediately engages the reverse contador.

Simultaneously, the control module disables the throttle control in the forward direction and the emergency reverse module signals the AT control with a full throttle signal. This abruptly reverses vehicle direction. The AT control also disables the normal plugging condition and forces maximum plugging current to the motor.

Additional circuitry in the control module stores the information from this condition and locks out the forward contactor. This mode can be reset by disengaging the deadman switch.

Service and Parts Manual Advanced Transistor Control

TOYOTA

KM

SWITCH

NOTES:

DEADMAN

SWITCH

Tracina Leaend

1. All boxes labeled Turtle Module are physicalh contained in a single module and are split out on this diagram for functional clarity onh.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity onh.

-

= Positive B+ (DC)

...-*..... .......... - Negative B- (DC) .....................

-- - Signal Voltage

= = Circuits Traced Earlier

Figure 4.1 0

Emergency Reverse

4.1 8

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Advanced Transistor Control Plugging

TOYOTA

Plugging is the recommended method of retarding travel speed and changing travel direction during operational maneuvers. Plugging may also be used to stop the vehicle. Plugging will not stop the vehicle as fast as braking, but will provide the operator with an alternate way to bring the vehicle to a smooth controlled stop.

(See Figure 4.1 1.)

1. The speed control twist grip/butterfly lever is moved from its original position back through neutral to a speed in the opposite direction. The farther the handle is moved in the opposite direction, the greater the plugging force.

2. Directional contactor (forward or reverse) which was originally closed, now opens and the contactor originally open, now closes.

3. Current flow through the motor's field windings is reversed and is attempting to turn the armature in the opposite direction. However, inertia of the vehicle causes the armature to continue spinning in the original direction until the vehicle stops.

The schematic on the next page shows a vehicle traveling forward with plugging to reverse.

Service and Parts Manual

Lift/Lower Svstem

TOYOTA

NOTES: 1 . All boxes labeled b r t l e Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controllet are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 4.1 1

Plugging

4.20

= Positive B+ (DC) ..-.>:.:.:..--,.. :.:.x.:.:.:. = Negative 5 (DC) = Signal Voltage = Circuits Traced Earlier

- --

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Serv~ceand Parts Manual Advanced Trans~storControl Turtle Speed

TOYOTA

1 To operate ~nTurtle Speed, the keyswitch must be turned to the Turtle Position.

(See Figure 4.12.)

2. Thls energizes the turtle relay coil and activates the turtle module. Thts reduces the allowable resistance to the motor controller at PMC1-1 Speed IS limited withln the limits of the turtle module by a var~ableres~storIn the turtle module.

D O NOT ADJUST THE MODULE SO THAT IT WILL ALLOW THE VEHICLE TO TRAVEL FASTER THAN 3.5 MPH (5.6 Km) IN THE TURTLE MODE.

Service and Parts Manual Advanced Transistor Control

TOYOTA

KtY

SWITM

DEADMAN

SWITCH

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller: are physically contained in a single module and are split out on this diagram for functional clarity only.

3. ,411 boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

-

= Positive B+ (DC)

........... - Negative B- (DC) .............

.-I.-.-.-.-.-.-.-.-.-.

--- = Signal Voltage

= Circuits Traced Earlier

Figure 4.1 2

Turtle Speed

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Lift/Lower Svstem Lift/Lower System

TOYOTA

The Lift/Lower system consists of an electrically operated hydraulic pump and related components. (See Figures 4.1 3 and 4.14.)

The following theory will cover both the electrical and the hydraulic system operation.

Lift

With the battery plugged in and the keyswitch turned on, closing the lift switch causes the following: 1. The lift pump contactor closes causing the lift pump motor to operate.

2. Hydraulic fluid is drawn from the reservoir into the lift pump and is sent, under pressure, to the lift cylinders.

3. Hydraulic pressure in the lift cylinders causes the forks to raise.

A lift cutout switch will interrupt power to the lift motor when the forks reach a preset lift limit.

4. With the lift switch opened, the pump contactor coil is de-energized. This stops the lift motor and pump. Hydraulic pressure is trapped by the check valve (5),the holding the static position of the relief valve (4) and closed lowering solenoid (7), forks at any position within limits.

~ e l i evalve f (4) will open should pressure in the system exceed preset limits.

--------

= High Pressure = Low Pressure

Figure 4.1 3

Electrical - Hydraulic Circuits for Lift

Service and Parts Manual Advanced Transistor Control

TOYOTA

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module ore physically contained in a single module and are split out on this diagram for functional clarity only.

= Positive B+ (DC) ............ . --.

- ---.-- Negative E .......... ............,..

L (DC)

-

--- Signal Voltage Circuits Traced Earlier =

=

Figure 4.1 4

Lift Switch Ciosed

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Lift/Lower System

TOYOTA

Closing the lowering switch causes the following: (See Figures 4.1 5 and 4.1 6.)

Lower

1. The lowering solenoid will open.

2. Hydraulic fluid in the lift cylinders will return to the system reservoir through the flow control valve.

I .; '

7

1- 11

I

,! '

I

L, - - - - - - - J Figure 4.15

Electrical-Hydraulic Circuits for Lower

= High Pressure = Low Pressure

Service and Parts Manual

Lift/Lower System

TOYOTA

NOTES: 1 . All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 4.1 6

Lower Switch Closed

Tracina Leaend

-

= Positive B i (DC)

..---.-........... ........-.. ............ _ Negative B- (DC)

---.

= Signal Voltage = Circuits Traced Earlier

NOTE: This schematic is for Theory of Operation only. Refer to the electrical schematic at the back of this manual when troubleshooting or performing maintenance.

Service and Parts Manual Chapter 5 Maintenance Index

TOYOTA

SUBJECT

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily or Every 8 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weekly or Every 50 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . .

Monthly or Every 200 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . .

Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Semiannually or Every 1.000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication and Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 5.2 5.2 5.3 5.3 5.4 5.4 5.5 5.6

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

5.7

Welding Precautions

Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Housing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Housing Vent Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Housing Steering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 5.9 5.9 5.9 5.11

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Tooth Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Gear Case Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Adjustment (For all Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deadman Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Return Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 200 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cushion Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Replacement (Model 6HBE30 & 6HBC30) . . . . . . . . . . . . . . . . . . . . .

Wheel Replacement (Model 6HBE40 & 6HBC40) . . . . . . . . . . . . . . . . . . . . .

Pallet Entry Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 500 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork And Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 5.12 5.15 5.16 5.16 5.17 5.20 5.20 5.20 5.21 5.22 5.22 5.24 5.24 5.24 5.24 5.24 5.26 5.26 5.26 5.26 5.26.1 5.27 5.27 5.27 5.27 5.27 5.28 5.28 5.29 5.29

Service and Parts Manual Chapter 5 Maintenance Index

TOYOTA

SUBJECT

PAGE

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowered Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.30 5.30 5.31

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . .

Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 8 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinders Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Leakage Wiper Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 200 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Every 1, 000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.32 5.34 5.34 5.35 5.35 5.35 5.37 5.37 5.37 5.37 5.37 5.37 5.39

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.41 Battery Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 lnspedion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 High Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 Resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47 Drive Motor General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 Drive Motor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 Drive Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48 Lift Motor General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 lnspedioh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 Traction System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 Current Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 Plug Current Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53 Acceleration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54 Deadman Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.56 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tiplnspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.56 5.56 5.56

Service and Parts Manual Chapter 5 Maintenance Index

TOYOTA

SUBJECT Contador Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contador Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Of Contactor Tips. Insulation And/or Core And Rod Assembly . . . . . . .

Contador Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Potentiometer Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turtle Speed Module (DA2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Reverse Module (DA1) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Other Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 5.57 5.57 5.57 5.58

5.60 5.60 5.60 5.61 5.61 5.62 5.62

5.63 5.64 5.64 5.65

Service and Parts Manual Scheduled Maintenance Scheduled Maintenance

TOYOTA

A regularly scheduled maintenance program is recommended to provide:

Maximum vehicle performance Maximum vehicle life Reduction of costly downtime Avoidance of many expensive repairs

Scheduled maintenance includes: Lubrication Inspection Service Perform all of the following scheduled checks and maintenance during the suggested intervals. See page 7.1 for lubrication equivalents. Refer to manufacturer's supplements for components not listed on the following pages.

To insure the use of the proper hydraulic fluid for the temperature environment of vehicle operation, refer to page 3.6.

Service and Parts Manual Scheduled Maintenance Lubrication and Maintenance

TOYOTA

The time intervals given in this guide are based on normal operating conditions.

When operating under abnormal or severe conditions, these services should be performed as often as required to maintain the unit in good operating condition.

Daily or Every 8 Operating Hours, Whichever Occurs First

Check the brake actuation and the operation of the drive motor cutout switch. Ensure brakes function properly.

Check the steering operation.

Check the lifting and lowering of the forks.

Check the exterior condition of the vehicle.

Report any damage that may hinder vehicle operation.

Service and Parts Manual Scheduled Maintenance Every 500 Hours

Semiannually or Every 1,000 Hours, Whichever Occurs First

TOYOTA

Service and Parts Manual Scheduled Maintenance

TOYOTA

Lubrication and Maintenance Guide

Lift

/ Linkage

Drive Support Bearings

Load Wheels (2)

Load Arms (6)

Casters (2)

/

Figure 5.1

\

Battery Cover Hinge

Lubrication Points (Model 6HBE30 Shown)

Service and Parts Manual Scheduled Maintenance Hydraulic System Oil

TOYOTA

Use hydraulic oil that conforms to specifications listed in Chapter 7 Lubrication Equivalency chart.

If the hydraulic system oil is stored in large containers, keep the containers free of contaminants such as dirt, water, and metal chips. Contaminated hydraulic oil is the major cause of hydraulic system failures. It is recommended that each storage container be marked - FOR USE IN HYDRAULIC SYSTEMS ONLY. In severe cold storage applications, which cause sluggish operation of the hydraulic system, use hydraulic oil conforming to specification MIL-H-5606 (Texaco Aircraft Hydraulic Oil type BB, or equivalent) to improve hydraulic system operation. Do not add this type of hydraulic oil to hydraulic systems that are using water glycol or phosphate ester.

Service and Parts Manual Welding Precautions

TOYOTA

Welding Precautions

A CAUTlo BEFORE

ATTEMPTING TO INSPECT, SERVICE, OR REPAIR THE VEHICLE, DISCONNECT THE BATTERY. DISCHARGE THE CAPACITORS BY MOMENTARILY TOUCHING A SUITABLE JUMPER WIRE ACROSS THE CAPACITOR TERMINALS. Perform ground tests on the vehicle. If any grounds are detected, remove them before proceeding with the welding operation.

Clean the area to be welded.

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

Attach the ground cable as close to the weld area as possible.

Do not perform any welding operations near the electrical components.

If the welding operation must be performed near the battery compartment, remove the battery from the vehicle.

After the welding operation is complete, all ground tests and electrical inspections should be performed before the vehicle is put back into operational service.

Service and Parts Manual Power Section

TOYOTA

Power Section

Battery Disconnect

Drum Brake

Horn \

Battery Discharge +our deter

, Lift

Motor

Lift Motor Solenoid

Figure 5.2

Component Identification and Location

5.8

Service and Parts Manual Drive Unit

TOYOTA

Drive Unit

PERFORMING ANY OF THE FOLLOWING SERVICES, DISCONNECT THE ACAUTIONBEFORE ATERY. Drive Unit Service

Inspect and service the drive housing support bearing at periodic intervals. Check the support bearing for any possible damage or excessive wear. Check the oil level in the drive housing periodically and change it as specified in Scheduled Maintenance.

Keep the drive housing vent plug clean and open to prevent pressure from building up in the housing. This could force lubricant out of the shaft seals.

Drive Housing Lubrication

After 100 hours of operation, check the oil level in the drive housing. Remove the pipe plug. With the unit in a level position, the oil level should be up to the bottom of the pipe plug opening. If necessary, add the specified oil through the plug opening, but do not overfill. Then, install the pipe plug securely.

After each operating interval of 1,000 hours, change the oil in the drive housing.

Ambient temperature conditions will indicate what grade of gear oil is to be used.

Change gear oil as follows: 1. Remove drain plug from bottom of gear housing cover and allow oil to drain.

Also, remove and clean the vent plug from the main case.

Allow sufficient time for the oil to drain.

2. After the oil has drained, flush the housing with a suitable solvent and allow to drain. Install the drain plug, and fill the drive housing with the specified gear oil through the oil fill hole in the top cover of the transmission. The drive unit housing will hold 2.25 qts. (2.130 liters) of oil. Do not overfill. lnstall the oil level plug and vent plug.

3. Operate the drive unit for 5 minutes to allow any air trapped within the unit to raise to the top and the fluid to reach all cavities; then recheck the oil level. Add oil as necessary to bring the oil up to the correct level.

Drive Housing Vent Plug

After each 100 hours of operation, check the drive housing vent plug to make certain it is clean and open. Remove the vent plug from the top cover of the drive housing. Wash it in a suitable cleaning solvent and dry it with clean compressed air to make certain it is not clogged. Install vent plug and tighten securely.

Service and Parts Manual

TOYOTA

Drive Unit

1

--

TORQUES

lTEM 7.

22.

1. Gear Sets (27 & 28) and (6 & 12) are matched sets. They must be replaced as such. Refer to the Parts Manual for part numbers as required.

2. Set pinion shaft (6) end play from .000" to .002' (.000mm to .050mm), using shim pack (30) as required.

3. Set wheel drive shaft (17) preload from .000"to .001"((.000mmto .025mm), using shim pack (13) as required.

4. Set pinion shaft (6) and spiral pinion (12) backlash from ,00390 .005" (.076mm to .127mm).

1. BEARING 2. CONICAL WASHERS 3. NUT 4. BEARING CUP/CONE 5. PIPE PLUG 6. PINION SHAFT 7. HEX HD. BOLT 8. NUT 9. DRIVE WHEEL

10. WHEEL HUB 1 1. COVER PLATE 12. SPIRAL GEAR 13. SHIM PACK 14. BEARING CUP/CONE 15. HEX HD. BOLT 16. LOCKWASHER 17. WHEEL DRIVE SHAFT 18. SEAL

Figure 5.3

19. SNAP RING 20. STEERING RlNG ASSY. 21. MAIN CASE 22. HEX HD. BOLT 23. TOP COVER/MOTOR MTG. PLATE 24. LOCK WASHER 25. HEX HD. BOLT 26. SEAL

Drive Assembly (Cutaway View)

25.

29.

YAL!JE

18 Ft. Lbs (25.2Nm) Ft. Lbs.'(77~m) Ft. Lbs. 1105NMI 120 150 in. Lbs. ' (13.56NM-16.95Nm) 50 Ft. Lbs. (70Nm) 50 Ft. Lbs. (70Nm)

-

27. HELICAL GEAR 28. HELICAL PINION 29. LOCKNUT 30. SHIM PACK 31. BEARING CUP/CONE

Service and Parts Manual Drive Unit Drive Housing Steering Bearing

TOYOTA

After each 500 hours of operation, lubricate the steering bearing and all the other grease fittings. After 1,000 hours of operation, or when steering becomes sloppy or stiff, check the bearing and the snap ring securing the bearing to the drive housing.

1. To remove the steering bearing: Remove the drain plug and vent plug. Allow oil to drain.

Disconnect the motor cables from the motor and the handle harness from the terminal block.

Block the frame.

Attach a hoist of suitable capacity to the drive unit.

Remove the capscrews which secure the drive unit to the frame.

Remove the drive unit.

Remove the snap ring that secures the bearing to the drive housing, then remove the bearing and steering ring assembly.

2. To reinstall the steering bearing proceed as follows: Install the bearing. Inner race is indexed to the transmission casting with a roll pin.

Replace the snap ring that secures the bearing to the drive housing.

Replace the drive unit using the hoist.

Replace the cap screws which secure the upit to the frame.

Reconnect the motor cables to the motor and the handle harness to the terminal block.

D O NOT REMOVE THE HOIST UNTIL THE CAPSCREWS ARE IN PLACE AND

ACAUTloNTORQUED.

3. Replace the drain plug.

4. Replace the oil.

5. Replace the vent plug and the oil level plug.

Service and Parts Manual Mechanical

TOYOTA

Mechanical Drive Unit Assembly

1. To determine the proper shim pack (30), use the following steps: (See Figure 5.4) A. Press the bearing cone (4) on the pinion shaft (6).

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. (See Figure 5.4) 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 (30).

MD - (Length

+ SD) = shim

2. Place the shim pack (30) in the case (21) and draw the bearing cup into position.

3. Place the case (21) in a fabricated assembly base and press the remaining bearing cup (4) into the case.

4. Insert pinion shaft (6) through the bottom of the case (21) and position it in place.

5. Press bearing cone (4) into place. Allow approximately .005" (. 727mm) end play.

6. Place helical gear (27) on the spline of the pinion (6).

7. Apply Loctite 271 to threads on pinion shaft (6).

8. Tighten the nut (3) to adjust the end play of the pinion shaft (.000" to .002") (.000mm to .050mm).

9. Press bearing cone (31) on spiral gear (12).

10. Place case (21) in fabricated stand.

1 1. Place shim (13) (Approx. .020" to .0301')(.508mm to .762mm) in bearing cup bore and position bearing cup (31) in place. The cup should be a slip fit. Tap in place with soft face hammer.

12. Prevent helical gear (27) from turning by inserting a 1h"bolt through pipe plug hole (5). Engage bolt with gear teeth.

13. Place the spiral gear (12) into position. While pressing the gear down into the bearing ,cup (31), check backlash. Required backlash is .003" to .005" (.076mrn to .127mm). Add to or subtract from the shim pack (13) to achieve the proper backlash. Check tooth pattern (Refer to Chart on page 5.1 5).

14. Once th.e backlash is correct, place the case in a fabricated support base with the spiral gear (1 2) in place, resting on the base.

15. Press bearing cup (1 4) in case, place bearing cone in cup and press seal (18) into the case.

16. Insert wheel drive shaft (17) through the seal and bearing while aligning spline of shaft with spiral gear (1 2). After aligning splines, press shaft through until seated.

Service and Parts Manual Mechanical

TOYOTA

Setting distance stamped on the very end of the pinion

1. BEARING 2. CONICAL WASHERS 3. NUT 4. BEARING CUP/CONE 5. PIPE PLUG 6. PINION SHAFT 7. HEX HD. BOLT 8. NUT 9. DRIVE WHEEL

10. WHEEL HUB 1 1. COVER PIATE 12. SPIRAL GEAR 13. SHlM PACK 14. BEARING CUP/CONE 15. HEX HD. BOLT 16. LOCKWASHER 17. DRIVE WHEEL SHAFT 18. SEAL

Figure 5.4

19. SNAP RlNG 20. STEERING RlNG ASSY. 21. MAIN CASE 22. HEX HD. BOLT 23. TOP COVER/MOTOR MTG. PLATE 24. LOCK WASHER 25. HEX HD. BOLT 26. SEAL

Drive Gear Data

27. HELICAL GEAR 28. HELICAL PINION 29. LOCKNUT 30. SHlM PACK 31. BEARING CUP/CONE

Service and Parts Manual Mechanical Drive Unit Assembly (Cont'd.)

TOYOTA

17. Place the case (21) in a fabricated support base.

18. Apply Loctite 271 to threads of drive wheel shaft (7).

19 Using locknut (8) tighten to 55 ft Ib (77Nm) to obtain setting .OOOHto .007" (.000mm to .025mm) preload.

20. Place wheel hub (10) or complete drive wheel (9) assembly on the drive wheel shaft (17).

21. Place the steering ring assembly (20) with the bearing loading hole against the case (21). The inner race is indexed to the case (21) with a spring pin. Install the retaining ring (19).

22. Use a thin bead of silicone to seal cover plate (11) to housing. Use 6 bolts (7) and lock washers. Torque to 78 ft. Ibs (25.2Nm).

23. Press seal (26) into cover (23).

24. Place the cover (23) on the case. Finger tighten the seven bolts (25) and lock washers (24).

25. Install the pipe plug (5)' drain plug and vent plug into the unit using anti-seize compound.

26. If removed, insert grease fittings to the steering ring (20) and fill with grease.

Service and Parts Manual

TOYOTA

Mechanical Drive Unit Tooth Pattern

Mount the gear sets according to the instructions in this Chapter. Adjust the shim packs to correct tolerances. Correct improper tooth patterns as shown in the chart.

The amount of the change depends on the position of the patterns on the teeth.

TOOTH PATTERN ON RING GEAR CONCAVE FLANK

CONVEX FLANK

DRI UEN CONCAVE FLANK

CORRECT PATTERN BY CHANGING THE SHIMS IN THE DIRECTION SHOWN

BY THE ARROWS

DRI UI NG CONVEX FLANK

1bL IDEAL P A T T E R N

fibL PATTERN AT T I P

1P A T T E R N A T R O O T

4\ 4

I

TOE PATTERN

J

HEEL PATTERN

Figure 5.5

Gear Set Tooth Patterns

5.15

\ ft

I+ C I

Service and Parts Manual Mechanical Drive Gear Case Data (Refer to Figure 5.4)

TOYOTA

Measure the pinion gear (6) end play:

With the bearings in place and the helical gear installed, check the end play of the pinion gear. It should be .OOOH to .002" (.000rnrn to .050rnrn). Adjust as required by tightening or loosening locknuts.

After adjusting pinion end play, set the drive wheel shaft (17) preload to .OOOHto .OO 7 " (.000mm to .025rnrn), using shims (13) as required.

To check gearing and backlash:

Gear Checking Procedure (Refer to Figure 5.4 bnd Figure 5.5)

1. Clean the pinion (6) and spiral gear (1 2). Apply a slight amount of red lead on the teeth of the pinion gear.

2. Install the shims, bearing, pinion and upper bearing, then rotate several times to right and left.

3. Check the tooth contact pattern on the bevel and pinion gear.

To adjust gearing and backlash:

1. Heel gearing of bigger end of spiral gear (1 2) on running reverse and of smaller end on running forward. Add the shims (13) in the bearing housing to keep away and adiust backlash.

Standard backlash 0.003-0.005 in. (0.08-0.73 rnm).

2. You can adjust drive wheel shaft (17) backlash with shims (13).

3. Adjust the shims (30) to bring the pinion gear close to the spiral gear center and adjust backlash.

4. Refer to adjustment of backlash above for heel gearing.

m

Tightening torque of locknut on drive wheel shaft is: 55 ft.lbs. (77Nrn), with a preload on the shaft of .000" to .00l1I(.000rnrn to .025rnrn).

Service and Parts Manual Mechanical Drive Unit Installation (See Figure 5.6 and Figure 5.7)

TOYOTA

Make certain the keyswitch is off and the battery is disconnected.

1. Make sure the housings are connected, covers are in place.

2. Attach the hoist to the drive unit (see page 5.1 9 ) and lift the unit into place on the vehicle frame.

3. Align the drive unit to the vehicle frame.

4. Install the six capscrews in the steering bearing and torque them to 50 ft./lbs.

(70 Nm).

5. Remove the hoist and install the brake drum.

6. Install the locknut on the brake drum.

7 . Mount the control handle.

8. Attach wiring harness and brake cable.

9. Connect battery and turn key switch on.

10. Check controls for proper operation.

Service and Parts Manual

TOYOTA

Mechanical

Locknut Brake Drum Mounting Bolts (4) Torque to 25-30

Mounting Bolt (7)

Transmission Assy

Drive Wheel Assy

Figure 5.6

Torque to 100 R./Lbs.

Drive Unit Assembly Removal/lnstallation

5.18

Service and Parts Manual Mechanical

Figure 5.7

Drive Unit Installation

TOYOTA

Service and Parts Manual Mechanical

TOYOTA

Brake ALLOW THE BRAKE TO COOL COMPLETELY BEFORE SERVICING. ACAUT~ON O n Models 6HBW3O16HBE30and 6HBE40 the brake is applied when the operator moves the handle up to within 10' of the vertical position or down to within 10' of the horizontal position. When you release the spring loaded handle, it returns to the vertical position and automatically applies the brake (Refer to Figure 5.8).

O n Models 6HBC3O16HBC40and 6TB50 the brake is applied by the operator actuated brake lever on the control handle. A parking brake is also provided on these models. It is actuated by the operator pulling the parking brake handle. Rotate the parking brake handle 90' and push all the way in to unlock the brake.

Power Off Brake On.

Power O n

Power Brake

Figure 5.8

Brake and Power Actuation Positions (Models 6HBW30, 6HBE30 and 6HBE40)

Power to the drive motor is interrupted when you apply the brake.

Daily Inspection

Make sure that the brake and the drive motor cutout switch are operating properly.

Adjust if necessary.

After Every 500 Hours of Operation

1. Inspect the brake shoes for wear. Replace if necessary.

2. Check the actuation of the brake and the drive motor cutout switch. Adjust if necessa ry.

Service and Parts Manual Mechanical Brake Adjustment (For all Models)

TOYOTA

To adjust the brake, use the following procedure: (See Figure 5.9)

1. Move handle down to a 45" angle. (For Models 6HBW30,6HBE3O1 6HBE40 only see Figure 5.8).

2. Loosen locknut (A) and (9) on either side of the brake rod.

3. Adjust brake nut (A) until brake is fully off.

4. Tighten locknuts on both sides of the brake rod.

5. Compressed length of spring when brakes are on (handle vertical) should be 1.94" (49mrn). Adjust spring screw (C) if necessary.

Stopping distance should be measured with a rated load. The vehicle should stop within approximately 6 feet (1.83 meters).

Figure 5.9

Brake Adjustment

Service and Parts Manual

TOYOTA

Mechanical Deadman Switch Adjustment

The deadman switch, located near the brake drum, should be adjusted so that electrical power is interrupted when the handle is moved up to within 10" of the vertical position or down to within 10" of the horizontal position (See Figure 5.10 below and page 5.20).

Handle Return Spring Adjustment (See Figure 5.1 1)

(Models 6HBW3O16HBE30and 6HBE40)

1. Vehicles without coast: Adjust spring preload so the handle will return to the full vertical position when released from any position.

2. Vehicles with coast: Coast spring cannot be adjusted. Adiust preload on handle return spring so the brake does not drag with the coast control engaged. This should provide enough preload for the handle to return to the vertical position when released from any position.

Handle Pivot (Ref.)

Coast Control

m

\ /

ndL 1

\

l 1

Locknut

'/

Deadman Switch

~ndleReturn Spring Adjusting

- Models 6HBW~3O16HBE30,6HBE40

Drive Motor Cut-Out Switch

Figure 5.1 1 Drive Motor Cutout Switch - Models 6HBC30, 6HBC40, 6TB50

5.22

Service and Parts Manual Mechanical

TOYOTA

Mechanical

Figure 5.1 2 Handle Assembly for 6HBW30, 6HBE30, 6HBE40

Hand Brake

Manual Parking Brake

Figure 5.1 3 Handle Assembly for 6HBC30, 6HBC40 and 6TB50

Service and Parts Manual Mechanical

TOYOTA

Drive Wheel Daily Inspection

Inspect the condition of the drive wheel. Steel chips and other foreign material should always be removed to prevent damage. If the wheel is badly worn or has an excessive amount of breaks, it should be replaced.

After Every 50 Hours of Operation

Lubricate the grease gun fittings.

After Every 200 Hours of Operation

Check the tightness of the drive wheel mounting capscrews. They should be tightened to 100 ft-lb (140Nm) of torque.

Cushion Drive Tire Replacement

1. Any misalignment of the tire and hub, while the tire is being pressed onto the

ACAUT'ON

hub, can cause possible damage to the hub. Because of this, a chamfer has 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 the pressing operation and reduce the possibility of misalignment.

TO PREVENT DAMAGE THE HUB MUST BE INSTALLED ON THE CIRCULAR RAM WITH ITS CHAMFERED SIDE UP. 2. Remove the wheel and tire assembly from the vehicle.

3. Check the inside surface of the metal insert of the new tire. Remove any scale or rust with sandpaper. Clean the inside of the metal insert and lubricate it with a soap solution.

4. Place a circular ram on the press table. (Refer to 5.1 4). The length of the ram must be longer than the width of the old tire to allow complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire, but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

5. 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 replaced at the same position that the old tire was installed on the hub. A spacer, slightly smaller in diameter than the inside diameter of the tire insert and the same thickness as the depth of the recess, can be used to obtain the proper amount of recess.

Service and Parts Manual

TOYOTA

Mechanical Cushion Drive Tire Replacement (Cont'd.)

6. Position the hub assembly with the old tire on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge whenever a tire is pressed onto the hub.

7. Center the hub assembly on top of the ram and make sure that they mate squarely.

8. Apply grease to the inside of the tire rim.

9. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so that they are concentric with each other.

10. Start pressing the new tire onto the hub and the old tire off of the wheel. Run the press slowly for the first few inches of travel because this is the critical stage of the pressing operation. If the tire begins to cock, stop the press immediately and realign the tire. A sharp jar with a soft-headed mallet will usually realign the tire on the hub.

If the new tire does not press on with a minimum of 5 tons (68,947 kPa) pressure, replace the hub.

1 1. Release the press. Remove the wheel and tire assembly and the old tire from the press table. Wipe off the grease and insped the wheel and tire assembly.

12. Install the wheel and tire assembly on the drive axle on the vehicle. Torque the mounting capscrews 700 ft. Lbs. (740 Nm)

OUTSIDE OF HUB AND TIRE ASSEMBLY

!M

NEW TIRE,

RAM

'PRESS TABLE Figure 5.1 4

Cushion Drive Tire Replacement (typical)

Service and Parts Manual

TOYOTA

Mechanical Load Wheels Inspection

Service

lnspect the condition of the load wheels. Remove steel chips and other foreign material to prevent damage to the load wheels. Replace the wheels if they are badly worn or have an excessive amount of breaks.

Every 50 hours - Lubricate the grease fitting.

Every 500 hours - Inspect the load wheel bearings.

Wheel Replacement (Model 6HBE30 & 6HBC301

1. Raise the forks and block them in the raised position. (Refer to Figure 5.1 5)

2. Mark all parts before removal so they can be installed in the same orientation and on the same side of the vehicle.

3. Remove the spring pin (4) from the load arm (1).

4. Remove the shaft (3). If necessary, hammer it out with a rod from the inside (between the forks).

Replace the bearings whenever the load wheels are replaced.

5. If the bearings are to be re-used, insert a brass drift pin into each end of the load wheel and knock the bearings out.

6. Install the bearings in the load wheel with the shields facing out.

7. Place the new load wheel on end 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 that the bearing is fully seated in the load wheel.

8. Install the washers (6) and the load wheel on the load arm casting with the shaft.

9. Insert the spring pin (4) in the load arm casting. Make sure the spring pin hole in the shaft is in line with the housing.

10. Lubricate the grease fittings.

See note 1.

Note: 1. Bearing Shield must face outward.

Legend 1. Load Arm 2. Load Wheel 3. Wheel Shaft 4. Spring Pin 5. Shield Bearing 6. Flat Washer-1" 7. Grease Fitting 8. Sleeve Bearing 9. Grease Fitting 10. Non Shielded Bearing

Figure 5.1 5

Load Wheel - 6HBE30 & 6HBC30 5.26

Service and Parts Manual

TOYOTA

Mechanical Wheel Replacement (Models 6HBE40 & 6HBC40)

1. Raise the forks and block them in the raised position. (Refer to Figure 5.1 5.1) 2. Mark all parts before removal so they can be installed in the same orientation and on the same side of the vehicle.

3. Remove the spring pin (13) from the tandem pivot (1 1).

4. Remove the wheel shaft (2). If necessary, hammer it out with a rod from the inside (between the forks).

Note:

Replace the bearings whenever the load wheels are replaced.

5. If the bearings are to be re-used, insert a brass drift pin into each end of the load wheel and knock the bearings out.

6. Install the bearings in the load wheel with the shields facing out.

7. Place the new load wheel on end 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 that the bearing is fully seated in the load wheel.

8, Install the flat washers (5) and the load wheel on the tandem pivot (11) with the wheel shaft (2).

9. Insert the spring pin (13) in the tandem pivot. Make sure the spring pin hole in the wheel shaft (2) is in line with the tandem pivot (11).

10. Lubricate the grease fittings.

See note 1 Legend: 1. Load Wheel 2. Wheel Shaft 3. Non-Shielded Bearing 4. Shield Bearing 5. Flat Washer - 1" 6. Grease Fitting 7. Trail Fork 8. Sleeve Bearing 9. Sleeve Bearing 10. Grease Fitting 1 1. Tandem Pivot 12. Grease Fitting 13. Spring Pin 1/4 x 1-112 14. Spacer

Note: 1. Bearing Shield must face outward.

Figure 5.15.1 Load Wheels - 6HBE40 & 6HBC40 5.26.1

Service and Parts Manual

TOYOTA

Mechanical Pallet Entry Wheels Daily Inspection

Inspect the condition of the pallet entry wheels. Remove steel chips and other foreign material to prevent damage to the pallet entry wheels. Replace the wheels if they are badly worn or have an excessive amount of breaks.

After Every 50 Hours of Operation

Lubricate the grease fittings.

After Every 500 Hours of Operation

Inspect the load wheel bearings.

Wheel Replacement (Refer to Figure 5.16)

1. Raise the forks and block them in the raised position.

2. Mark all parts before removal so they can be installed in the same orientation and on the same side of the vehicle.

3. Remove the cotter pin (6) and washer (5) from the roller pin (4).

4. Remove the roller pin (4) from the roller bracket (2).

5. Remove the roller (3).

Replace the bearings whenever the load wheels are replaced.

6. Align the new roller (3) with the holes in the roller bracket (2).

7. Insert the roller pin (3) through the roller bracket (2) and on through the roller (3).

8. Replace washer ( 5 ) and cotter pin (6) 9. Bend cotter pin.

10. Lubricate the grease fittings.

1. Do not install front roller until assembly is installed on fork.

Legend: 1. Entry Roller Assembly includes: 2. Entry Roller Bracket 3. Roller 4. Entry Roller Pin 5. Flat Washer 3/8 6. Cotter Pin 7. FI. Hd. Csk Screw 3/8-24 x 5/8 8. Hex Locknut 3/8-24

FORK m

y

(See Note 1.)

Figure 5.1 6 Pallet Entry Wheels (Models THBE40 & 6HBC40

Service and Parts Manual Mechanical

TOYOTA

Casters

Casters are used on Models 6HBE30, 6HBE40,6HBC30, 6HBC40 and 6TB50. (See Figure 5.1 7)

Daily Inspection

Inspect the condition of the casters. Remove steel chips and other foreign material to prevent damage to the casters. Replace the casters if they are badly worn or have an excessive amount of breaks.

Legend: 1. Yoke Assembly 2. Hex Bolt CIW Nut 3. Pin 4. Pin 5. Spring 6. Arm 7. Spacer 8. Wheel

Figure 5.1 7

9. Spacer 10. Retaining Ring 11. Hex Bolt C/WNut 12. Oilite Washer 13. Oilite Bushing 14. Wheel Axle 15. Oilite Bushing

Caster Assembly 5.28

Service a n d Parts Manual Mechanical

TOYOTA

Fork And Linkage After Every 50 Hours of Operation

Lubricate all fork a n d linkage grease fittings. If fittings must be replaced, install them so that they are accessible for greasing.

Inspect the forks for proper height adjustment. Adiust if necessary. (See page 5.30)

1. Box & Fork Weld 2. Box & Fork Weld 3. Box & Fork Weld 4. Bell Crank Sub-Assembly: 40. Sleeve Bearing 4b. Sleeve Bearing 4c. R.H. Bell Crank Mach.

4d. 65" Grease Fitting 4e. Setscrew 5. Bell Crank Sub-Assembly 50. Sleeve Bearing

5b. Sleeve Bearing 5c. L.H. Bell Crank Mach.

5d 65" Grease Fitting 5e. Setscrew 6. Pull Rod Sub-Assembly 60. Sleeve Bearing 6b. Pull Rod Mach.

6d. 65" Grease Fitting 6e. Grease Fitting 7. Front Fork Shaft 8. Load Wheel Assembly 9. Flat Washer 10. Eccentric Pin

Figure 5.18 Fork a n d Linkage

1 1. Lockwasher 12. Hex Nut 13. Setscrew 14. Rear Fork Shaft 16. Clevis Mach.

17. Hex Hd. Cap Screw 18. Lockwasher 19. Switch Actuator 20. Rear Link Shaft 21. Setscrew 22. Fork and Platform Weldment 23. Cylinder Pivot Pin

24. Vehicle Link Shaft 25. Cup Point Setscrew 26. N/A 27. vehicle Link Shaft 28. Grease Fitting

Service and Parts Manual

TOYOTA

Mechanical Fork Height Adjustment Lowered Fork Height

If the load wheels are new: (See Figure 5.18 and Figure 5.19)

1. Raise the forks a few inches from the floor and block them in place.

2. Loosen the nut (12) on the eccentric pin (10) and rotate the hexagon head of the eccentric pin until the top of the trail-fork touches the bottom side of the fork surface as shown at "A" in Figure 5.19.

3. Tighten the nut for the eccentric pin.

4. Remove the blocks and completely lower the forks. Check the lowered fork height at "B." The lowered fork height should be 31/4" (83 mm).

If the load wheels are worn: 1. Completely lower the forks. Measure the distance from the floor to the top of the fork at "B" in Figure 5.1 9. The lowered fork height should be 31/4" (83 mm).

2. If the fork height is incorrect, jack the forks up a few inches from the floor and block them in place.

3. Loosen the nut (12) on the eccentric pin (10). Rotate the hexagon head of the eccentric pin slightly to change the position of the load wheel.

4. Tighten the nut to lock the eccentric pin in place.

5. Remove the blocks and fully lower the forks. Check the lowered fork height at "B." The lowered fork height should be 31/4" (83 mm). Perform the adjustment procedure until the correct fork height is obtained.

6. Ensure both wheels are adjusted to share load equally.

"B" \

FORKS LOWERED 31/4#l

FLOOR LINE FORK LOWERED

Figure 5.1 9

Fork Height Adjustment

\

+/-

6" (83mm)

Service and Parts Manual

TOYOTA

Mechanical Lift Limit Switch Adjustment

The lift limit switch turns the hydraulic pump/motor "OFF" when a fully raised position has been reached. This is to prevent undue loading of the pump motor running at relief pressure after maximum cylinder travel has been reached. (See Figure 5.20) When activated, the lift limit switch cuts "OFF control power to the lift solenoid and thereby turns "OFF the hydraulic pump/motor. Adjustment of the switch is made by:

1. Raising the forks until they reach their fully raised position.

2. Adjusting the switch to activate (cut power off) when lift is 1 /2" to 1" (1 2.7 mm-25.4 mm) from fully raised position.

I Lift Cylinder

Frame Link Shaft

Bell Crank

Figure 5.20

Linkage Detail and Lift Limit Switch

5.3 1

I/

Pull Rod

Service and Parts Manual Hydraulic Hydraulic

TOYOTA

It is essential that the following general maintenance recommendations for this vehicle be closely adhered to: Store and handle hydraulic oil with extreme care to prevent moisture and foreign matter from entering the hydraulic system. Contaminated hydraulic oil is the major cause of hydraulic system failures. All hydraulic oil handling equipment, such as containers, funnels, and hand pumps, should be kept clean at all times and covered when not in use.

Keep all fittings and connections tight to eliminate leaks. Be careful, however, not to tighten brass fittings too much or they may be damaged or distorted.

Before a component is removed from the hydraulic system be sure to wash the component and its surrounding area with cleaning solvent to prevent the entrance of foreign matter into the system. Cap and plug all openings immediately.

Whenever a fitting with a pipe thread is removed, use a sealing compound on the outside of the threads before the fitting is installed. (Never use teflon tape.) Make sure all parts are clean before installation.

When a hose assembly is installed, make certain it is not twisted when the fittings are tightened. Always use two wrenches on a swivel type fitting; one to hold the hose and the other to tighten the fitting.

Keep hose clamps tight to prevent hoses from chafing and to avoid leaking.

Oil leaks at the cylinder packing should be corrected as soon as leaking becomes evident.

Clean the filler screen, breather cap, and reservoir at the recommended service intervals.

Periodically check the pump and motor hardware for tightness.

Dispose of waste fluid properly.

Service and Parts Manual Hydraulic

TOYOTA P u m Motor ~

Pump Adapter Lift

Lift Cylinders

Hose

Figure 5.21 Hydraulic System

Service - -. . . - - and -. . - Parts . -. . - .Manual . . -. . - -.

Hydraulic

TOYOTA

Inspection

During daily operation, occasionally inspect the floor area where the vehicle was operating to check for oil leaks from the hydraulic system. Correct leaks as soon as they become evident.

500 Hours

After each 500 hours of service, inspect all hoses and fittings in the hydraulic system.

Replace hoses which are damaged or deteriorated. Inspect for leaks and correct any that are evident.

Lift Motor

% Return Port

Filler/Breather Port

Lift Pressure Outlet/Return Port

Lowering Solenoid

/ iLF Figure 5.22 Hydraulic Motor, Pump, and Reservoir

5.34

Reservoir

Service and Parts Manual Hydraulic

TOYOTA

Hydraulic Reservoir

The oil level of the reservoir with the forks fully lowered should be within 1/4" (6.35 mm) of the bottom of the oil fill hole.

Checking and Adjusting Hydraulic Pump Relief Valve Pressure

The hydraulic system is protected by a relief valve located in the adapter body. (See Figure 5.22). The relief valve is preset by the manufacturer to open at a specified pressure.

Relief Valve Setting

1. The relief valve setting should be checked at regular intervals and whenever the hydraulic pump, fork linkage, or lift cylinders are serviced or repaired.

2. Follow steps 3 through 10 to check the relief valve setting: 3. Adjust the lift limit switch so that the switch WILL NOT shut the pump down when the forks reach their upper limit.

4. Completely retract the lift cylinders. Remove the 90' elbow. Install a female run tee with a 1/8" NPT 0-3,000 psi (0-20,684 kPa) pressure gauge in place of the elbow as shown in Figure 5.23.

5. Turn the keyswitch O N and leave the handle in the neutral (vertical) position.

6. Depress the LlFT button and observe the indicator on the pressure gauge. When the forks reach the upper limit of lift, the pump will make a high pitched squeal, indicating that the relief valve is opening.

7. If the relief valve opens at a lower or higher pressure than the specified pressure, the relief valve must be adiusted as follows: a. Remove locknut covering the relief valve adiustment screw (Figure 5.22). b. While depressing the LlFT button, turn the adiusting screw IN to increase the pressure setting or OUT to decrease the pressure setting. c. After the pressure gauge indicates that the relief valve is properly set, release the ,LIFT button. d. Re-install the locknut. e. Recheck the relief valve setting.

(Continued on the next page)

Service and Parts Manual Hydraulic Relief Valve Setting (Cont'd.)

TOYOTA

8. Completely retract the lift cylinders. Turn the key switch OFF. Remove the pressure gauge. Replace the plug.

9. Raise the forks and inspect all hoses and fittings for leaks.

10. Adjust the lift limit switch to shut the pump down when the forks reach their upper limit. (See page 5.31)

FEMALE RUN TEE

RELIEF VALVE

Figure 5.23 Checking Relief Valve Pressure

Service and Parts Manual Hydraulic

TOYOTA

Hydraulic Reservoir

To prevent air from entering the hydraulic lines, the reservoir must be maintained at the full level at all times (with the forks lowered).

Inspection Every 8 Hours

Check the hydraulic oil level in the reservoir. The oil level with the forks fully lowered should be 1/4" (6.35 mm) below the fill hole. Add the specified oil if necessary. (See page 7.1 )

Lift Cylinders Service

After each 50 hours of operation, check the lift cylinder hoses and fittings for leaks.

Repair if needed. Check the cylinder mounting. Make sure that the retaining ring at the bottom of the cylinders is tight against the frame. (Refer to Figure 5.24)

Oil Leakage Wiper Seal

Check for oil leakage at the wiper seal on each lift cylinder. Slight oil leakage at the seal indicates that the wiper seal and/or "0" rings are getting worn. When leakage becomes excessive, disassemble and inspect the complete assembly. Replace any components which are worn or broken. (Refer to Figure 5.24) When reassembling the cylinder, insert the retaining ring through the slot in the cylinder barrel and into the hole in the cylinder head. Rotate the cylinder head clockwise until the lock ring is in place.

Inspection Every 200 Hours

After each operating interval of 200 hours, the breather cap and hydraulic oil filter screen must be cleaned.

Cleaning Breather Cap

To clean the breather cap:

1. Remove the breather cap from the elbow.

2. Remove the filter element from the cap.

3. Clean the filter in a suitable cleaning solvent and dry it with compressed air.

4. Dip the filter in hydraulic fluid, then allow the oil to drain before installing the filter.

5. Install the filter in the breather cap and install the breather cap on the elbow.

Service a n d Parts Manual - -Hydraulic

TOYOTA

Hydraulic Reservoir (Cont'd.)

See Insert

-

Insert thru slot a n d into hole in bearing.

Rotate clockwise until lock ring is i n place.

Legend: 1. Head 2. Barrel Assembly 3. Piston Rod Assembly 4. Sleeve 5. Rod Bearing 6. Seal Replacement Kit includes: Retaining Ring 0-Ring (3) Wear Ring Back-up Washer Wiper Seal Lock Ring Slipper Ring

Figure 5.24 Lift Cylinder

5.38

Inspection Every 1,000 Hours

After each operating interval of 1,000 hours, the oil in the reservoir should be changed. This is very important because of the accumulation of condensation and contamination. Heating the oil during operation and cooling the oil when the vehicle is not in use contributes to condensation which is damaging to the system.

Contaminants such as dirt, rust, scale, and products of oil deterioration are also damaging to the system.

Drain and clean the reservoir as follows: 1. Completely retract the lift cylinders.

2. Disconnect the battery and remove and tag all wires and cables connected to the pump motor.

3. Remove and tag the hydraulic lines from the hydraulic unit. Plug all openings.

4. Remove the bolts which connect the hydraulic unit to the mounting bracket (frame).

5. Remove the hydraulic unit from the vehicle.

6. Remove the four bolts which connect the hydraulic reservoir to the adapter housing.

7. Remove the reservoir and properly dispose of old hydraulic oil.

8. After the oil has drained, flush the inside of the reservoir with a suitable cleaning solvent and clean the screen in the tank filler opening.

9. Dry the inside of the tank with clean, dry, compressed air.

10. While the reservoir is off, clean the inlet suction screen with clean, dry compressed air from the pump side.

11. Carefully install the reservoir on the adapter housing. Make sure that the adapter O-ring is properly in place.

(Continued next page)

Hydraulic Reservoir (Cont'd.)

Inspection Every 1,000 Hours (Cont'd.)

12. Install the hydraulic unit on the mounting bracket (frame).

13. lnstall the hydraulic lines on the hydraulic unit.

14. Fill the reservoir with the specified hydraulic oil. Use a funnel with a flexible neck. Fill the reservoir only until oil can be seen at the bottom of the elbow.

15. Conned all wires and cables to the pump motor. Conned the battery.

16. Install the breather cap. Raise and lower the forks and inspect all hoses and fittings for leaks.

Make sure that the oil is free of tiny air bubbles which may be seen only under close inspection.

17. Fully lower the forks.

18. Check the hydraulic oil level in the reservoir.

19. Raise and lower the forks to check for leaks.

Service and Parts Manual Electrical

TOYOTA

Electrical Battery Electrolyte Level

1 . The electrolyte level in the battery cells should be 5/8" (15.7 mm) above the baffles.

2 . Check the electrolyte level of the cells at least once a week.

3. Add only distilled water.

A CAUT~0N Specific Gravity

NEVER ALLOW THE PLATES TO BECOME EXPOSED DUE TO LOW ELECTROLYTE LEVEL. D O NOT OVERFILL THE CELLS; THE ELECTROLYTE WILL EXPAND AND SPILL OVER WHEN THE BAllERY WARMS UP.

1. The specific gravity of the electrolyte should be greater than 1.260 at the beginning of the shift.

2. Check the specific gravity of all the cells at least once a week. Return the electrolyte back to the same cell it was removed from.

3. The specific gravity should be approximately 1.275 when the battery is fully charged. DO NOT discharge the battery beyond the point where the specific gravity falls below 1 .I 25.

4. Take specific gravity readings at the same point in the charge/discharge cycle (i.e., after being charged).

Service and Parts Manual ~

~

Electrical Battery Exterior

TOYOTA

1. Inspect the battery cables to make sure that they are not frayed or loose. Inspect the battery connector to make sure that there is no foreign material inside the connector. Make sure that the filler plugs are tight and that the vent holes in the filler plugs are open.

2. The top of the battery should be kept clean and dry. Corrosion, dust, and moisture provide a conducting path to short circuit cells or create grounds.

3. A dirty battery or one which has had electrolyte spilled on it should be washed with a solution of 1 Ib (.45 kg) of baking soda added to 1 gal. (3.7 liters) of hot water. Disconnect the battery connector and remove the battery from the vehicle before cleaning the battery. Clean the entire top of the battery with the soda solution. After the foaming stops, flush the battery with clean water. Dry the battery completely before installing it in the lift vehicle. Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

D O NOT CLEAN THE TOP OF THE BATTERY WITH THE SODA SOLUTION WHILE IT ACAUT~ON IS INSTALLED IN THE VEHICLE. WATER WOULD SEEP INTO THE ELECTRICAL COMPARTMENTS AND CAUSE SERIOUS DAMAGE.

Battery Charging MAKE CERTAIN THAT THE VENT HOLES IN THE FILLER PLUGS ARE OPEN TO ACAUT~ON ALLOW HYDROGEN GAS TO ESCAPE FROM THE CELLS. WHEN THE BAllERY CHARGER IS CONNECTED TO THE BAITERY CONNECTOR, ACAUT~ON IT IS EXTREMELY IMPORTANT THAT THE CORRECT POLARITY IS OBSERVED. MAKE SURE THAT THE POSITIVE LEAD OF THE CHARGER IS CONNECTED TO THE POSITIVE TERMINAL AND THE NEGATIVE LEAD IS CONNECTED TO THE NEGATIVE TERMINAL.

1. The most important factor in battery service and life is proper charging. Make sure that the proper method for each application is carefully followed. In general, a battery may be charged at any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 11 O F (43OC).

Temperatures of 1 20°F (49OC) are allowed for only short periods of time.

°

2. A lead-acid battery should not require any routine overhaul or electrolyte change during its entire life, except in case of accidental loss of electrolyte. For exact information regarding charging and maintenance refer to the battery manufacturer's data.

Service and Parts Manual Electrical

TOYOTA

Battery Charging (Cont'd.)

D O NOT SMOKE NEAR THE BAlTERY. D O NOT EXPOSE THE BAlTERY TO AN OPEN FLAME DURING OR IMMEDIATELY AFTER CHARGING. Battery specific gravity readings with the electrolyte at 8 0 ' ~( 2 7 ' ~ ) :

Battery Storage

1. The battery should be stored in a clean, cool, dry location away from radiators and other sources of heat.

2. Before the battery is placed in storage, make certain that the electrolyte is at the proper level in all the cells, that the filler plugs are tight, and that the battery is fully charged.

3. Check the electrolyte level and the specific gravity every 30 days during storage.

Whenever the specific gravity is less than 1.230, the battery must be charged.

Motors Inspection

It is recommended that a partial inspection of the motor be made at least every 1,000 hours of vehicle operation. (See Figure 5.25). If the unit is operated in an abnormally severe or caustic environment or rigorous duty cycle, the inspection should be made at shorter intervals. A strict inspection schedule should be set up and rigidly adhered to in order to obtain the maximum efficiency of electrical equipment for this type of service. Each partial inspection of the motor should include the following.

Figure 5.25 Motor Brush Location

Brushes

1. Inspect the brushes for wear and for proper contact with the commutator. Record the amount of brush wear. This history will give an indication of whether a brush should be changed or if sufficient length is still available until the next inspection.

Refer to the following data concerning acceptable brush length and motor information. (See Table on page 5.48) 2. It is important to remember that overloading a unit is ultimately reflected upon the motor and brush wear; therefore, this must be taken into account when deciding on brush replacement.

3. Measure brush spring pressure using a spring scale hooked under the brush spring at the brush. Pull the scale on a line opposite the line of force exerted by the brush spring and take the reading just as the spring leaves the brush. (See Figure 5.26) 4. Check brush spring tension on brushes to make certain vibration or heating has not displaced or weakened the spring on the hammer plate on the brush. In the event of poor brush shunt contact with the holder, or a burned off shunt, the spring will conduct current which will reduce tension due to heating. If in doubt, replace with a new spring. Good spring pressure (tension)is vital to proper motor operation.

5. Clean brushes and holders. Wipe commutator with a dry, lint-free cloth. No lubricants of any kind should be used on or around the commutator.

-

Service and Parts Manual

TOYOTA

Electrical Motors (Cont'd.)

A. Place the paper strip between the brush face and commutator.

0. Hook the leather loop under the brush spring and attach to spring scale.

NOTE: If the brush spring has a loop at the brush, hook the spring scale directly into the spring.

C. Pull the spring scale on a line

Coil Spring

Pull Paper in Direction of Rotation

directly opposite the line of force exerted by the spring while exerting a light pull on the paper strip.

When the paper strip begins to move freely, the spring scale will be indicating the brush spring tension.

Figure 5.26 Checking Brush Spring Tension

6.Check brush holders for solid connection to mounting support. Tighten by drawing down on the mounting screws.

7. Check capscrews that hold brush cross connectors to brush holder body.

8. Ensure motor terminals are secured tightly to the motor frame. These terminals should be tightened firmly, but care must be taken not to tighten the terminals to the extent of stripping the threads or crushing the insulating parts.

9. Clean the cover band and plate. Make sure insulation is tight to metal surface and is not damaged. Assemble the cover band and plate on motor frame, making sure all openings in the frame are entirely covered. Tighten the covers to make good, all-around contact with the frame.

10. Check all the capscrews around the frame for tightness.

1 1. The outside frame of the motor should be kept clean and free from dirt. A free-air passage must be maintained around the motor to permit radiation of heat generated from the motor. The rapidity of removing heat from inside the motor determines the temperature in the electrical components. The lower the temperature, the longer the life of the insulation and therefore the life of the motor.

Service and Parts Manual

TOYOTA

Electrical Motors (Cont'd.)

Commutator

The commutator should be inspected for: Surface Condition High Mica

Inspection

The commutator must be smooth and clean to provide maximum brush wear. In commutators which are not kept clean, carbon dust can collect in grooves between the segments. This leads to a short circuit in the armature.

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

If the commutator appears rough, pitted, scored, or has signs of burning or heavy arcing between the commutator bars, the motor should be removed for servicing.

Servicing

If the commutator requires service, the armature will have to be removed from the motor.

High Mica

Most armatures have the mica undercut. However, if the armature does not have the mica undercut, this operation should not be done. The decision to undercut or not is determined by the type and grade of brush used in that particular motor. The mica should be undercut to a depth equal to the width of the mica. This is usually 1/32 inch, but may vary in some motors.

After the commutator has been undercut, the armature should be placed in a lathe and the commutator lightly sanded with 00 sandpaper to remove any burrs left from undercutting. The commutator should then be blown clean with dry compressed air.

Mica

Segments

Good Undercut

Mica

Segments

Mica

Bad Undercut

Figure 5.27 Mica Undercutting

Segments

Service and Parts Manual

TOYOTA

Electrical Motors (Cont'd.)

Resurfacing

Light pitting and wear can be removed with 00 or finer sandpaper. Excessive pitting or wear will have to be removed by resurfacing the commutator.

Determine the minimum commutator diameter from the Motor Reference Data Sheet for the particular motor being serviced. The commutator must not be turned below this diameter. To do so will impede the operation of the motor and possibly result in motor component damage.

Figure 5.28 below shows the dimensions for sharpening the lathe cutting tool.

Always make sure the cutting tool is sharp prior to resurfacing the commutator.

Position the cutting tool so the point is approximately 1/32" (0.76 mm) below the center line of the armature. Resurface the commutator at 800 rpm taking only light cuts each time. No more than 0.005" (. 127 mm) should be removed during any one cut. The final cut should not be more than 0.002" (.050mm). Refer to High Mica after machining is complete.

1/64 TO 1/32

(0.396 mm to 0.794 mm) Quarter Radius

t

1/2

0 2.7 mm)

7'36 1 / 2

1/2

02.7 mm)

DEG.

3/16 (4.76 mm)

1

?/.

28.57 mm]

$=0?32

& (28.57 mm)

(26.1 9 mm) 4- 1/2

(12.7 mm)

Figure 5.28 Commutator Cutting Tool

UNDER NO CIRCUMSTANCES SHOULD OIL BE APPLIED TO THE COMMUTATOR. ACAUTION

Service and Parts Manual

TOYOTA

Electrical Motors (Cont'd.)

Drive Motor General Data

LUBRICATION. None required. Sealed ball bearings are used at both ends of 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. Minimum diameter 2.87" (7.30 cm).

Replace armature when commutator has worn to this dimension.

BRUSH REPLACEMENT. Replace brushes when they have worn to the minimum length specified in the table below.

SPRING TENSION. Adjust spring tension per table below for new brushes.

Drive Motor Inspection

Refer to Motor Inspection on page 5.44.

Drive Motor Removal

1. Disconnect the battery and electrical leads from the drive motor 2. Disconnect the brake linkage and cam lever from the top cover motor mounting plate.

3. Remove the brake assembly from the top of the drive motor.

4. Remove the hex head bolts securing the mounting plate to the main case of the transmission.

5. Lift out the drive motor and mounting plate.

Drive Motor Replacement

To replace the drive motor, reverse the above procedure.

WHEN INSTALLING THE HEX HEAD BOLTS THAT SECURE THE MOUNTING PLATE, TORQUE THE HEX BOLTS TO THE SPECIFIED 25 30 FT. LBS. (35 42 NM). FAILURE TO TORQUE THESE BOLTS PROPERLY MAY CAUSE THE BRAKING AND STEERING TO FAIL. (See decal below and on mounting plate on

-

vehicle.)

Decal on Mounting Plate

-

Service and Parts Manual Electrical

Legend: 1. Fan 2. Armature & Fan Assembly 3. Frame 4. Poles 5. Field Coil Kit 6. Brush 7. Brush Spring 8. Brush Plate & Box Assembly 9. Bearing 10. Wavey Washer 1 1. Commutator Endhead 12. Terminal & Lead Assembly

Figure 5.29 Drive Motor (Exploded View)

TOYOTA

Service and Parts Manual Electrical

Lift Motor General Data

TOYOTA

LUBRICATION. No lubrication is required. Sealed ball bearings are used at both ends of the motor.

ARMATURE TEST. These armatures have standard wiring connections and can be tested on a growler using a metal strip or hacksaw blade to locate shorted windings.

COMMUTATOR. Minimum diameter is approximately 1.500" (3.8 1cm). Replace the armature when commutator has worn to this dimension.

BRUSH REPLACEMENT. Replace brushes when they have worn to the minimum length specified in the table above.

SPRING TENSION. Adjust spring tension per table below for new brushes.

Measure with a spring scale hooked under the brush spring at the brush. Pull the scale on a line opposite the line of force exerted by the brush spring and take the reading just as the spring leaves the brush.

lnspection

Refer to Motor lnspection on page 5.44.

Removal

1. Remove the hydraulic unit from the vehicle. Remove the bolts which attach the motor to the adapter housing.

2. Carefully slide the motor off the adapter housing, making sure that the pump assembly and the coupling are not lost.

Service a n d Parts Manual Electrical Electrical

Legend: 2. Excitation Winding 3. Armature 4. Bearing 5. Protective Cap 6. Flat Head Screw 7. Retainer 8. Bearing 9. Spring Washer 10. Retainer 11. Parts Set 12. Protective Cap

13. Commutator End Shield 14. Retainer 15. Fillister Head Screw 16. Fillister Head Screw 17. Spring Lockwasher 18. Fillister Head Screw 19. Brush Holder 20. Brush Spring 2 1. Carbon Brush Set 22. Pin

Figure 5.30 Lift Motor Assembly (Exploded View)

TOYOTA

Service and Parts Manual Electrical

TOYOTA

Traction System Adjustments Potentiometer Adjustments

Two potentiometers are provided for adjustment of acceleration and current limit. If adjustments should become necessary, refer to the table on page 5.53 for the desired setting.

Figure 5.31 shows the location of the adiustment potentiometers on the Controller.

All adjustments are made at the factory. However, should adjustment become necessary, or if a new control system has been installed, use the following procedure.

rn

Remove battery power during the following procedures. Battery power may be restored once the socket head screw is removed.

1. Remove the socket head screw (1/8"Allen wrench) for the selected potentiometer to be adjusted. (Refer to Figure 5.31) 2. Adjust the internal potentiometer with a small insulated screwdriver 3. Set potentiometer per each of the following procedures below.

4. Replace socket head screw and nylon seal washer. Tighten to 8 inch-pounds (.904Nm) maximum to prevent stripping.

Current Limit Setting D O NOT JACK VEHICLE UP DURING CURRENT LIMIT ADJUSTMENT. RESTRAIN

ACAUTION ~EHI~LE~E~~RELYT~PREVENTMO~EMENT.AHEAWLOADONTHEFORKSIS RECOMMENDED SO THE DRIVE WHEEL DOES NOT SPIN.

-

To properly adjust the current limit, the battery must be a minimum of 24 volts and have a specific gravity of at least 1.260. The drive motor must be relatively cool (at room temperature).

1. Connect an ammeter (300 amps full scale minimum) in series with the negative M line on the controller. (See schematic page 7.7). A clamp-on ammeter is sufficient for this measurement.

2. O n Models 6HBW30, 6HBE30 and 6HBE40, insure that the handle is in the upright position and the brakes are securely on.

3. O n Models 6HBC30, 6HBC40 and 6TB50, insure that the brake lever is fully engaged and the brakes are securely on.

4. Using extreme caution, bypass the deadman switch using jumper wire between terminals S2- 1 and S2-2.

The deadman switch is located near the brake drum on all models. (See Page 5.55) 5. Move the Directional/Speed control to full speed (against stops), and observe the current reading on the meter.

(Continued on next page)

Service and Parts Manual Electrical

TOYOTA

Traction System Adjustments (Cont'd.)

Current Limit Setting (Cont'd.)

6. Adjust Current Limit pot as necessary to match specifications. (Refer to the potentiometer adjustment table below.) Turning the pot clockwise will increase the current limit while turning the pot counterclockwise will decrease the current limit.

D O NOT HOLD THE POWER ON LONGER THAN 15 SECONDS. FOR EVERY 15 ACAUTIQN SECONDS THAT THE MOTOR IS ON. ALLOW 30 SECONDS FOR THE MOTOR TO COOL BEFORE RETESTING.

Plug Current Adjustment

Plugging current is factory set. Do not field adjust. Due to the nature of this setting (it can only be measured during plugging) it is recommended not to measure the actual current.

Acceleration Adjustment

1. Adjust potentiometer as required to increase or decrease the rate at which the vehicle accelerates.

2. Test and readjust as required.

For an increased acceleration rate, turn the potentiometer clockwise. For a decreased acceleration rate, turn the potentiometer counterclockwise.

Service and Parts Manual Electrical

TOYOTA

Potentiometer

Current Limit Adjust Factory Set To 1 o'clock Position Plug Current Adjust Factory Set To 3 o'clock Position. Do not field adjust.

, Acceleration Adjust Factory Set To 1 o'clock Position

Figure 5.31 Potentiometer Location and Function

Service and Parts Manual Electrical Deadman Switch Adjustment

TOYOTA

O n Models 6HBW3OI6HBE30 and 6HBE40, adjust the Deadrnan switch so it will actuate within the first 1/4" (6.4 mm) of brake lever travel. (See Figure 5.32) O n Models 6HBC30, 6HBC40 and 6TB50, the switch is set to disengage with the first movement of the brake lever (no air gap). (See Figure 5.33)

Deadman Switch

Figure 5.32 Deadman Switch Adjustment (Models 6HBW30, 6HBE30 and 6HBE40)

Deadman Switch

Figure 5.33 Deadman Switch Adjustment (Models 6HBC30t6HBC40 and 5.55

Service and Parts Manual Electrical

TOYOTA

Contactors

Clean and inspect the contactors regularly to help insure their proper operation. See Scheduled Maintenance, page 5.3 for the proper time schedule.

Cleaning

When cleaning contactors: Wear safety glasses. Remove dust, dirt, and other foreign materials from contactors using dry, filtered, compressed air (maximum 30 psi) (206 KpA).

Use a cleaning solution on a clean cloth to remove stubborn dirt, if necessary.

l nspection

1. Visually inspect all parts for: nicks broken or damaged leads broken terminals or springs burned contact tips cracked or deteriorating bushing, insulation or contact guards stripped threads other obvious damage

2. Replace defective parts as necessary.

Tip lnspection

When inspecting contactor tips, remember: Darkening of points does nat indicate burning.

Burning means loss of contact point material.

The contact may be used until the material is almost completely gone.

Replace the contact points if there is m e n o u g h 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 nat. file contact points to remove discoloration or minor irregularities - this Do is wasteful and produces a surface more susceptible to sticking.

If a cone and crater appear, remove the cone &with sandpaper or emery cloth.

a file; D o not use

Service and Parts Manual Electrical

TOYOTA

Contactor Table

and Field Weaken

and FW

Contactor Coil Replacement

D.P.S.T. Center Off Intermittent Duty SPST

(2.82 mm-3.25 mm)

If you suspect a defective contactor coil, test the coil with an ohmmeter, as outlined on page 5.65 before you replace one (Testing Electrical Components). Coil replacement is very similar for all the contactors. Refer to Figure 5.34 for the typical illustration of a contactor. Observe the following cautions:

D O NOT LOOSEN THE TOP FRAME SCREWS (9) FROM THE FRONT END ACAUT~ON PLATE (6). THEY DETERMINE THE TOTAL STROKE.

A CAUT~0N Replacement Of Contactor Tips, Insulation And/or Zore And Rod

BE CAREFUL WHEN REASSEMBLING THE MOVABLE CORE (8) AND FRONT END PLATE ( 6). D O NOT DEFORM THE TEFLON LINING.

.

1 To remove the coil (5), first remove screws (9A).

2. Carefully remove the frame and core assembly (1) including the Teflon washer (4) and coil (5).

3. Be sure the brass tube is wedged tightly into the frame and core assembly (1).

Replace it if it is loose.

4. Be sure the Teflon washer (4) is not loose, torn or folded. Replace it if it is damaged.

5. Slide the frame and core assembly (1) with the washer (4) and new coil (5) into the contactor frame assembly (2,3,6). Be sure the movable core and rod assembly (8) enters the frame and core assembly (1) freely in order to avoid damage to the Teflon washer (4).

6. Use a "C" clamp or hand arbor press and two 3/4" I.D. nuts which encircle the core bottom for protection.

(Continued next page.)

Service and Parts Manual Electrical Replacement Of Contactor Tips, Insulation And/or Core And Rod Assembly (Cont'd.)

TOYOTA

Remove the base buss bar assembly from multideck units so that clamping pressure is applied directly to the plate and tie rod assembly. Apply pressure until the core bottoms out and there is no further movement.

7. Press the end frame and core assembly (1) into position and tighten the four frame side screws (9A) that secure the frame and core assembly (1) to the sideplate (2, 3).

Replacement of these components is very similar for all contadors. Refer to Figure 5.34 for typical contador exploded view and follow the general disassembly and reassembly procedure.

Leave all shims in place when replacing contad tips as they are necessary for proper contact gap and overtravel.

Contactor Disassem bly/ Reassembly

1. Remove any external buss bars if present.

2. Remove nut (33) and its associated hardware.

3. Lift off, as applicable, in the following order, the: non-metallic washer (32) bushing (31) if present insulation (2 I), buss bars, if present contact spring (30) and movable contact bar (29) bushing (28) non-metallic spacer, if present bushing (28), if present washer (27), if present second set of comparable components, if present.

4. Remove screws (24) and (26) and their associated hardware, if present.

5. Remove the buss bar assembly (or stationary buss bar(s) (22), if present).

6. Remove the following, if applicable: insulation (21) screw (20) insulators (19), (18) detent (17)

The core and rod assembly is now accessible for inspection or replacement.

7. Reverse the order to reassemble. Refer to Contactor Table on page 5.57 for individual contact gap setting.

Service and Parts Manual Electrical 1. Frame & Core Assembly 2. Side Plate 3. Side Plate 4. Non-Metallic Washer 5. Coil 6. Front End Plate 7. Return Spring 8. Movable Core & Rod Assembly 9. Top Frame Screw 9A. Bottom Frame Screw 10. Insulating Clip 11. Nut 12. Screw 13. Switch (Interlock) 14. Actuator 15. Mounting Plate 16. Interlock Kit 17. Detent 18. lnsulation 19. Insulation 20. Screw 21. lnsulation 22. Stationary Buss Bar 23. Screw 24. Screw 25. Bridge Guide 26. Screw 27. Washer 28. Bushing 29. Contact Bar 30. Contact Spring 31. Bushing 32. Non-Metallic Washer 33. Nut 34. Suppressor Assembly

Figure 5.34 Typical Contactor Exploded View

5.59

TOYOTA

Service and Parts Manual Electrical

TOYOTA

Checking Components Diodes

Use a Simpson 260 multimeter, or equivalent, to check diodes. Use RX1 ohm scale.

Replace the entire assembly if defective diodes are found.

STANDARD

D I ODE

Figure 5.35 Diode

Plug Diode Test

1. Disconnect the battery.

2. Remove the cable from the controller A2 terminal.

3. Use an ohmmeter to check the resistance between the motor controller terminal A2 and B+ terminals.

4. To test for the presence of a diode inside the controller, swap the two meter leads and look for a low resistance one way and a higher resistance the other way. If your meter has a diode test function, use that. If the diode is shorted, replace the controller.

5. Reconnect the A2 cable to the motor controller and reconnect the battery.

6. If the plug diode tests okay, there is a short in the motor circuit. An ordinary ohmmeter will not work to find the short, because the resistances of the motor windings are so low.

Service and Parts Manual Electrical Throttle Potentiometer Setting

TOYOTA

1. Disconnect the handle harness at the bottom end of the handle prior to adjustment. This will insure that feedback, from other circuitry in the vehicle, will not affect the V.O.M. readings.

2. Conned a V.O.M. to pins VR-1 and VR-3. The resistance measurement should be 13,000 +/- 1,300 ohms. Disconnect meter.

3. In order to electrically center the potentiometer, the Directional/Speed Control Handle must be in the neutral position. Use an Allen wrench (3/32") to loosen the screw on the gear located on the shaft of the potentiometer.

4. Connect the V.O.M. to pins VR-2 and VR-4. Measure the potentiometer resistance while rotating the potentiometer shaft until the V.O.M. reads as close to 0 ohms as possible.

Tighten the Allen screw and proceed to Step #5. Secure the Allen screw using Loctite. A paint dot on the shaft and on the bushing should line up for reference.

5. With the V.O.M. still connected to pins VR-2 and VR-4, verify that the forward and reverse throttle positions are equal. Rotate the Directional/Speed Control Handle fully in both directions. Record the maximum resistance value in both cases. In either direction the resistance value should be 5,000 +/- 500 ohms when equalized.

Since this value is variable, it is important that in both directions the resistance value is equalized to within 200 ohms maximum.

6. To determine the ideal maximum potentiometer position add the previously recorded readings in Step #5 and divide that result in half. (See example below.)

Loosen the potentiometer nut (1/2 turn) so that the potentiometer will move in the bracket with finger force applied.

Example

5,000 ohms C.W.

+ 5,200 ohms C.C.W. = 10,200 ohms

10,200 + 2 = 5,100 ohms (ideal resistance setting)

7. 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 nut securely to prevent the pot from moving in the bracket. Repeat Step #5.

Service and Parts Manual Electrical

TOYOTA

Turtle Speed Module (DA2) 1. Connect ohmmeter pin 1 (+)to pin 5 (-). Resistance should be greater than 10 megohms.

2. Apply 22 volts +/- 2 volts between pin 2 (B+) and pin 6 (B-).

3. Rotate the potentiometer fully in one direction then fully in the other direction (20 turns total). The resistance should vary from 4,750 ohms +/- 500 ohms to 9,750 ohms +/- 500 ohms.

4. An intial setting of 7,000 ohms can be used. Change the resistance to vary turtle speed. See table below.

Service and Parts Manual

TOYOTA

Electrical Turtle Speed Module (DA2) (Cont'd.)

Replacement

If you suspect a defective Turtle Module, perform the following procedure: 1. Disconnect the battery.

2. Disconnect the cable connector from the Turtle Module.

3. Remove the screw, lockwasher and flat washer.

4. Mount the new Turtle module with screw, lockwasher and flat washer.

5. Reconnect the cable to the Turtle Module.

6. Reconnect the battery.

7. Verify Turtle speed operation.

Motor Controller

Turtle Module Figure 5.36 Turtle Module

Service and Parts Manual Electrical

TOYOTA

Emergency Reverse Module (DA1) Test Procedure

1. Conned 24V relay between P2 and P4.

2. Adjust trim pot R l , fully clockwise.

3. Apply 24 VDC to PI with respect to P3.

4. Relay should not be energized.

5. Reduce voltage at P I to 18V. 6. Turn trim pot 1/2 turn, counterclockwise, and wait 7 seconds. Repeat until relay is energized.

7. Remove voltage at P I and then reapply full 24V. 8. Reduce voltage by 1 volt and wait 7 seconds. Repeat until voltage is 19V. Relay should not be energized. If it is, turn trim pot 1/4 turn clockwise, then go back to step 7 and repeat.

9. Reduce voltage by .2V and wait 7 seconds. Relay should energize when voltage is 18V +/- 1%.

10. After trip voltage has been set, determine the time delay between reaching trip voltage and energizing the relay. This time should be 5 to 7 seconds.

Service and Parts Manual Electrical Testing Other Electrical Components

TOYOTA

The table below gives the recommended test procedures for electrical components not previously covered. The checks are all made by the use of an ohmmeter (SimpsonModel 260 or equivalent). The readings do not absolutely mean components checked will function properly in the system under different current and voltage conditions. The ohmmeter, however, will indicate most shorted or open circuited conditions.

These ohmmeter readings are obtained when the component is removed from the vehicle circuit.

Service and Parts Manual Chapter 6 Troubleshooting Index

TOYOTA

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Traction System Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Overview Field Replaceable Units Wiring Inspection Procedure

Vehicle Does Not Run . Directional Contactors Do Not Close Vehicle Does Not Run . Directional Contactors Energize Vehicle Runs In One Direction Only . Opposite Direction Contactor Does Not Energize Vehicle Runs In One Direction Only . Directional Contactors Work Normally Vehicle Does Not Run In High Speed (Forward only) Plugging Does Not Operate Properly Vehicle Does Not Accelerate Properly Emergency Reverse Module Does Not Activate When Button Is Depressed Emergency Reverse Module Checks OK No Reverse Travel With S25 Depressed . . . . .

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

6.4 6.6 6.7 6.8 6.9 6.10 6.10 6.11 6.12

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

6.13 6.13 6.14

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

Lift/Lower Problems Forks Do Not Lift When Lift Button Is Pushed Forks Do Not Lower When Lower Button Is Pushed

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

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

Service and Parts Manual overview Overview

TOYOTA

It is important when you troubleshoot vehicle problems to: Use a logical, commonsense approach.

Begin with the simplest solution and work towards the most complex.

The following will aid in developing a logical and systematic troubleshooting procedure.

1. Verify the problems by: Obtaining as much information as you can about the problem.

Determining, if possible, what the vehicle's performance was before the problem began.

Reviewing any records which should have been kept about the vehicle's performance.

Operating the vehicle yourself to verify the problem.

2. Locate the vehicle problem area by: Opening the compartment covers and visually inspecting the systems, then referring to the electrical and mechanical maintenance sections for general information which may save you time.

Determining if the problem is in the control circuit or the power circuit if there is no obvious physical problem.

3. Establish a logical testing sequence by: Using the appropriate schematic diagram(s). Begin at the power source and establish a sequence of testing points to locate the problem. Use the schematic(~) in conjunction with the appropriate flow diagram.

Establishing test points which indicate that all components between any new test point and the power source are good.

Avoiding haphazard checking, which provides inconclusive results.

4. Use the troubleshooting flow diagrams by: Consulting the list of vehicle problems.

Following the appropriate flow diagram from the beginning to where the probable cause is isolated.

5. Identify the cause of the problem by: Checking for improper vehicle usage.

Bringing the problem to the service manager's attention to avoid repetition of the cause.

6. Correct the problem by: Repairing or replacing defective components following instructions in the Maintenance section of this manual.

Complying with appropriate safety procedures.

Service and Parts Manual Overview

TOYOTA

Overview (Cont'd.)

WHENEVER TROUBLESHOOTING PROCEDURE REQUIRES CLOSING KEYSWITCH S1, THE VEHICLE MUST BE BLOCKED. THIS WILL AVOID ACCIDENTS CAUSED BY UNEXPECTED VEHICLE TRAVEL.

ACAUT'oN

DISCONNECT POWER WHEN CHECKING ELECTRICAL CIRCUITS OR COMPONENTS WITH AN OHMMETER. CURRENT CAN DAMAGE THE OHMMETER!

7. Save time and trouble. Look for simple causes first.

Visually inspect all wiring and electrical components for: Loose connections or connectors Loose or broken terminals Damaged terminal blocks or strips Broken wiring and shorted conditions (especially close to metal edges or surfaces) Use an ohmmeter to check for wiring continuity.

Field Replacement Units (FRU)

The following components were designed as Field Replacement Units (FRU) and should be replaced when suspected of being defective.

Motor Controller Turtle Module Emergency Reverse Module Plugging Module It is recommended that service personal make up a service kit which includes the components listed above. It is also recommended these components be bench tested prior to being part of the service kit and occasionally thereafter.

Using Troubleshooting Chapter 6, it is recommended that you do the following:

1. Identify the problem.

2. Remove and replace the suspect component with a known good component from your service kit.

Following this simple procedure will have the vehicle up and running in the shortest amount of time.

If you choose to test any of these components, we recommend the testing be done in your shop using the test procedures outlined in this manual.

The Tmubleshooting Charts that follow could not cover every fault contingency possible in the operation or maintenance of the vehicle. Should particular problems arise, which are not covered sufficiently in this chapter, the matter should be referred to your Toyota dealer.

Service and Parts Manual Overview Wiring Inspection Procedure

TOYOTA

Visually inspect all wiring in all compartments for: Broken wiring and shorted conditions, especially close to metal edges or surfaces.

Loose connections Loose or broken terminals Damaged terminal blocks or strips

If the problem has not been found, use the following procedure: a. Check that fuses are good. b. Check parts for proper installation and correct electrical polarity. c. Check all wiring for proper connections. d. Check insulation resistance. It should be more than 1 megohm (measure on a x 100 ohm range). Check only with a volt-ohmmeter. Place negative lead: (-) of the meter to the chassis and the positive lead. (+)to the live parts and vice versa.

If a vehicle problem cannot be located in the wiring or if a short-to-frame condition exists, troubleshoot in accordance with the flow diagrams on the following pages by determining exactly which operation(s)the vehicle is failing to perform. To accomplish this do the following: Jack up and block the vehicle so the drive wheel is off the floor.

Slowly operate all the vehicle's functions observing when a malfunction occurs.

Refer to the listing of vehicle problems to find the most applicable category.

Perform the procedure in the appropriate flow diagram.

USE EXTREME CARE WHENEVER THE VEHICLE IS JACKED UP FOR ANY REASON. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE JACK STANDS OR SOLID BLOCKS TO SUPPORT VEHICLE - DO NOT RELY ON JACKS.

Reference Chapter 7 schematic legends for test points when troubleshooting.

Service and Parts Manual Traction System Problems Traction System Problems Vehicle Does Not Run - Directional Contactors Do Not Close Condition: Keyswitch closed Deadman switch closed

!k Charge . or replace battery

Is battery charged?

(22.5V to 25.5V)

1

Are battery terminals and quick disconnect plug OK?

Repair or replace

1

Are fuses FU2 and FU3 OK?

i

Replace fuses

Yes

Is there continuity at the

Replace keyswitch

keyswitch?

1

Yes

I Is there continuity at the deadman switch?

Yes

Is there power at the motor controller at B+?

Yes

Continued next page

I

Replace deadman switch

No

TOYOTA

Service and Parts Manual Traction Svstem Problems Vehicle Does Not Run - Directional Contactors Do Not Close (Cont'd.)

Is there power output at the throttle potentiometer?

1 Yes Are wiring harness and connections OK? I Yes

1

I Replace control module. OK?

Replace motor controller

No No

Replace throttle potentiometer

Replace or repair

TOYOTA

Service and Patis Manual Traction System Problems Vehicle Does Not Run - Directional Contactors Energize Condition: keyswitch closed deadman switch closed Is fuse FU2 OK?

P

Replace fuse (250 Amp)

Yes Are contactor tips OK?

v

Clean tips or replace contactor (see page 5.56)

/ Yes

1

Replace buss bar

Is contactor buss bar OK? Yes Is there continuity at the drive motor through field and armature?

Replace drive motor

Yes

Is throttle pot adjusted properly? (See page 5.61 .)

1

Adjust/replace throttle potentiometer

Yes

I

Are wiring harness and connections OK?

7 1 Yes

Replace Control Module

Repair or replace

TOYOTA

Service and Parts Manual Traction System Problems Vehicle Runs In One Direction Only - Opposite Direction Contactor Does Not Energize

Can B+ be measured at affected contactor coil?

1

Check wiring between contador and B+.

I

Yes

Check for continuity of contactor coil. OK?

Replace contactor coil.

Yes

Check for continuity in wiring between conta&or coil and B-. OK?

1

Are contactor tips OK?

, Repair/replace wiring.

.Ll

Repair/replace contactor tips.

1 Yes 1

Is throttle potentiometer adjusted properly?

Adjust/replace throttle pot.

Yes

Replace control module. OK?

Yes

Return vehicle to service.

No 1

Replace motor controller. OK?

Yes

Return vehicle to service.

If the vehicle travels OK in reverse, but has no forward travel, inspect the Emergency Reverse Switch (S25) and associated wiring.

TOYOTA

Service and Parts Manual Traction System Problems Vehicle Runs In One Direction Only - Directional Contactors Work Normally

Are contactor t i ~ OK? s

Clean or replace contactor (See page 5.57)

i

Replace buss bar

1

Is contactor buss bar OK? Yes

1

Are wiring harness and connections OK?

1

Yes

Is throttle potentiometer adjusted properly? (See page 5.61)

Repair or replace

TOYOTA

Service and Parts Manual Traction System Problems

TOYOTA

Vehicle Does Not Run In High Speed (Forward only)

Is battery charged?

122.5V to 25.5W

No

Charge or replace battery

1 Yes I

Check for continuity across field weaken foot switch (S26). OK?

Does field weaken contactor coil test OK? (See page 5.57)

Does field weaken resistor test OK?

1

Yes

Are wiring harness and connections OK?

i

Replace control module

Replace switch

-"'

"place

coil

If open, replace resistor

INL ~ e p a i or r replace

Service and Parts Manual Traction System Problems Plugging Does Not Operate Properly

Rotate plug current pot on control module for response. (See page 5.53)

1

OK

Reset plug current pot to maximum.

Vehicle Does Not Accelerate Properly

Adjust accelerator pot on control module per application. (See page 5.53)

Does not re-

1

Redace motor controller

TOYOTA

Service and Parts Manual Traction System Problems Emergency Reverse Module Does Not Activate When Button Is Depressed

Is emergency reverse switch 625) OK?

+-Replace 525.

I Yes With no power, measure resistance across pins 1 and 2 of emergency reverse module DA2.

Resistance should be approximately 5K ohms.

Replace DA2

OK?

I

Yes

Check for continuity across pins 4 and 6 of DA2. OK?

I

Replace DA2

Yes

Check wiring. OK?

v Replace motor controller.

Repair/replace wiring

TOYOTA

Service and Parts Manual Traction System Problems Emergency Reverse Module Checks OK. N o Reverse Travel With S25 Depressed

Does 525 check OK?

1

No

Replace S25

1 Check wiring from reverse contactor coil through S25 to B-. OK?

Replace motor controller

Repair/replace

TOYOTA

Service and Paris Manual

TOYOTA

Lift/Lower Problems Lift/Lower Problems Forks Do Not Lift When Lift Button Is Pushed

i

Does lift pump motor run?

i

1

Are fuses FU 1 , and FU3 OK?

Yes

Replace fuse Yes

Is reservoir fluid level OK?

Refill Reservoir

1

Is keyswitch yesOK?

p.

Replace keyswitch

Yes 1

Is pressure relief setting set prop-

Adjust pressure relief per page 5.35

Is lift cutout switch

1 Yes

I Yes

I

Is lower solenoid OK? ,

1

I

1

Repair or replace solenoid

Do lift buttons operate OK?

1

Yes

-Y, Is lift pump OK?

Is there something mechanical preventing lift?

Replace cutout switch

Replace lift buttons

Yes

1s pump contactor coil OK?

1

contactor coil

Yes

DO pump yes contactor tips close?

Is pump contactor coil suppresser

"0

tre ; n tor ti s OK?

Replace contactor coil suppresser

OK?

Is lift pdmp motor

OK?

1 Yes 1

Check wiring harness and connectors

Repair or replace pump

z

Service and Parts Manual Lift/Lower Problems Forks Do Not Lower When Lower Button Is Pushed

Do the lowering buttons check OK?

Replace buttons

I Yes Does the lowering solenoid coil test OK?

1

Replace solenoid coil

Yes

I Does the coil suppresser test

Repair or replace solenoid

OK?

1

Yes

I

Are wiring harness and connections OK?

/

Repair or replace

Yes

Is the mechanical portion of the lowering solenoid OK? Yes

Is there something mechanically preventing the forks from lowering?

Repair or replace lowering solenoid

TOYOTA

Service and Parts Manual Chapter 7 Appendix Index

TOYOTA PAGE

SUBJECT

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

Standard Torque Data For Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Equivalency Chart

Conversion Table

7.1 7.2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Decimal Equivalent Chart

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

Schematic Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Model 6HBW30 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Models 6HBE30 & 6HBE40

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

Electrical Schematic . Models 6HBC30 & 6HBC40 . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Model 6TB50

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

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Model 6HBW30 (Cold Storage) . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . Models 6HBE30 & 6HBE40 (Cold Storage)

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

Electrical Scehmatic . Models 6HBC30 & 6HBC40 (Cold Storage) . . . . . . . . . . . . . .

Electrical Schematic . Model 6TB50 (Cold Storage)

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

7.4

Service and Parts Manual

TEXACO LUBE P/N 'LUBE 'A' Hyd. Res- Aircraft ervoir Oil for Cold Hyd Oil 15 Mil-HStorage (+40° 20°F) applications. 56068

'*LUBE 'Bl' Hyd. Reservoir Oil for Cold Storage In & Out (20' to 70') application.

TOYOTA

Appendix

Lubrication Eauivalenw Chad

TOYOTA PRODUCTS LUBRICATION EQUIVALENT CHART SHELL CHEVRON PHILLIPS GULF EXXON ClTGO Aeroshell Aviation Univis J13 Fluid 4 Hydraulic similar to Mil-HFluid A Mil-HMil-H5606A 5606A 5606A

MOBlL

Tellus T Oil 32

HD AZ 32 1627 Rando

LUBE 'B' Hyd. Res- Rando Oil HD46 ervoir Oil for Hydraulic Standard (+50° Oil Mil-H120°F) applications. See NOTE 1. 176728

Pacemaker Nuto H46 Magnus A, XD-20 31 5 Hydraulic Oil Mil-H460001 B

LUBE 'C' Drive URSATEX Unit Gear Case for 1OW-30 below 30°F. Pump 21 66 Motors w/oil cup, foot pedal, lift chains, etc. for above and below 30°F.

C-6 1 OW30 Motor Oil Mil-H461 52

Exxon Extra Motor Oil 1OW-30 API Service SE

Trop-Artic Gulflube All Season Motor Oil Motor Oil X.H.D. 1OW-40 Mil- 1OW-30 L-46152

LUBE 'D' Drive Unit Gear case for above 30°F.

Multigear Lubricant EP 85W-90 Mil-L21058

Premium Gear Oil MP90 MilL-21058

Gear Oil GX BOW90 Mil-L21 058

Philube SMP Gear Oil SAE 80W90 Mil-L2105C

Multipurpose Gear Lubricant 8OW-90

LUBE 'E' Drive Unit and Caster swivel, caster spring rod pivots, steer gear box, load wheels, uprights, reach arms, caster wheel bearings, etc., (above and below 30°F).

Regal AFB 2 Grease Mil-G18709A

HEP2 RONEX (above MP or 30°F only) UNIREX N2

Philube 1B and RB Grease

Gulfcrown Alvania Grease Grease EP2 No. 2

FLUID 'G' Brake Fluid SAE. (SAE J17-03F type 70R-3 or exceed). Do not use anything less than Dot 5.

LUBE 'H' AGMA #8 See NOTE 2.

SOHlO

Harmony 46-AW

DTE-15

Tellus T Oil-46

Multron 1OW-30 Mil-L46152 API Service SE

Delvac Special 1OW-30 API Service SE

Gear ep Spirax HD- Universal Gear 90 85W-90 Lubricant 80WMil-L90 Mil-L21 05B 21058

Mobilube HD 80W90

Bearing Guard "LT"

Mobil Grease 77

Shell Rotella T Oil 15W40 API Service SE CC and CD

Delco 400 Motor Oil 15W-40 API Service SE

Avi-Motive Grease

Dow Corning Silicone or Equivalent

I Honor Cyl. Oil 680

Cylesstic TK-680

Hector 630s Sene1 186 Valvata J680

Cyl Oil 680X

LUBE 'J' Cold Temperature Synthetic Oil 30°F to 85OF

Super Cyl. 600W. SHC626

NOTE 1: Agway UF Hyd. Fluid is also approved. 'CLASS I ** CLASS II

NOTE 2: Fisk Brother's Lubriplate CP-8 gear oil is also approved.

Figure 7.1 Lubrication Equivalency Chart

Service and Parts Manual Standard Torque Data for Bolts

A~~endix

Standard Torque Data for Bolts

IDENTIFICATION

Figure 7.2

Standard Torque Data for Bolts

7.2

TOYOTA

Service and Parts Manual Conversion Table

Appendix

Conversion Table

Figure 7.3

Conversion Table

TOYOTA

Service and Parts Manual Decimal Equivalency Chart

Appendix

Decimal Equivalency Chart

Figure 7.4

Decimal Equivalent Chart

7.4

TOYOTA

Service and Parts Manual Appendix

Schematic Legend

Schematic Legend

Figure 7.5

Schematic Legend

TOYOTA

Service and Parts Manual Electrical Schematic

,

A

I

TOYOTA

Appendix

B

I

C

I

D

I

E

I

F

I

G

I

H

I

J

1

-

KEY SW 1 TCH

DEADMAN

SW l TCH

2

3

4

5

6

7

8

9

_I

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.6

Electrical Schematic for the Model 6HBW30

I

K

I

L

I

M

I

N

I

P

I

Service and Parts Manual Electrical Schematic

Appendix

Figure 7.7

Electrical Schematic for Models 6HBE30 & 6HBE40

TOYOTA

Service a n d Parts M a n u a l Electrical Schematic

A~~endix

TOYOTA

KEY SWITCH

DEADMAN SWITCH

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.8

Electrical Schematic f o r Models 6HBC30 & 6HBC40

Service and Parts Manual Electrical Schematic

Appendix

KEY

sw l TCH

TOYOTA

DEADMAN SW l TCH

NOTES: 1. All boxes labeled Turtle Module are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control Module are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.9 Electrical Schematic for Model 6TB50

7.9

Service and Parts Manual Hydraulic Schematic

Appendix

TOYOTA

1. Inlet Strainer 2. Pump Motor 3. Pump 4. Relief Valve 5. Check Valve 6. Lift Cylinders 7. Lowering Solenoid 8. Flow Control Valve

Figure 7.1 0 Hydraulic Schematic

7.1 0

Service and Parts Manual Electrical Schematic ( c o l d Storage)

A

I

B

TOYOTA

Appendix

I

C

I

D

I

E

I

F

I

G

I

H

I

1

2

3

4

5

6

7

8

NOTES: 1. All boxes labeled Turtle Mod& are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor C o n t r h are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled Control are physically contained in a single module and are split out on this diagram for functional clarity only.

9 Figure 7.1 1

Electrical Schematic for the Model 6HBW30 (Cold Storage)

I 7.1 1

J

I

K

I

L

I

M

I

N

I

P

1

Elecdrical Schematic (cold Storage)

Service and Parts Manual Appendix

TOYOTA

KEY SWITCH

NOTES: 1. All boxes labeled Turtle M o d are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor Controller are physically contained in a single module and are split out on this diagram for functional clarity only.

3. AII boxes labeled Control are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.1 2 Electrical Schematic for Models 6HBE30 & 6HBE40 (Cold Storage)

Service and Parts Manual Electrical Schematic ( c o l d Storage)

Appendix

TOYOTA

KEY WITCH

NOTES: Mod& are physically contained in a single module and are split out on this diagram for functional clarity only.

1. All boxes labeled 2. All boxes labeled Motor are physically contained in a single module and are split out on this diagram for fundional clarity only.

3. All boxes labeled -01 Mod& are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.1 3 Eledrical Schematic for Models 6HBC30 & 6HBC40 (Cold Storage)

DEADMAN SW l TCH

Service and Parts Manual Electrical Schematic (Cold Storage)

Appendix

KEY SW l TCH

TOYOTA

DEADMAN swI T C H

NOTES: 1. All boxes labeled are physically contained in a single module and are split out on this diagram for functional clarity only.

2. All boxes labeled Motor are physically contained in a single module and are split out on this diagram for functional clarity only.

3. All boxes labeled -01 Mo& are physically contained in a single module and are split out on this diagram for functional clarity only.

Figure 7.1 4 Electrical Schematic for Model 6TB50 (Cold Storage) 7.1 4

Service and Parts Manual Alphabetical Index

Advanced Transistor Control, 4.2 Controller Keyswitch Input, 4.5 Controller Thumbwheel Throttle Inputs, 4.5 Current Limiting, 4.3 Emergency Reverse Plug Breaking Inhibit, 4.5 Low Voltage Cutback, 4.3 Plugging, 4.4 Runaway Protection, 4.4 Static Return to Neutral Protection, 4.4 Thermal Protection, 4.4 Aisle (Pallet) Entry Wheels, 5.27 After Every 50 Hours of Operation, 5.27 After Every 500 Hours of Operation, 5.27 Daily Inspection, 5.27 Wheel Replacement, 5.27

Battery, 3.2,5.41 Adding Water, 3.2 Charging, 5.42 Connector, 3.4 Electrolyte Level, 5.41 Hydrometer Use, 3.2 Specific Gravity, 5.41 Storage, 5.43 Voltage Check, 3.3 Brake, 5.20 Break-In Period, 3.9 Battery, 3.9 Motors, 3.9 Pump, 3.9

Casters, 5.28 Daily Inspection, 5.28 Contactor, 5.56 Cleaning, 5.56 Coil Replacement, 5.57 Contactor Table, 5.57 Disassembly/Reassembly, 5.58 Inspection, 5.56 Tip Replacement, 5.57 Control Module, 4.6

TOYOTA

Deadman Switch Adjustment, 5.22 Diode, 5.60 Plug Test, 5.60 Drive Motor, 5.44 Adjustments and Inspection, 5.44 Brushes, 5.44 Commutator, 5.46 General Data, 5.48 High Mica, 5.46 High Mica Resurfacing, 5.47 Inspection, 5.48 Removal, 5.48 Servicing, 5.46 Drive Unit, 5.9, 5.1 0, 5.1 1 Gear Case Data, 5.16 Gear Checking Procedure, 5.16 Gear Tooth Pattern, 5.1 5 Installation, 5.1 7 Lubrication, 5.9 Service, 5.9 Steering Bearing, 5.1 1 Vent Plug, 5.9 Drive Wheel, 5.24 Cushion Drive Tire Replacement, 5.24 Daily Inspection, 5.24 Adjustment, 5.21 Inspection, 5.20

Electrical, 5.41 Electrical System, 1 .l0 Advanced Transistor Control, 1.12 Battery, 1 .l 0 Drive Motor, 1 .I 0 Lift Limit switch, 1.1 2 Electrical (Traction) System Adjustments, 5.52 Acceleration Adjustment, 5.53 Current Limit Setting, 5.52 Drive Motor Cutout Switch Adjustment, 5.55 Plug Current Adjustment, 5.53 Potentiometer Adjustments, 5.52 Electrical Testing Contactor Coils, 5.65 Horn, 5.65 Relay Coils, 5.65 solenoid coils, 5.65 Throttle Potentiometer, 5.65

Service and Parts Manual Alphabetical Index

TOYOTA

E (Cont'd.)

Electrical Wiring Model 6HBW30, 1.1 3 Models 6HBE30, 6HBE40, 1.1 4 Models 6HBC30, 6HBC40, 1.1 5 Model 6TB50, 1.16 Emergency Reverse Module (DAl ) Test Procedure, 5.64

Fork and Linkage, 5.29 Fork Height Adjustment, 5.30 Lift Limit Switch Adjustment, 5.31

Handle Return Spring Adjustment, 5.22 Hydraulic Inspection, 5.34 Lift Cylinders Service, 5.37 Relief Valve Setting, 5.35 Reservoir, 5.35 Reservoir Inspection, 5.37 Hydraulic Fluid Temperature Range, 3.6 Hydraulic Oil Level, 3.5 Hydraulic Pump Motor, 5.50 General Data, 5.50 Inspection, 5.50 Removal, 5.50 Hydraulic System, 1.7 Breather Cap, 1.8 Check Valve, 1.8 Drive Motor, 1.l0 Flow Control Valve, 1.7 General, 1.7 Lifi Cylinders, 1.8 Lowering Solenoid, 1.7 Pump, 1.8 Pump Motor, 1.8 Relief Valve, 1.7 Reservoir, 1.8 Hydraulic System Oil, 5.7

Installafion, 3.1 Checking the Battery, 3.1 Visual Inspection, 3.1

Lifi Cylinder Oil Leakage Wiper Seal, 5.37 Lifi/Lower System, 4.23 Keyswitch on, 4.23 Load Wheels, 5.26 Daily Inspection, 5.26 Replacement, 5.26 Lubrication, 3.5 Lubrication and Maintenance Guide, 5.6

Mechanical, 1.4 Coast Control, 1.6 Drive Unit, 1.4 Drum Brake, 1.6 Handle Assembly, 1.5 Model Identification, 1.2

Operational Checks, 3.7 Brake, 3.7 Coast Control, 3.8 Emergency Reverse Switch, 3.7 Fork/Lift Linkage, 3.7 Overview, 1.l, 1.2, 1.3

Power Section, 5.8

Receiving Inspection Guide, 3.8

Theory of Operation, 4.1 Battery Plugged IN, 4.7 Battery Plugged IN/Keyswitch Turned On, 4.9 Deadman Switch Closed, 4.1 1 Diredional/Speed Control Forward, 4.1 3 Directional/Speed Control-High Speed, 4.1 5 Emergency Reverse Switch, 4.1 7 Plugging, 4.1 9 Turtle Speed, 4.2 1

Service and Parts Manual Alphabetical Index

Throttle Potentiometer Setting, 5.61 Transmission Assembly, 5.12 Troubleshoot, 6.1 Wiring Inspection Procedure, 6.3 Turtle Speed Module Replacement, 5.63 Test/Adjustment, 5.62

Vehicle Specifications, 1.3

Welding Precautions, 5.5

TOYOTA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

nYmA

Throughout the Parts Manual you will find certain abbreviations used in the description of parts. Please use this guide to clarify their meaning.

A AC AR BC C/w Cfl DC DIA ESNA GPM GR H/D HR HZ LH N/S NOM NPTF PG PLTD

P/N REF RH RHS SB SLTD STD STR UNC UNF V VAC VDC

w/ w/o

Amps Alternating Current As Required Battery Compartment Complete With Controllerflransistor Direct Current Diameter Manufacturer's Name Gallons Per Minute Grade Heavy Duty Hour Hertz Left Hand Not Shown Nominal Threads For Dry Seal Pressure Tight Joints Page Plated Part Number Reference Right Hand Round Headed Screw Part Of Manufacture Part Number (Example Slotted Standard Straight Unified National Course Thread Unified National Fine Thread Volt Volt Alternating Current Volt Direct Current With Without

REF: lndicates that there is an existing page showing further breakdown of this assembly. The referenced figure number will be referenced at the end of the item description.

REF ONLY: Indicates the location of the referenced assembly on the illustration.

However due to the size of the assembly drawing, or to the number of variations of the referenced assembly, these items are not shown within the illustration. Page numbers are referenced at end of item description.

NOTE: All dimension of hardware listed in the parts description are given in inches, unless otherwise specified. If an

" M i s shown in the description of the part, this indicates that the dimensions given are metric. If information is needed on whether a fastener is U.S.S. or S.A.E. standard, please contact the Toyota Parts Technical Line for assistance.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

THIS PAGE INTENTIONALLY LEFT BLANK

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

SPECIAL SERVICE TOOLS TOOL LIST

DESCRIPTION

00590-04667-7 1

Pin Extractor

00590-04668-71

Pin Extractor

00590-04669-71

Pin Extractor

00590-04670-71

Pin Extractor

00590-04671 -71

Crimping Tool

00590-04672-71

Extraction Tool

00590-04673-71

Model 114 1 Accessory

00590-04674-7 1

Model 1 142 Tester

00590-04675-71

Curtis Battery Book One

00590-04676-71

Bearing/Sealing Ring Tool

00590-04677-71

Battery Pak lifter

mYmA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

THIS PAGE INTENTIONALL LEFT BLANK

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M O D E L 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 TABLE OF C O N T E N T S

mYmA

Truck Final Assembly . 00590-01 390~71.00590~01391~71,00590~01392~71, 00590-01 393.71.

00590-01 299.71. 00590-71 -01401 -71 ..All Models .................................................................. 1-2 Truck Final Assembly . 00590.00357.71. Model 6TB50 ............................................................. 1-4 Tractor Cover Assembly. 00590.00459.71, 00590-00466-71 . All Models ................................... 1-6 Caster Installation. 00590-00001.71, 00590-00007-71. All Models ............................................ 1-8 Caster Installation. 00590-01 548.71, 00590-01551 -71 . All Models Prior to 4/1/96 .................... 1-10 Swivel Caster Assembly . Standard . 00590-00002-71 . Currently Used on all Models ................... 1-12 Swivel Caster Assembly. Heavy Duty 00590-00008-71 . Optional For 8000# Trucks Only ............ 1-14 Swivel Caster Assembly 00590-01 552.71, 00590-01 567-71 . Heavy Duty (After 1 1/20/95) ........... 1-16 00590-01 277.71,00590.0128 3.71 .

Finish Instructions . 00590-01 269.71.00590.01273.71, Model 6HBW30 ........................................................................................................................... 1-18 Finish Instructions. 00590-01 269.71, 00590-01 273.71,00590.01277.71, 00590-01 283-71 .

Models 6HBE30/6HBE40 ......................................................................................................... 1-20 3.71 .

Finish lnstructions . 00590-01 269.71, 00590-01 273~71.00590~01277~71.00590~0128 Models 6HBC30/6HBC40 ....................................................................................................... 1-22 Finish lnstructions . 00590-01 269.71, 00590-01 273.71. 00590-01 277.71, 00590-01283-71 .

Model 6TB50 ............................................................................................................................... 1-24 Coast Installation. 00590-00290-71 . Models 6HBE30. 6HBE40. 6HBW30 ...................................1-26 Keyswitch Installation . 00590.00530.71. 00590-00537-71 . All Models ....................................... 1-28 Coupler Installation . 00590.00034.71. 00590-00053-71 . Model 6TB50 ..................................... 1-30 Load Backrest. 00590.00980.71, 00590-00984-71 . Models 6HBW30/6HBE30 ........................... 1-32 Load Backrest. 00590.00969.71, 00590.00970.71, 00590-00976-7 . Model 6HBC30 ...............1-34 Load Backrest . 00590.00749.71, 00590-00754-71 . Model 6HBE40/6HBC40 ............................. 1-36

AND STFFRING SFCTION 2-1 2-2 2-3 2-4

3- 1 3-2 3-3 3-4 3-5 3-6 3-7 3-8

4- 1 4- 1 4- 1

1.71 Handle Assembly . 00590-01 344~71,00590~01346~71,00590~01348~71,00590~0135 2-2 Models 6HBC30/6HBC40/6TB50 Handle Assembly . 00590-01 342~71,0590~01300~71,00590~01343~71,00509~0130 5.71 Models 6HBW30/6HBE30/6HBE40 ............................................................................................... 2-4 Handle Mounting and Installation. 00590-0021 4-71 2-6 Models 6HBW30/6HBE30/6HBE40/6HBC40/6TB50 Brake Assembly . 00590-00384-71 . All Models ............................................................................ 2-8

Drive Unit Final Assembly . 00590-01 309~71,00590~01583~71,00590~01312~71,00590~0158 4.71 Models 6HBW30/6HBE30/6HBE40 ............................................................................................. 3-2 Drive Unit Final Assembly . 00590-01 354.71, 00590-01 355-71 .

Models 6HBC30/6HBC40/6TB50 .............................................................................................. 3-4 Transmission Assembly . 00590-0041 0-71 . Model 6HBW30 ........................................................ 3-6 Transmission Assembly . 00590-00455-71 . All Other Models ...................................................... 3-8 Drive Unit Sub-Assembly. 00590.00394.71, 00590-00452-71 . All Models ................................. 3-10 Motor Sub-Assembly . 00590.00453.71, 00590-00399-71 . All Models ........................................ 3-12 Traction Motor . 00590-04576-71 . Model 6HBW30 .................................................................... 3-14 Traction Motor . 00590-04573-71 . Models 6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ................ 3-16

System Electrical . 00590-01 585.71, 00590-01 588-71Sheet 1 of 4 . Model 6HBW30 (Used Up to 6/24/96) ................................................................................................................

4-2 System Electrical. 00590~01585~71,00590~0158 8.71 . Sheet 2 of 4 . Model 6HBE30/6HBE40 (Used Up to 6/24/96) ...................................................................................................................

4-3 System Electrical . 00590-01585-/ i, 00590-01588-71 . Sheet 3 of 4 . Model 6HBC30/6HBC40 4-4 (Used Up to 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 TABLE OF CONTENTS

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FI FCTRICAL SFCTION CONT'D. System Electrical - 00590-01 585-71,00590-01588-71 - Sheet 4 of 4 - Model 6TB50 (Used Up to 6/24/96) ................................................................................................................... 4-5 System Electrical - 00590-01 589-71, 00590-01 596-71 - Sheet 1 of 4 - Model 6HBW30 (Used After 6/24/96) .....................................................................................................................

4-8 System Electrical - 00590-01589-71,00590-01596-71- Sheet 2 of 4 - Model 6HBE30/6HBE40 (Used After 6/24/96) .....................................................................................................................

4-9 System Electrical - 00590-01 589-71,00590-01596-71- Sheet 3 of 4 - Model 6HBC30/6HBC40 (Used After 6/24/96) 4-1 0 System Electrical - 00590-01 589-71,00590-01596-71- Sheet 4 of 4 - Model 6TB50 (Used After 6/24/96) ......... ..................................................................... .......... ............................ 4- 11 Transistor Controller Assembly - 00590-01303-71,00590-01345-71, 00590-01 347-71, 00590-01 307, 00590-01 349-71, 00590-01 352-71 - All Models ................................................... 4-14 Controller Diagram Reference -00590-01605-71, 00590-01 606-71, 00590-01607-71 .................. 4-1 7 Rail Switch Assembly - 00590-01 292-71, 00590-01 297-71 - Models 6HBE30/6HBE40 ................... 4-1 8 Foot Switch lnstallation - 00590-01 370-71,00590-01374-71, 00590-01 383-71, 00590-01 388-71 Models 6HBC30/6HBC40/6TB50 (Up to 6/24/96) ......................................................................... 4-20 Foot Switch lnstallation - 00590-01 599-71, 00590-01 602-71 - Models 6HBC30/6HBC40/6TB50 (After 6/24/96) ............................................................................................................................. 4-22 Hour Meter/Discharge Indicator lnstallation - 00590-0051 4-71, 00590-0051 7-71, 00590-0051 9-71, 00590-00520-71,00590-00526-71,00590-00527-71,00590-00529-71 - All Models ................. 4-24 Contactor Assembly - 00590-00545-71, All Models ....................................................................... 4-26

5- 1 5-2 5-3

Hydraulic System - 00590-00254-71 - All Models .......................................................................... 5-2 Purnp/Motor Assembly - 00590-00266-71 - All Models .................................................................. 5-4 D.A. Cylinder - 00590-04545-71 - All Models ............................................................................... 5-6

Platform & Rest Assembly - 00590-00969-71, 00590-00970-71,00590-00976-71 - All Models ..... 6-2 Entry Roller lnstallation - 00590-00207-71 - Model 6HBC30 .......................................................... 6-4 Entry Roller lnstallation - 00590-00757-71 - Models 6HBE40/6HBC40 ........................................... 6-6 Entry Roller lnstallation - 00590-00305-71 - Models 6HBW30/6HBE30 ........................................... 6-8 Load Wheel Assembly - 00590-00010-71,0590-00024-71 - Models 6HBW30/6HBE30/6HBC30 ...6-10 Split Load Wheel Assembly - 00590-01 62 1 -71, 00590-01 626-71 - Models 6HBE40/6HBC40 ......... 6- 12 Load Wheel Assembly - 00590-00095-71 - Models 6HBC40/6HBE40 ............................................ 6-14 Fork And Tractor Sub-assembly - 27" Width - 00590-00242-71, 00590-00301 -71, 00590-00994-71, 00590-01 025-71,00590-01031-71,00590-01037-71,00590-01043-71,00590-01050-71, 00590-01 055-71,00590-01060-71,00590-01065-71,00590-01076-71,00590-01081~71, 00590-01 087-71,00590-01094-71,00590-01107-71,00590-01110-71,00590-01117-71, 00590-01 124-71,00590-0113 1-71,00590-01135-71,00590-01142-71 Models 6HBW30/6HBE30/6HBC30 ............................................................................................... 6-16 Fork And Tractor Sub-assembly -24" Wide - 00590-00242-71,00590-00301-71,00590-01148-71, 00590-01 155-71,00590-01157-71,00590-01159-71,00590-01161-71 00590-01 163-71, 00590-01 165-71,00590-01167-71, 00590-01 169-71,00590-01171-71 , 00590-01 173-71, 00590-01 1 75-71,00590-01177-71,00590-01180-71,00590-01183-71,00590-01186-71, 00590-01 189-71,00590-01192-71,00590-01195-71,00590-01198-71 Models 6HBW30/6HBE30/6HBC30 6-20 Fork And Tractor Sub-Assembly - 22" Wide - 00590-00242-71, 00590-00301 -71,00590-01 201 -71 00590-01 208-71,00590-01210-71, 00590-01 21 2-71,00590-01214-71,00590-01216-71, 00590-0121 8-71,00590-01220-71,00590-01222-71,00590-01224-71,00590-01226-71, 00590-01 228-71,00590-01230-71, 00590-01 233-71,00590-01236-71,00590-01239-71, 00590-01 242-71,00590-01245-71,00590-01248-71,00590-01251-71 Models 6HBW30/6HBE30/6HBC30 ...............................................................................................

6-24 Fork And Tractor Sub-Assembly -27" Width- 00590-00242-71,00590-00301-71,00590-01627-71, 00590-01 637-71,00590-01640-71,00590-01644-71,00590-01648-71,00590-01651-71, 00590-01655-71, 00590-01 658-71 - Models 6HBE40/6HBC40 ....................................................6-27

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

'TaYmA

POWER SFCTlON Truck Final Assembly. 00590-01 390.71.00590~01391~71.00590-01 392.71.00590.01393.71.

00590-01 299.71. 00590-71 -01 401 -71 ..All Models .................................................................. 1-2 Truck Final Assembly . 00590.00357.71, Model 6TB50 ................................................................ 1-4 Tractor Cover Assembly. 00590.00459.71. 00590-00466-71 . All Models ................................... 1-6 Caster Installation. 00590-00001 .71, 00590-00007-71. All Models ............................................ 1-8 Caster Installation. 00590-01 548.71, 00590-01 551 -71 . All Models Prior to 4/1/96 .................... 1-10 Swivel Caster Assembly . Standard . 00590-00002-71 . Currently Used on all Models ................... 1-12 Swivel Caster Assembly. Heavy Duty 00590-00008-71 . Optional For 8000# Trucks Only ............ 1-14 Swivel Caster Assembly 00590-01552.71, 00590-01 567-71 . Heavy Duty (After 1 1/20/95) ........... 1-16 Finish Instructions . 00590-01 269.71. 00590-01 273.71. 00590-01 277.71, 00590-01 283-71 .

Model 6HBW30 ........................................................................................................................... 1-18 Finish Instructions. 00590-01 269.71. 00590-01 273.71. 00590-01 277.71,00590.0128 3.71 .

Models 6HBE30/6HBE40 ....................................................................................................... 1-20 Finish Instructions. 00590-01 269.71. 00590-01 273.71. 00590-01 277.71,00590.0128 3.71 .

Models 6HBC30/6HBC40 ........................................................................................................ 1-22 3.71 .

Finish Instructions. 00590-01 269.71, 00590-01 273~71,00590~01277~71.00590~0128 Model 6TB50 ............................................................................................................................... 1-24 Coast Installation . 00590-00290-71 . Models 6HBE30, 6HBE40, 6HBW30 ................................... 1-26 Keyswitch Installation. 00590.00530.71. 00590-00537-71 . All Models ....................................... 1-28 Coupler Installation. 00590.00034.71, 00590-00053-71 . Model 6TB50 ..................................... 1-30 Load Backrest . 00590.00980.71, 00590-00984-71 . Models 6HBW30/6HBE30 ........................... 1-32 6.7 . Model 6HBC30 ............... 1-34 Load Backrest . 00590.00969.71, 00590.00970~71.00590~0097 Load Backrest . 00590.00749.71. 00590-00754-71 . Model 6HBE40/6HBC40 ............................. 1-36

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

V

w

MODEL 6HBC30/6HBC40

MODEL 6HBW3O

L

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J

MODEL 6TB50

MODEL 6HBE40/6HBE30

Figure 1 - 1 . Truck Final Asserrtbly - 00590-01 390-71,00590-01391-71,00590-01392-71,00590-01393-71,0059001 299-71,00590-71-01401-71 - - All Models.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

FIGURE 1-1 ITEM NO. 1 2 3

4

I

QTY. 1 2 1

PART NUMBER 00590-00357-71 00590-00305-71 00590-0021 4-71

1

100590-00242-71

DESCRIPTION Final Assembly (See Figure 1-2) Entry Roller Installation (See Figure 6-4) Handle Mounting- and Installation (6HBW30/6HBE30) (See Figure 2-3) I Fork & Tractor Sub-Assembly - All Models 22" & 27" Fork Width (See Figure 6-9)

1

1

00590-00301 -71

Fork & Tractor Sub-Assembly 24" Fork Width (See Figure 6-9)

5 6

1 1

00590-00757-71 00590-00254-71

Entry Roller Installation (See Figure 6-4) Hydraulic System (See Figure 5-1)

7 8 9 10

2 1 1 1

00590-00207-71 00590-00290-71 00590-01 292-71 00590-01 344-71

Entry Roller Installation (See Figure 6-2) Coast Installation (See Figure 1-15) Rail Assembly (6HBE Only) (See Figure 4-5) Handle Assembly (See Figure 2-1)

11

1

00590-00 100-71

Hand Grip (See Figure 2-1)

1

100590-01370-71

I

12

I

I

I

IFoot Switch Installation (See Figure 4-6)

ToYmA USED ON D G, H A, B, E

I A, B, C, E, F, G, H A, B, C, E, 6 G, H E, F A, B, C,

A, B, C B, E, G B, E, G c, D, 6 H B, C, D, E, F, G, H I

A= 00590-01390-71 - 6HBW30 - Standard

B= 00590-01391 -71 - 6HBE30 - Standard

C= 00590-01 392-71 - 6HBC30 - Standard

D= 00590-01393-71 - 6TB50 - Standard E= 00590-01 299-71 6HBE40 - Long John F= 00590-01401 -71 - 6HBC40 - Long John G= 00590-01 397-71 - 6HBE30 - Long John H= 00590-01399-71 - 6HBC30 Long John

-

-

List 1-1. Truck Final Assembly - 00590-01 390-71,00590-01391-71,00590-01392-71,00590-01393-71, 00590-01 29971, 00590-71-01401-71 - A l l Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-2. Truck Final Assembly - 00590-00357-71, Model 6TB50.

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-2 ITEM NO. 1 2 4 4A 4B

5 6 7 8 9 10 11 12 13

QTY. 1 1 2 2 4 2 2 2 2 2 8 8 1 4 4 4

PART NUMBER 00590-00471 -71 00590-0036 1-7 1 00590-00091 -71 00590-00095-71 00590-0001 2-71 00590-00092-71 00590-00096-71 00590-00359-71 00590-00360-71 00590-0001 9-71 00590-00358-71 00590-00005-71 00590-0003 1 -71 00590-00358-71 00590-00030-71 00590-00005-71

DESCRIPTION Final Weldment Wheel Shaft & Plate Weldment Load Wheel Assembly - Neutra - Medium Poly I Load Wheel Assembly - Tan - Hard Poly Bearing Wheel - Neutral - Medium Poly Wheel - Tan - Hard Poly Spacer External Snap Ring Grease Fitting Hex Head Cap Screw 3/8- 1 6 x 1 -1 /4 Lockwasher 3/8 Front Rest Weldment Hex Head Cap Screw 3/8- 14 x 1 - 1 /4 Non Locking Nut 3/8-16 Lockwasher 3/8

List 1-2. Truck Final Assembly - 00590-00357-71, Model 6TB50

mYmA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

\~ractor

Assembly

Figure 1-3. Tractor Cover Assembly - 00590-00459-71, 00590-00466-71 - Ail Models.

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-3 ITEM NO. 1

2 3 4 5 6 7 9

QTY. PART NUMBER 1 00590-01 467-71 00590-01 468-71 1 4 00590-01 466-71 4 00590-00463-71 00590-00460-71 5 00590-00462-71 5 00590-00 113-71 5 1 00590-00469-71 I 1 100590-00465-71 2 100590-00467-71

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DESCRIPTION Tractor Cover Weldrnent Tractor Cover Weldrnent Flat Socket Head Machine Screw 5/16 -1 8 x 3/4 Anchor Nut 5/16-18 Socket Head Cap Screw 1/4-20 x 3/4 Hex Nut 1/4-20 Steel Lockwasher 1 /4 Dash Filler - Model 6HBE30 Dash Filler -All Other Models Leg - Pad

ALL MODELS A= Assembly 00590-00459-71 - Models 6HBW30/6HBC30/6HBC40/6TB50 B= Assembly 00590-00468-71 - Models 6HBE30/6HBE40

List 1-3. Tractor Cover Assembly - 00590-00459-71,00590-00466-71 - All Models

USED ON A B

B A B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-4. Caster Installation - 00590-00001 -71,00590-00007-71 - All Models.

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

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FIGURE 1-4 ITEM NO. 1 3 4 5 6

DESCRIPTION PART NUMBER QTY. 2 00590-00002-71 Caster Assembly - Standard (See Figure 1-6) 00590-00004-71 Flat Washer 3/8 8 00590-00005-71 Lockwasher 3/8 8 00590-00008-71 Caster Assembly - Heavy Duty (See Figure 1-7) 2 00590-00009-71 Hi-Collar Lockwasher 3/8 8 Caster Shim 1/8 4 7 00590-00006-71 9 00590-00003-71 Socket Head Cap Screw 3/8- 1 6 x 1 - 1 /2 8 A= Assembly 00590-00001-71 - Standard B= Assembly 00590-00007-71 - Heavy Duty - 8000# Truck Only

List 1-4. Caster Installation - 00590-00001-71,00590-00007-71 All Models

USED ON A A A B B B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

VJ

HEAVY DUTY INSTALLATION

my(TTA

STANDARD INSTALLATION

Figure 1-5. Caster Installation - 00590-01548-71, 00590-01551-71 - All Models .

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-5 ITEM NO.

QTY.

1 2 3 4 5 6 7 10

2 8 8 8 2 8 4 4

PART NUMBER

00590-00002-71 00590-00003-71 00590-00004-71 00590-00914-71 00590-01 556-71 00590-01549-71 00590-00006-71 00590-01554-71

ToYmA

DESCRIPTION Caster Assembly - Standard (See Figure 1-6) Socket Head Cap Screw 3/8-16 xl 1/2 Flat Washer 3/8 Hex Head CODScrew Caster Assembly - Heavy Duty (See Figure 1-8) Hex Head Cap Screw 3/8-16 xl 3/4 Caster Shim 1/8 Heavy Duty Caster Shim - 1 /8

A= 00590-01548-71 - Standard B= 00590-01551-71 - Heavy Duty 8000# Trucks Only -All Models

-

List 1-5. Caster Installation - 00590-01548-71, 00590-01551 -71 - All Models

USED ON A A A A

B

I I

I3 B

B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

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Figure 1-6. Swivel Caster Assembly - Standard - 00590-00002-71 - Currently Used on all Models.

1/31/97

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

FIGURE 1-6 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

QTY. 1 2 1 1 2 2 1 1 2 4 1 2 2 1 4

PART NUMBER 00590-04600-71 00590-04599-71 00590-04601-71 00590-04602-71 00590-04597-71 00590-04594-71 00590-04593-71 00590-04585-71 00590-04598-71 00590-04603-71 00590-04596-71 00590-04694-71 00590-04595-71 00590-04604-71 00590-04592-71

mYmA

DESCRIPTION Yoke Assembly Hex Bolt C/W Nut Pin Pin Spring Arm Spacer Wheel Kit Spacer Retaining Ring Hex Bolt C/W Nut Oilite Washer Oilite Bushing Wheel Axle Oilite Bushing

List 1-6. Swivel Caster Assembly - Standard - 00590-00002-71 - Currently Used o n all Models

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-7. Swivel Caster Assembly - Heavy Duiy 00590-00008-71

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- Optional For 8000# Trucks Only.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-7 ITEM NO. 1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 1 1 1

PART NUMBER 00590-04788-71 00590-04787-71 00590-04589-71 00590-04790-71 00590-04791 -71 00590-04792-71 00590-04793-71 00590-04794-71 00590-04795-71 00590-04796-71 00590-04797-71 00590-04798-71 00590-04593-71 00590-04694-71 00590-04599-71 00590-04591-71 00590-04590-71 00590-04602-71 00590-04592-71 00590-04603-71 00590-04595-71 00590-04596-71 00590-04601 -71 00590-04585-71

1

00590-04584-71

l'oYmA

DESCRIPTION Top Plate Swivel Head Assembly 0-Ring Seal King Bolt Metal Seal Bearing Cone Bearing Cup Thrust Bearing Upper Washer Lower Washer Grease Fitting Pivot Arm Assembly Spacer Oilite Washer Hex Bolt complete with Nut Spring Spacer Spring Pin Between Legs Oilite Bushing Leg/Pin Retaining Ring Oilite Bushing Leg/Axle Pivot Axle Pin Between Arms Caster Wheel Kit (Not Shown) includes: Wheel without Bearings, Bearing Components, Spacer,String Guards, Washer Seal and Axle Caster Wheel Kit (Not Shown) includes: Wheel without Bearings, Bearing Components, Spacer,String Guards, Washer Seal and Axle

A= Premium Kit

B= Standard Kit List 1-7. Swivel Caster Assembly - Heavy Duty 00590-00008-71 Optional For 8000# Trucks Only

USED ON

A

B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-8. Swivel Caster Assembly 00590-01552-71,00590-01567-71 - Heavy Duty .

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-10 ITEM NO. 1 2 3 4 5 6 7 9

Qr/

PART NUMBER

mYmA

DESCRIPTION

1 Yoke Weldment 00590-04756-71 1 NSS Bearing Cup 1 00590-04757-71 Screw 1 00590-04758-71 Washer 1 Spring Kit 00590-04826-71 1 Shroud Assembly 00590-04766-7 1 1 NSS Bushing Hinge Pin 1 00590-04768-71 1 Hinge Pin 00590-04769-71 1 Axle Assembly with Grease Fitting 10 00590-04770-71 Axle Assembly with Grease Fitting 1 00590-04771 -71 1 11 00590-04776-71 Grease Fitting Roll Pin (For Axle) 12 00590-04772-71 1 4 Washer (For Wheel Alignment) 13 00590-04773-71 Base Plate Kit: includes Items 17 thru 21 1 00590-04755-71 Base Plate Kit: includes Items 17 thru 21 1 00590-04803-71 17 1 NSS Mounting Plate 1 18 NSS Felt Seal 19 1 NSS Thrust Bearing 1 20 NSS Bearing Cup 21 1 NSS Bearing Cone 2 22 00590-04759-71 Washer 1 Slotted Jam Nut 00590-04760-71 23 1 24 Drive Pin (Roll Pin) 00590-04761 -71 1 25 00590-04762-71 Hub Cap 1 Wheel 26 00590-04780-71 27 2 Wheel Bearing 00590-0001 2-71 A= 3" x 5" Bolt Hole Centers For 00590-01 552-71 Assembly B= 2-5/8" x 3-5/8" Bolt Hole Centers For 00590-01567-71 C= Standard D= Cold Storage NSS= Not Sold Seperately List 1-8. Swivel Caster Assembly 00590-01 552-71, 00590-01567-71 - Heavy Duty -

USEDON

c D

c D

A

B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

mymA

STANDARD

Model Volts Note: Decal Will Be Found On Motor Housing

VlEW-

Figure 1 -1 1. Finish instructions - G0590-01269-71,00590-01273-71, 00590-01 277-71, 00590-01 283-71 - Model 6HBW30.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1- 1 1 ITEM NO. 1 2

QTY. 1 2

PART NUMBER 00590-01 274-71 00590-01 261 -71

Warning Decal Toyota Decal

3

1

00590-01 258-71

Emergency Disconnect Decal

1 00590-01 262-71 1 00590-01 260-71 00590-01 275-71 1 00590-01 276-71 1 00590-01 280-71 1 00590-01 282-71 1 1 00590-01 278-71 00590-01 285-71 1 00590-01 284-71 1 AR 00590-01 259-71 1 00590-01 271 -71 00590-00498-71 1 00590-01 272-71 1 1 00590-01 263-71 00590-01 270-71 1 1 00590-01 255-71 1 00590-01 281 -71 None 00590-01 281 -71 00590-01 281 -71 2 2 00590-01 281 -71 I I 4 )00590-01265-71

Warning Decal Low Lift Specification Plate Platform Seat - Right Hand Platform Seat - Left Hand Leg Guard Pad Back Pad Danger Decal Tow Tractor Warnina " Decal Tow Specification Plate - U.S. No Riding - Decal - 9" Black Turtle Speed Decal Coast Safety Decal Motor Specification Decal Warning Decal Operating Decal Manual Pocket Platform Pad Platform Pad Platform Pad Platform Pad I Specification Plate Studs

4 5 6 7 8 10 11 12 13 15 16 17 18 19 20 21 22

23

1

mYmA USED ON A, B, C A, B, C, D A, B, C, D A, B, C A, B, C B, D B, D B, C, D B B C. D C C, D D D D

DESCRIPTION

1

I

A A A B C D

A= Assembly 00590-01269-71 - Model 6HBW30 B= Assembly 00590-01273-71 - Models 6HBE30/6HBE40 C = Assembly 00590-01 277-71 - Models 6HBC30/6HBC40 D= Assembly 00590-01 283-71 - Model 6TB50

List 1-9. Finish Instructions - 00590-01 269-71,00590-01273-71,00590-0 1277-71,00590-01283-71 - Model 6HBW30.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

mymA

B

I

Note: Decal Will Be

Found On Motor Housing

Figure 1-1 2. Finish lnstructions - 00590-01 269-71, 00590-01273-71,00590-01277-71, 00590-01 283-71 Models 6HBE30/6HBE40 .

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-12 ITEM NO. 1 2

QTY. 1 2

PART NUMBER 00590-01 274-71 00590-01 261-71

Warning Decal Toyota Decal

3

1

00590-01 258-71

Emergency Disconnect Decal

4 5 6 7 8 10 11 12 13 15 16 17 18 19 20 21 22

1 1 1 1 1 1 1 1 1 AR 1 1 1 1 1 1 1 None 2 2 4

00590-01 262-71 00590-01 260-71 00590-01275-71 00590-01 276-71 00590-01 280-71 00590-01 282-71 00590-01 278-71 00590-01 285-71 00590-01 284-71 00590-01 259-71 00590-01271-71 00590-00498-71 00590-01 272-71 00590-01 263-71 00590-01 270-71 00590-01 255-71 00590-01281-71 00590-01 281-71 00590-01 281-71 00590-01 281-71 00590-01 265-71

Warning Decal Low Lift Specification Plate Platform Seat - Right Hand Platform Seat - Left Hand Leg Guard Pad Back Pad Danger Decal Tow Tractor Warning Decal Tow Specification Plate - U.S. No Riding Decal - 9" Black Turtle Speed Decal Coast Safety Decal Motor Specification Decal Warning Decal Operating Decal Manual Pocket Platform Pad Platform Pad Platform Pad Platform Pad Specification Plate Studs

23

DESCRIPTION

ToYmA USED ON A, B, C A, B, C, D A, B, C, D A, B, C A, B, C 8, D B, D B, C, D B

B C, D C C, D D D D A A A B C D

A= Assembly 00590-01269-71 - Model 6HBW30 B= Assembly 00590-01273-71 - Models 6HBE30/6HBE40 C= Assembly 00590-01 277-71 - Models 6HBC30/6HBC40 D= Assembly 00590-01 283-71 - Model 6TB50

List 1-1 0. Finish Instructions - 0 0 5 9 0 - 0 1 269-71, 0 0 5 9 0 - 0 1 273- 71,00590-01277-71, 0 0 5 9 0 - 0 1 283-71 - Models 6MBE30/6HBE40.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

STANDARD

@'

mymA

p A- MOTOR DFCAl

dFCT~oN

C-C

Note: Decal Will Be

Found On Motor Housing

Figure 1-1 3. Finish Instructions - 00590-01 269-71,00590-01273-71,00590-01277-71,00590-01283-71 Models 6HBC30/6HBC40.

-

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-1 3 1 PART NUMBER ITEM NO. QTY. 1 II 1 100590-01274-71 2 00590-01 261-71 2 I

3

I

I

23

1

I USED

DESCRIPTION

1 Warning- Decal Toyota Decal

I

00590-01 258-71

1 I

4 5 6 7 8 10 11 12 13 15 16 17 18 19 20 21 22

ToYmA

,

1 100590-01262-71 00590-01 260-71 1 1 00590-01 275-71 1 00590-01276-71 1 00590-01 280-71 00590-01 282-71 1 1 00590-01 278-71 00590-01 285-71 1 00590-01284-71 1 AR 00590-01 259-71 1 00590-01 271 -71 1 00590-00498-71 1 00590-01 272-71 1 00590-01 263-71 1 00590-01 270-71 1 00590-01 255-71 00590-01 281 -71 1 None 00590-01 281-71 00590-01 281 -71 2 281 -71 2 00590-01 I 4 (00590-01265-71

Emergency Disconnect Decal I

lWarnina" Decal Low Lift Specification Plate Platform Seat - Right Hand Plaiform Seat - Left Hand Leg Guard Pad Back Pad Danger - Decal Tow Tractor Warning Decal Tow Specification Plate - U.S. No Riding Decal - 9" Black Turtle Speed Decal Coast Safetv Decal Motor Specification Decal Warning Decal Operating Decal Manual Pocket Platform Pad Platform Pad Platform Pad Platform Pad I Specification Plate Studs

1

I ON

I A, B, C A, B, C, D A, B, C, D I A, B, C A, B, C B, D B, D B, C, D B B C, D C C, D D D D

I

A A A B C D

A= Assembly 00590-01269-71 - Model 6HBW30 B= Assembly 00590-01273-71 - Models 6HBE30/6HBE40 C= Assembly 00590-01277-71 - Models 6HBC30/6HBC40 D= Assembly 00590-01 283-71 - Model 6TB50

List 1-1 1. Finish Instructions - 0 0 5 9 0 - 0 1 269-71,00590-01273-71,00590-01277-71,00590-01283-71 6HBC30/6HBC40.

- Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TBSO POWER

mymA

STANDARD

"\

VIEW D

-

b

Note: Decal Will Be Found On Motor Housing DFTAlL A- MOTOR DFCAl

Figure 1-1 4. Finish Instructions - 00590-01269-71,00590-01273-71, 00590-01 277-71,00590-01283-71 Model 6TB50.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1 - 1 4 ITEM NO. 1 2

1 2

Warning Decal Toyota Decal

1

00590-01 258-71

Emergency Disconnect Decal

00590-01 262-71 1 00590-01 260-71 1 1 00590-01 275-71 1 00590-01 276-71 1 00590-01 280-7 1 1 00590-01282-71 1 00590-01 278-71 1 00590-01 285-71 1 00590-01 284-71 00590-01 259-71 AR 00590-01271-71 1 1 00590-00498-71 00590-01 272-71 1 00590-01 263-71 1 1 100590-01270-71 I 1 100590-01255-71 1 00590-01 281 -71 None 00590-01 281 -71 2 100590-01281-71 1I 2 100590-01281-71 1 4 100590-01265-71

Warnina Decal Low Lift Specification Plate Platform Seat - Right - Hand Platform Seat - Left Hand Leg Guard Pad Back Pad Danger Decal Tow Tractor Warning Decal Tow Specification Plate - U.S. No Riding Decal - 9" Black Turtle Speed Decal Coast Safetv Decal Motor ~~ec';fication Decal Warning - Decal Operating Decal 1 Manual Pocket Platform Pad Platform Pad Platform Pad I Platform Pad I ISpecification Plate Studs

3 4 5 6 7 8 10 11 12 13 15 16 17 18 19 20 21 22

I

1

23

1

USED ON A, B, C A, B, C, D

DESCRIPTION

PART NUMBER 00590-01 274-71 00590-01 261 -71

QTY.

mYmA

A, B, C, D A,. B,. C A, B, C 8, D B, D B, C, D B B C, D C C, D D D D

-

1

I

I I

1

I

I

A A A B C D

A= Assembly 00590-01269-71 - Model 6HBW30

B= Assembly 00590-01273-71 - Models 6HBE30/6HBE40 C= Assembly 00590-01 277-71 - Models 6HBC30/6HBC40 D= Assembly 00590-01 283-71 - Model 6TB50

List 1-1 2. Finish instructions - 00590-01 269-71, 00590-01 273-71, 00590-01 277-71, 00590-01 283-71 - Model 6TB50.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

mymA

i

HANDLE NOT SHOWN FOR CLARITY

Figure 1-15. Coast Installation - 00590-00290-71 - Models 6HBE30, 6HBE40, 6HBW30.

1 /3 1 /97

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-15 ITEM NO. 1 2 3 4 5 6 7 8 9 10 (N/S)

QTY. 1 1 1 2 1 1 1 1 2 2 1

PART NUMBER 00590-00299-71 00590-00292-71 00590-00004-71 00590-00296-71 00590-00295-71 00590-00291 -71 00590-00298-71 00590-00294-71 00590-00 108-71 00590-00293-71 00590-00498-71

"I'UYmA

DESCRIPTION Coast Mount Weldment Hex Head Cap Screw 3/8-24 x 4.75 GR5 Flat Washer 3/8 Cup - Spring Spring Bumper Swivel Weldment Spirol Pin 3/8 x 2.50 Socket Head Cap Screw 3/8-24 x 1 GR8 Lockwasher 3/8 Coast Safety Decal

N/S = Not Shown

List 1-1 3. Coast Installation - 00590-00290-71 - Models 6HBE30, 6HBE40, 6HBW30

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

FOR COMPLETE ILLUSTRATION SEE FIGURES 4-1 AND 4-2 (BOTTOM LEFT SECTION OF ELECTRICAL SYSTEM ILLUSTRATION)

Figure 1-1 6. Keyswitch Installation - 00590-00530-71, 00590-00537-71 - All Models.

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-16 ITEM NO. 1 2 3 4 5 6

QTY. 1 1 1 1 1 1

QTY. 00590-00533-71 00590-00534-71 00590-00535-71 00590-00536-71 00590-00532-71 00590-00539-71

mYmA

DESCRIPTION Turtle Speed Module Assembly Round Head Machine Screw #8-32 x 1 -1/4 Flat Washer #8 Lockwasher #8 Keyswitch - 3 Position Keyswitch - 2 Position

ALL MODELS A= Assembly 00590-00530-71 - With Turtle Module B= Assembly 00590-00537-71 Without Turtle Module

-

List 1-1 4. Keyswitch Installation - 00590-00530-71, 00590-00537-71 - All Models

USED ON A A A, B A, B A

B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-1 7. Coupler Installation - 00590-00034-71, 00590-00053-71 - Model 6TB50.

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1 - 1 7 ITEM NO. 1

2 3 4 5 6 7 8 9

QTY. 1 1 1 1 1 1 1 1 1 1 2 4 4 4 1 4 1

PART NUMBER 00590-00040-71 00590-00041 -71 00590-00042-71 00590-00043-71 00590-00044-71 00590-00045-71 00590-00050-71 00590-00051 -71 00590-00055-71 00590-00035-71 00590-00052-71 00590-00036-71 00590-00037-71 00590-00038-71 00590-00054-71 00590-00039-71 00590-00060-71

mYmA

DESCRIPTION Coupler Assembly: includes Snap Ring Spiral Pin Spiral Pin Torsion Spring Coupler Weldment Pin Latch Weldment Coupling Sub Weldment Chain #2 - 24" S Hook Hex Head Cap Screw 3/4-16 x 2 Hex Nut 3/4-16 Flat Washer 3/4 Coupling - Eye & Pin Weldment Lockwasher 3/4 Eye Bolt (Blank With Shoulder)

Model 6TB50 A= Assembly 00590-00034-71 - Coupler B= Assembly 00590-00053-71 - Eye Coupler

List 1-15. Coupler Installation - 00590-00034-71, 00590-00053-71 - Model 6TB50.

USED ON A

A A

A, B A, B A, B B A, B B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-1 8. Load Backrest - 00590-00980-71,00590-00984-71

mymA

- Models 6HBW30/6HBE30.

1/31/97

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-18 ITEM NO. 2

4 5 6

QTY. 1 1 6 6 6

PART NUMBER 00590-00983-71 00590-00985-71 00590-00981 -71 00590-00396-7 1 00590-00982-71

mYaA

DESCRIPTION Backrest - 48" Backrest - 60" Flat Socket Head Screw 1/2-20 x 13/4 GR8 1 /2 Flat Washer Plated Hex Nut 1 /2-20

6HBW30/6HBE30 A= 00590-00980-71 - 4 8 High B= 00590-00980-71 - 6 0 High

List 1-1 6. Load Backrest - 00590-00980-71,00590-00984-71 - Models 6HBW30/6HBE30.

USED ON A B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

mymA

\

1

~

0

- A

VIEW A

1

FORK & PLATFORM WELD I

I

II -

J'

-

Figure 1-1 9. Load Backrest - 00590-00969-71, 00590-00970-71,00590-00976-7 - Model 6HBC30.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-19 ITEM NO. 1 2 3

5 6 7 8

QTY. 1 4 4 6 1 1 2 4 6 4 6

PART NUMBER 00590-00031 -71 00590-00029-71 00590-00004-7 1 00590-00004-71 00590-00971 -71 00590-00977-71 00590-0091 3-71 00590-00030-71 00590-00030-71 00590-00005-71 00590-00005-71

l'oYmA USED ON A A, B, C A B, c B C 8, c A B,c A B

DESCRIPTION Front Rest Weldment Hex Head Cap Screw 3/8- 16 x 1 - 1 /2 Flat Washer 3/8 Fiat Washer 3/8 Backrest Frame - 48" Backrest Frame - 60" Hex Head Cap Screw 3/8-16 x 1 Non Locking Hex Nut 3/8-16 Non Locking Hex Nut 3/8- 16 Lockwasher 3/8 Lockwasher 3/8

A= 00590-00969-71 - 38" High B= 00590-00970-71 48" High

-

C = 00590-00976-71 - 60" High List 1-1 7. Load Backrest - 00590-00969-71, 00590-00970-71,00590-00976-7

- Model 6HBC30

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

Figure 1-20. Load Backrest - 00590-00749-71,00590-00754-71

mymA

- Model 6HBE40/6HBC40.

1/31/97

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER FIGURE 1-20 ITEM NO. 1

3 4 5

QTY. 1

1 6 6 2

PART NUMBER 00590-00752-71 00590-00755-71 00590-00750-71 00590-00751 -71 00590-00753-71

ToYmA

DESCRIPTION Load Backrest - 48" Load Backrest - 60" Hex Head Cap Screw 1/2-13 x 3 Lock Nut 1/2-13 Backrest Mounting Angle

A= 00590-00749-71 - 48" High B= 00590-00754-71 - 60" High -

-

List 1-1 8. Load Backrest - 00590-00749-71,00590-00754-71

- Model 6HBE40/6HBC40

USED ON A

B A, B A, B A, B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 POWER

THIS PAGE INTENTIONALLY LEFT BLANK

mymA

M O D E L 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING

2-1 2-2 2-3 2 -4

mYmA

Handle Assembly - 00590-01 344-71,00590-01346-71,00590-0 1348-71,00590-0135 1-7 1 Models 6HBC30/6HBC40/6TB50 ...................................................................................

2-3 Handle Assembly - 00590-01 342-71,0590-01300-71,00590-01343-71,00509-01305-71 Models 6HBW30/6HBE30/6HBE40 ................................................................................

2-5 Handle Mounting and Installation - 00590-0021 4-71 2-7 Models 6HBW30/6HBE30/6HBE40/6HBC40/6TB50 Brake Assembly . 00590-00384-71 . All Models ............................................................. 2-9

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING

mymA

Figure 2-1. Handle PLssembly - 00590-01 344-71,00590-01346-71,00590-01348-71,00590-01351-71

Models 6HBC30/6HBC40/6TB50

2-2

M O D E L 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING FIGURE 2-1 ITEM NO. 1 2

3 4

5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33 34 35 36

QTY. 1 1 1 2 1 1 1 1

2 2 4 2 2 1 2 6 1 1 1 2 2 1 1 1 2 1 1 1 2 1 1 1 1 3 2 1 2

PART NUMBER 00590-001 60-71 00590-01 306-71 00590-00 167-7 1 00590-00106-71 00590-01 345-71 00590-01 347-71 00590-01 349-71 00590-01 352-71 00590-00100-7 1 00590-00113-71 00590-00107-71 00590-00 114-71 00590-001 70-71 00590-00154-71 00590-00 108-71 00590-00 105-7 1 00590-00 1 6 1 -71 00590-01 288-71 00590-00 1 7 1 -71 00590-00104- 71 00590-00112-71 00590-001 63-71 00590-00169-71 00590-00172-71 00590-001 1 1-71 00590-001 16-71 00590-00 1 55-7 1 00590-00159-71 00590-001 15-71 00590-00168-71 00590-001 12-71 00590-00102-71 00590-00 1 10-7 1 00590-01 421 -71 00590-00 1 09-7 1 00590-00162-71 00590-01 287-71

ToYmA

DESCRIPTION Handle Machining Control Arm Wiring Harness - Cold Storage Control Arm Wiring Harness -Standard Socket Head Cap Screw 1/4-20 x 1 Transistor Controller Assembly (See Figure 4-3) Transistor Controller Assembly (See Figure 4-3) Transistor Controller Assembly (See Figure 4-3) Transistor Controller Assembly (See Figure 4-3) Hand Grip Lock Washer 5/16 Socket Head Machine Screw 5/16-18 x 1-1 /4 Spirol Pin 1 /8 x 1-1 /4 Plug Knuckle Guard Machining Socket Head Screw 3/8-24 x 1 Button Socket Head Screw 1/4-20 x 1/2 Cover Channel Lever Weldment Brake Cable Hex Head Cap Screw 5/16-18 x 5/8 Flat Washer 5/16 Link Lever Weldment Clevis Pin Parking Lever Flat Washer #10 Brake Actuator Plate Lever Weldment Brake Handle Channel Cotter Pin 3/32 x 1/2 Clevis Pin Flat Washer 1/4 Round Head Machine Screw 1/4-20 x 3/4 Locking Nut 1/4-20 Butterfly Knob Socket Head Machine Screw 1/2-13 x 1 -1/4 Brake Block Hand Grip

A= Assembly 00590-01344-71 - 6HBC30/6HBC40 - Standard B= Assembly 00590-01346-71 - 6TB50 - Standard C= Assembly 00590-01 348-71 - 6HBC30/6HBC40 - Cold Storage D= Assembly 00590-01351 -71 - 6TB50 - Cold Storage

List 2-1. Handle Assembly - 00590-01 344-71,00590-01346-71,00590-01348-71,00590-01351-71 Models 6HBC30/6HBC40/6TBSO

USED ON

A B C D

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING

-

-

mymA

-

ITEM 14 REMOVED FOR CLARITY

Figure 2-2. Handle Assembly - 00590-01 342-71,0590-01300-71,00590-01343-71,00509-01305-71 Models 6HBW30/6HBE30/6HBE40

2-4

M O D E L 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE A N D STEERING

USED

FIGURE 2-2 ITEM NO. 1 2 3

4 5 6 7 8 9 10 14 N/S 20

'TOYmA

I

1

PART NUMBER QTY. 1 00590-00199-71 2 00590-001 06-71 00590-01303-71 1 1 00590-01 307-71 2 00590-001 00-71 1 00590-00167-71 00590-01306-71 1 4 00590-00107-71 2 00590-001 14-71 00590-001 70-71 2 1 00590-001 98-71 2 00590-00191-71 2 00590-0142 1-71 2 I 00590-00205-71 2 100590-01423-71

ON

DESCRIPTION Handle Machining Flat Head Cap Screw 1/4-20 x 1 Transistor Controller Assembly (See Figure 4-3) Transistor Controller Assembly (See Figure 4-3) Hand Grip Control Arm Harness Control Arm Harness Socket Head Machine Screw 5/16- 1 8 x 1 - 1/4 Spirol Pin 1/8 x 1 -3/4 Plug Knuckle Guard Machine Flanged Head Machine Screw 3/8-24 x 1 Butterfly Knob Roll Pin 1/8 x 1 1 /4

1 Grip Extension

A, B C, D A, B C, D

I B,D

A= 00590-01 342-71 - 6HBW30 Standard

B= 00590-01 300-71 - 6HBE30/6HBE40 Standard C= 00590-01343-71 - 6HBW30 - Cold Storage D= 00590-01305-71 - 6HBE30/6HBE40 - Cold Storage N/S = Not Shown

List 2-2. Handle Assembly -00590-01 342-71,0590-01300-7 1,00590-01 343-71 ,00509-01 305-7 1

Models 6HBW30/6HBE30/6HBE40

mymA

M O D E L 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE A N D STEERING

1

L-)Ai

TOP O F DRIVE MOTOR I

MICROSWITCH REMOVED FO R CLARITY

I

SECTION A-A

Figure 2-3.Handle Mounting and Installation - 00590-00214-71 Models 6HBW30/6HBE30/6HBE40/6HBC40/6TB50

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING FIGURE 2-3 ITEM NO. 1

2 3 4 5 6 7 8 9 12 13 14 15 16 17 19 20 21 22 23 24 26 27 28 29

QTY. 1 1 1 1 1

3 2 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 2 1 2 1 2

PART NUMBER 00590-01 344-71 00590-01 346-71 00590-01 348-71 00590-01 351 -71 00590-01 342-71 00590-0 1 300-71 00590-01 343-71 00590-01 305-71 00590-00 109-7 1 00590-00234-7 1 00590-00231 -71 00590-00227-71 00590-00239-71 00590-00229-71 00590-00235-71 00590-00238-71 00590-00241 -71 00590-00230-71 00590-00223-71 00590-002 15-7 1 00590-0021 9-71 00590-00222-71 00590-00224-71 00590-00216-71 00590-00233-71 00590-0022 1-7 1 00590-00030-71 00590-00225-71 00590-00237-71 00590-002 18-71 00590-00220-71 00590-00240-71

DESCRIPTION Handle Assembly (See Figure 2- 1 ) Handle Assembly (See Figure 2-1) Handle Assembly (See Figure 2-1) Handle Assembly (See Figure 2-1) Handle Assembly (See Figure 2-2) Handle Assembly (See Figure 2-2) Handle Assembly (See Figure 2-2) Handle Assembly (See Figure 2-2) Socket Head Machine Screw 1/2- 13 x 1-1 /4 Bushing Machine Shaft Handle Pivot Roll Pin 1/8x 1-1/2 Handle Mounting Bracket Handle Return Spring Brake Lever, Machine Brake Lever Shaft Brake Ball Joint Brake Adjusting Rod Nut 5/16-24 Bumper Pad Socket Head Cap Screw 5/16-28 x 3/4 Cam Follower Lock Washer 5/16 Bushing Spring Spacer Socket Head Set Screw 3/8- 1 6 x 2- 1/2 Nut 3/8- 1 6 Roll Pin 1/8 x 1 Spring Guard Flat Hex Socket Cap Screw 1/4-20 x 1/2 Socket Head Cap Screw 10-24x1/2 Cup Point Disk Stop

'ToYmA USED ON A B C D E F G H

A= 6HBC30/6HBC40 - Standard

B= 6TB50 - Standard C= 6HBC30/6HBC40 - Cold Storage D= 6TB50 - Cold Storage E= 6HBW30 Standard F= 6HBE30/6HBE40 - Standard G= 6HBW30 - Cold Storage H= 6HBE30/6HBE40 - Cold Storage

-

List 2-3. Handle Mounting and Installation - 00590-002 14-71 Model 6HBW30/6HBE30/6HBE40/6HBC40/6TB50

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE AND STEERING

Figure 2-4. Brake Assembly - 00590-00384-71 - All Models

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 BRAKE A N D STEERING FIGURE 2-4 ITEM NO. 1 2 3 4 5

6

QlY. 1 1 1 1 2 2

PART NUMBER 00590-04523-71 00590-0451 8-71 00590-04522-71 00590-0451 9-71 00590-04520-71 00590-04521 -71

DESCRIPTION Backing Plate Cam Brake Lever

Clip Brake Shoe Return Spring

List 2-4. Brake Assembly - 00590-00384-71 - All Models

mYmA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBCJ0/6HBC40/6TB50 BRAKE AND STEERING

THIS PAGE INTENTIONALLY LEFT BLANK

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

-

mYmA

Drive Unit Final Assembly 00590-01309-71,00590-0 1583-71,00590-01312-71, 00590-0 1584-7 1 - Models 6HBW30/6HBE30/6HBE40 ...................................................3-3 Drive Unit Final Assembly 00590-01 354-71, 00590-01355-71 Models 6HBC30/6HBC40/6TB50 .................................................................................. .3-5 Transmission Assembly - 00590-00410-71 - Model 6HBW30 ......................................... 3-7 Transmission Assembly - 00590-00455-71 - All Other Models ........................................ 3-9 Drive Unit Sub-Assembly - 00590-00394-71, 00590-00452-71 - All Models ................... 3-1 1 Motor Sub-Assembly - 00590-00453-71, 00590-00399-71 - All Models ..........................3-1 3 Traction Motor - 00590-04576-71 - Model 6HBW30 ...................................................... 3- 15 Traction Motor - 00590-04573-71 - Models 6HBE30/6HBE40/6HBC30/6HBC40/6TB50 .3-17

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

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TRACTOR PLATFORM

T

TOP VIEW BRAKE DRUM REMOVED FOR CLARITY

SECTION A-A

Figure 3-1. Drive Unit Final Assembly - 00590-01 308-71,00590-01583-71,00590-01312-71,00590-01584-71 Models 6HBW30/6HBE30/6HBE40

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-1 ITEM NO. 1

QTY. PART NUMBER 1 00590-00394-71 1 00590-00452-71 1 00590-00450-71 2 4 00590-00385-71 3 4 4 00590-00005-71 1 00590-00443-71 5 1 00590-00445-71 6 7 1 00590-00448-71 1 00590-00383-71 8 1 00590-00446-71 9 1 00590-00444-71 10 00590-00447-71 1 11 1 12 00590-00388-71 1 00590-01 313-71 13 1 00590-00439-71 14 1 00590-00441 -71 1 00590-0039 1 -71 15 1 00590-00387-71 16 17 00590-00267-71 5 5 00590-00224-71 18 1 00590-00384-71 19 1 21 00590-01 539-71 00590-00386-71 6 22 I A=6HBE30/6HBE40 - Standard B= 6HBW30 - Standard C= 6HBE30/6HBE40 - Cold Storage D= 6HBW30 - Cold Storage I

DESCRIPTION Drive Unit Sub-Assembly (See Figure 3-5 ) Drive Unit Sub-Assembly (See Figure 3-5 ) Motor Adapter Hex Head Cap Screw 3/8-16 x 7/8 Lockwasher 3/8 Set Screw 1/4-20 x 5/16 Brake Adiustinn Screw Pad Microswitch (Brake) Clevis Pin Cotter Pin 3/32 x 3/4 Spring Internal Tooth Lockwasher 1/2 Boot Switch Brake Drum Brake Drum Woodruff Key #607 Flexable Locknut 3/4-16 Hex Head Cap Screw 5/16- 18 x 7/8 Lockwasher 5/16 Brake Assembly (See Figure 2-4 ) Clevis Cast D 1/2-13 x 1-1 /4 Socket Head C ~ Screw I

ToYmA USED ON A,C B, D

C, D A, B C, D

I

List 3-1. Drive Unit Final Assembly - 00590-01 309-71,00590-01583-71, 00590-0131 2-71,00590-01584-71 Models 6HBW30/6HBE30/6HBE40

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

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A TRACTOR, PLATFORM

BRAKE DRUM REMOVED FOR CLARIM

n

"b

SECTION A-A

Figure 3-2. Drive Unit Final Assembly - 00590-01 354-71, 00590-01 355-71 - Models 6HBC30/6HBC40/6TB50

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-2 ITEM NO. QTY. PART NUMBER 1 1 00590-00394-71 2 1 00590-00392-71 3 2 00590-00385-71 4 2 00590-00005-71 5 1 00590-00383-71 6 1 00590-00169-7 1 I I 7 I 1 100590-00389-71 8 00590-00388-71 1 9 1 00590-01313-71 10 00590-00439-71 1 00590-00441 -71 1 11 00590-00391-71 1 1 12 00590-00387-71 13 5 00590-00267-71 14 00590-00224-71 5 1 15 00590-00384-71 17 00590-00386-71 6 18 1 00590-00393-71 19 1 00590-00390-71 A= 00590-01354-71- Standard B= 00590-01355-71- Cold Storage

DESCRIPTION Drive Unit Sub-Assembly (See Figure 3-5 ) Motor Adapter Hex Head Cap Screw 3/8-16 x 7/8 Lockwasher 3/8 Microswitch (Brake) Clevis Pin 4 I Cotter Pin 1 /16 x 3/4 Internal Tooth Lockwasher 1/2 Switch Boot Brake Drum Brake Drum Woodruff Key #607 Flexable Locknut 3/4- 16 Hex Head Cap Screw 5/16-18 x 7/8 Lockwasher 5/16 Brake Assembly (See Figure 2-4 ) Socket Head Cap Screw 1 /2-13 x 1 -1/4 Switch Actuator Return Spring

List 3-2. Drive Unit Final Assembly -00590-01 354-71, 00590-01 355-71 Models 6HBC30/6HBC40/6TB50

ToYmA USED ON

B A B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

Figure 3-3. Transmission Assembly - 00590-0041 0-71 - Model 6HBW30

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-3 ITEM NO. 1 1a 2

20 2b 3 4 6 7 8 9 90 9b 9c 9d 10 11 12 13 14 15 16 17 18 19 20 21 22 24 26 27 28 29 30 32

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 26 26 2 2 1 1 AR AR AR AR AR AR AR AR 1 1 6 1 1 6 1 2

PART NUMBER DESCRIPTION Helical Gear and Pinion Set 00590-00436-71 Helical Pinion Gear 00590-04531 -71 Spiral Gear and Pinion Set: Includes 00590-00435-71 NOT SOLD SEPARATELY Spiral Pinion NOT SOLD SEPARATELY Spiral Gear Main Case Machining 00590-00425-71 Cover Plate 00590-00424-71 High Pressure Hex Plug 1/8 NPTF 00590-0041 9-71 Snap Ring 00590-0042 1 -71 Drive Wheel Shaft 00590-0041 1-71 00590-00426-71 Steering Bearing Assembly: Includes NOT SOLD SEPARATELY Outer Bearing Race NOT SOLD SEPARATELY Inner Bearing Race NOT SOLD SEPARATELY 3/4 Dia. Ball Bearing NOT SOLD SEPARATELY 11/16 Dia. Ball Bearing Pipe Plug 1/2 NPTF 00590-00420-71 Bearing 00590-0041 2-71 Bearing 00590-0041 4-71 Bearing 00590-0041 3-71 Shim - 3.5 O D 00590-00427-71 Shim - 3.5 O D 00590-00428-71 Shim - 3.5 O D 00590-00429-71 Shim 3.5 O D 00590-00430-71 Shim 2.0 OD 00590-00431 -71 Shim 2.0 OD 00590-00432-71 Shim - 2.0 O D 00590-00433-71 Shim - 2.0 O D 00590-00434-71 Lock Nut 3/4-16 00590-00387-71 Lock Nut 1 3/8-18 00590-0041 7-71 Lockwasher 5/16 00590-00224-71 Oil Seal 00590-00415-71 Vent Plug 00590-0041 8-71 Hex Head Cap Screw 5/16-18 x 3/4 00590-0041 6-71 Spiral Pin 3/16 x 5/8 00590-00422-71 Grease Fitting 00590-00423-71

List 3-3. Transmission Assembly - 00590-0041 0-71 - Model 6HBW30

ToYmA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

Figure 3-4. Transmission Assembly - 00590-00455-71 - All Other Models

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-4 ITEM NO.

1 1a 2 20 2b

3 4 6 7 8 9 90

9b 9c 9d 10 11 12 13 14 15 16 17 18 19 20 21 22 24 26 27 28 29 30 32

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 26 26 2 2 1 1 AR AR AR AR AR AR AR AR

1 1 6 1 1 6 1 2

PART NUMBER

DESCRIPTION Helical Gear and Pinion Set 00590-00436-71 Helical Pinion Gear 00590-04531 -71 Spiral Gear and Pinion Set: Includes 00590-00435-71 NOT SOLD SEPARATELY Spiral Pinion NOT SOLD SEPARATELY Spiral Gear Main Case Machining 00590-00425-71 Cover Plate 00590-00424-71 High Pressure Hex Plug 1 /8 NPTF 00590-0041 9-71 00590-01 31 1-71 Snap Ring Drive Wheel Shaft 00590-0041 1-71 00590-00426-71 Steering Bearing Assembly: Includes NOT SOLD SEPARATELY Outer Bearing Race NOT SOLD SEPARATELY Inner Bearing Race NOT SOLD SEPARATELY 3/4 Dia. Ball Bearing NOT SOLD SEPARATELY 1 1/16 Dia. Ball Bearing Pipe Plug 1/2 NPTF 00590-00420-7 1 Bearing 00590-0041 2-71 Bearing 00590-004 1 4-7 1 Bearing 00590-0041 3-71 Shim - 3.5 OD 00590-00427-71 00590-00428-71 Shim - 3.5 OD 00590-00429-71 Shim - 3.5 OD Shim - 3.5 OD 00590-00430-71 Shim - 2.0 OD 00590-00431 -71 Shim - 2.0 O D 00590-00432-71 00590-00433-71 Shim - 2.0 OD Shim - 2.0 OD 00590-00434-71 Lock Nut 3/4-16 00590-00387-71 00590-0041 7-71 Lock Nut 1 3/8-18 00590-00224-71 Lockwasher 5/16 Oil Seal 00590-0041 5-71 Vent Plug 00590-0041 8-71 00590-0041 6-71 Hex Head Cap Screw 5/16-18 x 3/4 00590-00422-71 Spiral Pin 3/16 x 5/8 00590-00423-71 Grease Fitting List 3-4. Transmission Assembly - 0 0 5 9 0 - 0 0 4 5 5 -7 1 - All Other Models

ToYmA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

Figure 3-5.Drive Unit Sub-Assembly - 00590-00394-71, 00590-00452-71 - All Models

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TOYmA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-5 ITEM NO. 1 2

PART NUMBER QTY. 00590-00453-71 1 1 00590-00399-71 00590-0041 0-71 1 00590-00455-71 1 I 1 100590-00085-71 00590-00086-7 1 1 00590-00087-71 1 00590-00088-71 1 00590-00084-71 1 7 00590-00395-71 , 13 00590-00246-71 00590-00398-71 6 00590-00397-71 6 00590-00396-71 6 00590-00437-71 1 I I I

3 3A 3 3A 38 .

4 5 6 7 8 9 -

I

-

-

-

~

~~-

DESCRIPTION Motor Sub-Assembly (Model 6HBW30) (See Figure 3-6 ) Motor Sub-Assemblv (All Other Models), .(See Fiaure 3-6 ) Transmission Assembly (Model 6HBW30) (See Figure 3-3 ) Transmission Assembly. (All Figure 3-4 ) . Other Models). (See .

I Drive Wheel Assemblv includes Poly Tire (Hard/Black) Drive Wheel Assembly includes Rubber Tire (Black) Wheel Hub Hex Head Cap Screw 1/2-13 x 1 -1/2 GR5 Lockwasher 1 /2 Conical Washer 1 /2 Hub Bolt Flat Washer 1/2 PLTD. Retainer Strap I -

5

-

1

A= Assembly 00590-00394-71 - 6HBW30 B= Assembly 00590-00452-71 - 6HBE30/6HBE40/6HBC30/6HBC40/6TB50

List 3-5. Drive Unit Sub-Assembly - 00590-00394-71, 00590-00452-71 - All Models

USED ON A B A B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

mymA

PINION GEAR USE P/N 00590-04529-71 FOR MODEL 6HBW30. (See Figure 3-3) USE P/N 00590-04531 -71 FOR MODELS 6HBE30/6HBE40/6HBC30 /6HBC40/6TB50 (See Figure 3-4)

Figure 3-6. Motor Sub-Assembly - 00590-00453-71,00590-00399-71

- All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-6 ITEM NO. 1

2 3 4 5 6 7 9 10 11

1

PART NUMBER 00590-04573-71

1 1 1 1 1 1 1 6 2 4

00590-04576-71 00590-00408-71 100590-00387-71 00590-00407-71 00590-00405-71 100590-00409-71 100590-00400-71 00590-00404-71 00590-00403-71 100590-00406-71

QW.

I

I I

I

1 4

1

I

I

I

mYmA

DESCRIPTION Motor (6HBE30/6HBE40/6HBC30/6HBC40/6TB50) (See Fiaure 3-8 ) " Motor (6HBW30) (See Figure 3-7 ) Woodruff Key Locknut 3/4:16 ESNA PLTD Snap Ring Bearing Top Cover 1 Oil Seal Hex Head Cap Screw 1/4-20 x 2-5/8 - Self Tapping Hex Head Cap Screw 1/4-20 x 3 - Self Tapping . i ~ o r h e 1/4 r Sealing

/

1

-

A= Assembly 00590-00394-71 6HBW30 B= Assembly 00590-00452-71 - 6HBE30/6HBE40/6HBC30/6HBC40/6TB50

List 3-6. Motor Sub-Assembly - 00590-00453-71,00590-00399-71

- All Models

USED ON B A

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

Figure 3-7. Traction Motor - 00590-04576-71 - Model 6HBW30

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-7 ITEM NO.

1 2 3 N/S 5 6 7 8 9 10 11 12

/

I

I

QTY. PART NUMBER DESCRIPTION 1 Fan I 1 100590-04715-71 I 1 100590-04716-71 IArmature & Fan Assemblv 1 NOT SOLD SEPARATELY Frame 1 NOT SOLD SEPARATELY Poles 1 Field Coil Kit 00590-0471 8-71 00590-04567-71 Brush 4 Brush Spring 4 00590-04574-71 Brush Plate & Box Assembly 00590-04721 -71 1 Bearing 2 00590-04566-71 Spring Washer 00590-04568-71 1 1 NOT SOLD SEPARATELY Commutator Endhead Terminal & Lead Assembly (Not Illustrated) 1 00590-04720-71

N/S = Not Shown

List 3-7. Traction Motor - 00590-04576-71 - Model 6HBW30

TOYmA

I

USED

ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

mymA

Figure 3-8.Traction Motor - 00590-04573-71 - Models 6HBE30/6HBE40/6HBC30/6HBC40/6TB50

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT FIGURE 3-8 ITEM NO. QTY. 1 1 1 2 1 3 4 1 1 5 1 6 1 7 1 8 2 9 1 10 1 11 1 12 N/S= Not Shown

mYmA

DESCRIPTION PART NUMBER 00590-04799-7 1 Fan 00590-0471 5-71 Armature NOT SOLD SEPARATELY Housing NOT SOLD SEPARATELY Pole Shoes Terminal And Lead Assembly 00590-04720-71 00590-04567-71 Brush Set (4 per set) Brush Spring Set (4 per set) 00590-04574-7 1 Brush Plate & Box Assembly 00590-04721 -71 00590-05466- 71 Bearing 00590-04568-7 1 Spring Washer NOT SOLD SEPARATELY Commutator Endheod 00590-04800-71 Field Coil Kit

List 3-8. Traction Motor - 00590- 04573-71 --Models 6HBE30/6HBE40/6HBC30/6HBC40/6TB50

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 DRIVE UNIT

THIS PAGE INTENTIONALLY LEFT BLANK

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 E LECTRlCAL

TOYmA

System Electrical - 00590-01585-71, 00590-01588-71 - Sheet 1 of 4 Model 6HBW30 (Used Up to 6/24/96) ...........................................................................4-6 System Electrical - 00590-01589-71,00590-01596-71- Sheet 4 of 4 4 11 Model 6TB50 (Used After 6/24/96) ...............................................................................

Transistor Controller Assembly - 00590-01303-71, 00590-01345-71,00590-01347-71, 00590-01 307, 00590-01349-71, 00590-01 352-71 - All Models .................................... 4-15 Controller Diagram Reference -00590-01 605-71, 00590-01 606-71, 00590-0 1 607-71 ... 4-17 Rail Switch Assembly . 00590-01 292-71, 00590-01 297-71 - Models 6HBE30/6HBE40 ....4-19 Foot Switch Installation - 00590-01 370-71, 00590-01374-71,00590-01383-71, 00590-0 1 388-71 Models 6HBC30/6HBC40/6TB50 ..................................................4..2 1 Foot Switch lnstallation - 00590-01 599-71, 00590-01 602-71 Models 6HBC30/6HBC40/6TB50 ................................................................................... 4-23 Hour Meter/Discharge Indicator lnstallation - 00590-0051 4-71,00590-00517-71, 00590-00519-71,00590-00520-71,00590-00526-71 , 00590-00527-71, 00590-00529-71 All Models 4-25 4-26 Contactor Assembly - 00590-00545-71, All Models ........................................................

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

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-

VIEW B B

NOTE: FOR OPTIONAL TRUCK MODULE AND KEYSWITCH INFORMATION SEE FIG 1-1 3

Figure 4- 1. System Electrical - 00590-01 585-71,00590-01588-71 Sheet 1 of 4 - Model 6HBW30 (Used Up to 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

TOYCTTA

KNSWITCH

-

VlEW A A

VlEW B - B

Figure 4-1. System Electrical - 00590-01 585-71,00590-01588-71 - Sheet 2 of 4 - Model 6HBE30/6HBE40 (Used Up to 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mymA

VlEW A - A

VlEW B

-B

NOTE: FOR OPTIONAL TRUCK MODULE AND KEYSWITCH INFORMATION SEE FIG 1-1 3

Figure 4-1. System Electrical - 00590-01 585-71, 00590-01588-71 - Sheet 3 of 4 - Model 6HBC30/6HBC40 (Used Up to 6/24/96)

4-4

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mYmA

VlEW A - A

VlEW B

-B

NOTE: FOR OPTIONAL TRUCK MODULE AND KEYSWITCH INFORMATION SEE FIG 1-13

Figure 4-1. System Electrical - 00590-01585-71,00590-01588-71 - Sheet 4 of 4 - Model 6TB5O (Used Up to 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-1 ITEM NO. 1 2 3 4 6 7 8 9 10 11 12 13 14 15 .(N/S).

17 18 19 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 38 39 40 41 43 46

1

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NUMBER 00590-00541 -71 00590-00545-71 00590-00598-71 00590-01 379-71 00590-01 379-71 00590-00590-71 00590-01 377-71 00590-00552-71 00590-00553-71 00590-00554-71 00590-01 360-71 00590-00548-71 00590-01 587-71 00590-00584-71 00590-01 429-71 00590-00574-71 00590-01370-71

1

00590-01374-71

1

00590-01 383-71

1

00590-01 388-71

AR AR AR 1 1 4 4 AR AR 8 9 AR 2 8 2 2 2 3 4 3 4 9 1 1 2

00590-00534-71 00590-00556-71 00590-00557-71 00590-00570-71 00590-00571-71 00590-00224-71 00590-00558-71 00590-00559-71 00590-00567-71 00590-00542-71 00590-00 113-71 00590-00596-71 00590-00560-71 00590-00462-71 00590-00551 -71 00590-00569-71 00590-00564-71 00590-00562-71 00590-00566-71 00590-00561 -71 00590-00565-71 00590-00568-71 00590-00595-71 00590-00383-71 100590-00572-71

mymA

DESCRIPTION Emergency Reverse Module Assembly Contactor - Triple Set (Model 6HBW30) Contador - Triple Set (All Other Models) Control Modular Bracket (All Models Except 6HBW30) Control Modular Bracket (Model 6HBW30 Only) Main Wiring Harness (Standard) Main Wiring Harness (Cold Storage) Fuse - 15 Amp Fuse - 150 Amp Fuse - 250 Amp Horn Module Motor Controller Control Module High Power Cable Assembly Horn - 24V Battery Connector Assembly - 24V Tran.

Foot Switch lnstallation (Standard) (Models 6HBC30 & 6HBC40) , .

(See Figure 4-5) Foot Switch Installation (Standard) (Model 6TB50) (See Figure 4-6) Foot Switch Installation (Cold Storage) (Models 6HBC30 & 6HBC40) (See Figure 4-6) Foot Switch Installation (Cold Storage) (Model 6TB50) (See Figure 4-5) Round Head Machine Screw #8-32 x 1-114 Self Locking - T.Y-Rap .

Plastic Mounting Anchor Flexible Latch 2.00" Flexible Latch 2.00" Lockwasher 5/16 Round Head Machine Screw #8-32 x 318 Round Head Machine Screw #8-43 x 7/8 Flat Washer #8 Hex Head Cap Screw 1/4-20 x 1/2 Lockwasher 1/4 Machine Screw 32x3/4 Machine Screw 1/4-20 x 1- 1 /8 Hex Nut 1/4-20 Soacer Assemblv Shakeproof External Washer 1/4 Cup Point Socket Head Set Screw 1/4-20 x 1 - 1/4 Screw 1/4-20 x 5/8 Flat Washer #12 Hex Head Cap Screw 5/16-18 x 5/8 Hex Jam Nut 5/16-18 Flat Washer 1/4 Variable Resistor Shunt (All Models Except 6HBW30) Lift Brake Switch - Standard (Hose Clamp

-

A= Assembly 00590-01585-71 Standard B= Assembly 00590-01588-71 - Cold Storage -

List 4-1. System Electrical - 00590-01585-71,00590-01588-71 - All Models Up To 6/24/96

USED ON

A B

A A B B

I

A

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-1 -CM NO. 47 48 49 51 52 53 54

QTY. 6 3 1 1 1 1 1

PART NUMBER 00590-00281 -71 00590-00 1 1 2-7 1 00590-01 359-71 00590-00592-71 00590-00544-71 00590-0041 6-71 00590-00543-71

DESCRIPTION Hex Head Cap Screw 1/4-28 x 1/2 Washer 1/4 Flat Spacer (Models 6HBW30/6HBE30/6HBE40/6HBC30) Suppressor Assembly Wire Snubber Assembly (Not Used on 6TB50) Hex Head Cap Screw 5/16-18 x 3/4 (Not Used on 6TB50) Switch Bracket (Not Used on 6TB50)

A= Assembly 00590-01585-71 - Standard B= Assembly 00590-01588-71 - Cold Storage

List 4-1. System Electrical - 00590-01585-71, 00590-01 588-71 - All Models Up To 6/24/96

ToYmA USED ON

ELECTRICAL

-

V

VlEW A A

VlEW B

-B

Figure 4-2. System Electrical - 00590-01 589-71,00590-01596-71- Sheet 1 of 4 - Model 6HBW30 (Used After 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mYmA

KEYSWITCH

-

U

VlEW A A

VlEW B - B

Figure 4-2. System Electrical - 00590-01 589-71,00590-01596-71- Sheet 2 of 4 - Model 6HBE30/6HBE40 (Used After 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

-

mymA

V

VlEW A A

-

VlEW B B

NOTE: FOR OPTIONAL TRUCK MODULE AND K:EYSWITCH INFORMATION SEE FIG 1-1 3

Figure 4-2. System Eledriclrl - 00590-01589-71,00590-01596-71- Sheet 3 of 4 - Model 6HBC30/6HBC40 (Used After 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

ToYmA

VIEW B - B

Figure 4-2. System Electrical - 00590-01 589-71,00590-01596-71- Sheet 4 of 4 - Model 6TB50 (Used After 6/24/96)

mymA

MODEL ~ H B W ~ O / ~ H B E ~ O / ~ H B E ~ O / ~ H B C ~ O / ~ H B C ~ ~ / ~ T B ~ O ELECTRICAL FIGURE4-2 ITEM NO. 1 2 3 4 6 7 8 9 10 11 12 13 14 15 (N/S)

17 18 19 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 38 39 40 41 43 46 47 48 49 51

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NUMBER 00590-00541 -71 00590-00545-71 00590-00598-71 00590-01379-71 00590-01 379-71 00590-01 595-71 00590-01 597-71 00590-00552-71 00590-00553-71 00590-00554- 71 00590-01 360-71 00590-01 587-71 00590-00550-71 00590-00584-71 00590-01 361 -71 00590-00574-71 00590-0 1 599-7 1

1

00590-01 602-71

AR AR AR 1 1 4 4 AR AR 8 9 2 2 8 2 2 2 3 4 3 4 9 1 1 2 6 3 1 1

00590-00534-71 00590-00556-71 00590-00557-71 00590-00570-71 00590-00571 -71 00590-00224-71 00590-00558-71 00590-00559-71 00590-00567-71 00590-00542-71 00590-001 13-71 00590-00596-71 00590-00560-71 00590-00462-71 00590-0055 1 -71 00590-00569-71 00590-00564-71 00590-00562-71 00590-00566-71 00590-00561 -71 00590-00565-71 00590-00568-71 00590-00595-71 00590-00383-71 00590-00572-71 00590-00281 -71 00590-001 12-71 00590-01 359-71 00590-00416-71

DESCRIPTION Emergency Reverse Module Assembly Contactor - Triple Set (Model 6HBW30 Only) Contactor - Triple Set (All Other Models) Control Module Bracket (All Models Except 6HBW30) Control Module Bracket (Model 6HBW30 Only) Main Wiring Harness (Standard) Main Wiring Harness (Cold Storage) Fuse - 15 Amp Fuse - 150 Amp Fuse - 250 Amp Horn Module Motor Controller Control Module High Power Cable Assembly Horn 24V Battery Connector Assembly - 24V Tran.

Foot Switch Installation (Standard) (Models 6HBC30/6HBC40/6TB50) (See Figure 4-7) Foot Switch Installation (Cold Storage) (Models 6HBC30/6HBC40/6TB50) (See Figure 4-7) Round Head Machine Screw #8-32 x 1 -1/4 Self Locking Ty-Rap Self Adhesive Ty-Mount Flexible Latch - 2.00" Flexible Latch - 2.00" Lockwasher 5/16 Truss Head Machine Screw #8-32 x 3/8 -.

Round Head Machine Screw #8-43 x 7/8 Flat Washer #8 Hex Head Cap Screw 1/4-20 x 1/2 Lockwasher 1 /4 Machine Screw #32 x 3/4 Machine Screw 1/4-20 x 1 - 1 /8 Hex Nut 1/4-20 Spacer Assembly Shakeproof External Washer 1/4 Cup Point Socket Head Set Screw 1 /4-20 x 1 -1/4 Screw 1/4-20 x 5/8 Flat Washer #12 Hex Head Cap Screw 5/16-18 x 5/8 Hex Jam Nut 5/16-18 Flat Washer 1/4 Variable Resistor Shunt (All Models Except 6HBW30) Lift Brake Switch - Standard Hose Clamp Hex Head Cap Screw 1/4-28 x 1/2 Washer 1/4 Flat Spacer (Models 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40) Hex Head Cap Screw 5/16- 18 x 5/8 (Model 6TB50 Only) -

~

USED ON

A

B

A B

-

-

A= Assembly 00590-01589-71 Standard B= Assembly 00590-01596-71 Cold Storage

List 4-2. System Electrical - 00590-01589-71, 00590-01 596-71 - All Models (Used After 6/24/96)

A

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE4-2 ITEM NO. QTY. 1 52 1 53 1 54

PART NUMBER 00590-00544-71 00590-004 16-7 1 00590-00543-71

ToYmA

DESCRIPTION Wire Snubber Assembly (Not Used on Model 6TB50) Hex Head Cop Screw 5/16-18 x 3/4 (Not Used on Model 6TB50) Switch Bracket (Not Used on Model 6TB50)

A= Assembly 00590-01589-71 - Standard B= Assembly 00590-01596-71 - Cold Storage

List 4-2. System Electrical - 00590-01589-71,00590-01596-71 - All Models (Used After 6/24/96)

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

SECTION X - X

//I 1

+

mymA

DETAIL C

SECTION Y - Y

-

SECTION Z Z

L3

Figure 4-3. Transistor Controller Assembly - 00590-01303-71,00590-01345-71, 00590-01347-71, 00590-01307,00590-01 349-71,00590-01352-71 - All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-3 ITEM NO. 1 2

QTY. 1 1 1

1 1

3 4 5 6 7 8 9 11 12 13 14 15 16 18 20 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 47 52 53 54 55

PART NUMBER 00590-001 48-71 00590-01 353-71 00590-001 97-71 00590-00 151 -71 00590-01 308-71

1 00590-01 350-71 00590-001 47-71 1 1 00590-001 22-71 2 00590-00 130-7 1 00590-001 34-71 3 1 00590-0451 3-71 1 00590-00 140-71 00590-001 37-71 1 1 00590-001 23-71 00590-001 49-71 2 1 00590-001 43-71 See Table 00590-00132-71 See Table 00590-001 33-71 See Table 00590-00 131 -71 1 00590-00 144-71 7 00590-001 29-71 1 00590-00141-71 See Table 00590-001 50-71 1 00590-001 42-71 2 00590-00135-71 1 00590-045 15-71 00590-001 79-71 2 00590-00195-71 2 00590-001 45-71 1 2 00590-001 93-71 00590-00180- 71 2 2 00590-00136-71 1 00590-001 46-71 See Table 00590-001 21 -71 See Table 00590-00 138-7 1 1 00590-00202-71 1 00590-00181 -71 2 00590-00139-71 1 00590-00196-71 00590-01 422-71 1 00590-01411-71 1 1 00590-01 41 2-71 1 00590-01 41 3-71

'ToYmA

DESCRIPTION Steering Cover, Machining Controller Harness Model 6TB50 Controller Harness (Model 6HBW30/6HBE30/ 6HBE40) Controller Harness (Models 6HBC30/6HBC40) Controller Harness (Models 6HBW30/6HBE30/ 6HBE40) Controller Harness ( Models 6HBC30/6HBC40) Controller Harness (Model 6TB50) Potentiometer Gear Socket Head Set Screw #8-32 x 3/16 Lockwasher Variable Resistor Torsion Spring Spirol Pin Return Lever Flanged Sleeve Bearing Flat Washer Flat Washer #4 Spring Washer #4 Nut #4-40 Bracket Pan Head Machine Screw #6-32 x 1/2 Switch Cover Switch Bracket Assembly Bracket Spring Pin Push Button Control Switch 0-32 x 34 Socket Head Cap Screw #I Round Head Screw #4-40 x l 1/8 Bracket Emergency Reverse Switch Hex Nut # l o - 3 2 Spring Pin Actuator Shaft Hex Spacer Compression Spring Heater Assembly - Models 6HBE30/6HBE40 Heater Assembly - Models 6HBC30/6HBC40/6TB50 Compression Spring Insulator Safety Button Horn Button Lower Button Lift Button

USED ON B A

A B B A

B B

A= Standard B = Cold Storage

List 4-3. Transistor Controller Assembly - 00590-01 303-71, 00590-01345-71, 00590-01 347-71, 00590-01 307, 00590-01 349-71,00590-01352-71 - All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRlCAL

ASSEMBLY P/N

MODEL

mymA

QTY ITEM 13

QTY ITEM

QTY ITEM

14

15

QTY ITEM 26

QTY ITEMS 3 4 & 35

00590-1303-71

6HBW30/6HBE30/ 6HBE40 Standard

4

14

10

3

6

00590-1 345-71

6HBC30/6HBC40 Standard

2

12

8

3

6

00590-1 347-71

6TB50 Standard

2

8

4

1

2

00590-1307-71

6HBW30/6HBE30/ 6HBE40 Cold Storage

4

14

10

3

6

00590-1 349-71

6HBC30/6HBC40 Cold Storage

2

12

8

3

6

00590-1 352-71

6TB50 Cold Storage

2

8

4

1

2

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

ToYmA

Figure 00590-01605-7 1

Model 6HBW30/6HBE30/6HBE40

Figure 00590-01606-71

Model 6HBC30/6HBC40

Figure 00590-01607-71

Model 6TB50 Figure 4-4. Controller Diagram Reference -00590-01 605-71,00590-01606-71,00590-01607-71

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mymA

I END RIDER TRACTOR ASSEMBLY

Figure 4-5. Rail Switch Assembly - 00590-01 292-71,00590-01297-71 - Models 6HBE30/6HBE40

4-1 8

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

ITEM NO.

1 2 3 4 5 7 12 14 15 16 17 18 19 20 21 22 23 24

1 QTY. I I

I

1

1 1 1 1 1 4 2 8 8 8 2 2 2 1 1 1 1 1

PART NUMBER

100590-00286-71 00590-00284-71 00590-00285-71 00590-00150-71 00590-00288-71 00590-00129-71 00590-00282-71 00590-00283-71 100590-00121-71 00590-00138-71 00590-0031 2-71 00590-00180-71 00590-00313-71 00590-00202-71 00590-01411-71 00590-01 41 2-71 00590-01413-71 00590-01414-71 I

'mYmA

DESCRIPTION Iswitch HousingSwitch Cover Switch Mounting Bracket Switch Assembly Rail Control Harness Pan Head Machine Screw #6-32 x 1 /2 Socket Head Cap Screw 5/16-1 8 x 1 /2 Lock Nut #4-40 I Hex S~acer Compression Spring Hex Head Cap Screw #lo-32 x 7/8 Hex Nut #lo-32 Lockwasher #10 Heater Assembly Horn Button Lower Button Lift Button Rabbit Button

A= Assembly 00590-01 292-71 = Standard B= Assembly 00590-01 297-71 = Cold Storage

List 4-5. Rail Switch Assembly - 00590-01 292-71,00590-01297-71,

Models 6HBE30/6HBE40

B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mymA

Figure 4-6. Foot Switch Installation - 00590-01 370-71,00590-01374-71,00590-01383-71, 00590-01 388-71 Models 6HBC30/6HBC40/6TB50 (Up to 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-6 ITEM NO.

1 2 3 4 5 6 60

6b

9 10 11 12 13

QTY. 2 2 2 2 1 1 1 1 1 1 1 3 3 3 2 2

PART NUMBER

00590-00342-71 00590-00343-71 00590-001 12-71 00590-001 13-71 00590-00346-71 00590-01 371 -71 00590-00349-71 00590-00350-71 00590-01384-71 00590-00349-71 00590-01385-71 00590-00341 -71 00590-00345-71 00590-00347-71 00590-00344-71 00590-00365-71

DESCRIPTION Round Head Machine Screw #lo-32 x 5/8 Round Head Machine Screw 1 /4-28 x 1 /2 Flat Washer 1/4 Lockwasher 1 /4 Cable Clamp Foot Switch Assembly - Standard: includes Foot Switch Foot Wiring Harness Foot Switch Assembly - Cold Storage: includes Foot Switch Foot Wiring Harness Grommet Tube Clamp Nail Grip Stud Lockwasher # 1 0 Strap - 15"

mYmA USED ON

A, B A, B A, B C, D C, D C, D

A= Assembly 00590-01370-71 - Models 6HBC30/6HBC40 - Standard B= Assembly 00590-01374-71 - Models 6TB50 - Standard C= Assembly 00590-01383-71 - Models 6HBC30/6HBC40 - Cold Storage D= Assembly 00590-01 388-71 - Models 6TB50 - Cold Storage -

-

List 4-6. Foot Switch Installation - 00590-01 370-71,00590-01374-71,00590-01383-71,00590-01388-71 Models 6HBC30/6HBC40/6TB50 (Up to 6/24/96)

-

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TBSO ELECTRICAL

mymA

Figure 4-7. Foot Switch installation - 00590-01599-71, 00590-01 602-71 - Models 6HBC30/6HBC40/6TB50 (After 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-7 ITEM NO. 1 2 3 4 5 6 60 6b

7 70 7b 9 10 11 12 13

QTY. PART NUMBER 2 00590-00342-71 2 00590-00343-71 2 00590-001 12-71 2 00590-00568-71 1 00590-00346-71 1 00590-01 600-71 1 00590-00349-71 1 00590-00350-71 1 00590-01 603-71 1 00590-00349-71 1 00590-01 604-71 3 00590-00341 -71 00590-00345-71 3 3 00590-00347-71 2 00590-00344-71 2 00590-00365-71

DESCRIPTION Round Head Machine Screw #lo-32 x 5/8 Round Head Machine Screw 1/4-28 x 1/2 Flat Washer 1 /4 Flat Washer Set 114 Cable Clamw Foot Switch Assembly: includes Foot Switch Foot Wiring Harness Foot Switch Assembly: includes Foot Switch Foot Wiring Harness Grommet Tube Clamp Nail Grip Stud Lockwasher # 10 Strap - 15"

mYmA USED ON

A, B A, B A, B C, D C, D C, D

A= Assembly 00590-01 370-71 - Models 6HBC30/6HBC40 - Standard

B= Assembly 00590-01374-71 - Models 6TB50 - Standard C= Assembly 00590-01383-71 - Models 6HBC30/6HBC40 - Cold Storage D= Assembly 00590-01388-71 - Models 6TB50 - Cold Storage

List 4-7. Foot Switch Installation - 00590-01 599-71, 00590-01 602-71 - Models 6HBC30/6HBC40/6TB50 (After 6/24/96)

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

myaA

DISCHARGE METER INSTALLATION

HOUR METER INSALLATION

,DASH PANEL

ELECTRICAL WIRING FOR METER INSTALLATION HOUR / DISCHARGE INSTALIATION

Figure 4-8. Hour Meter/Discharge Indicator Installation - 00590-0051 4-71,00590-00517-71,00590-00519-71, 00590-00520-71,00590-00526-71,00590-00527-71,00590-00529-71 - All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL FIGURE 4-8 ITEM NO.

DESCRIPTION

PART NUMBER

1 2

QTY. 1 1

00590-00518-71 00590-00515-71

Discharge Meter Hour Meter

3

1

00590-0051 6-7 1

Plug Button

4

1 1 1 1 1 2 2 2

00590-00525-71 00590-00528-71 00590-00524-71 00590-00523-71 00590-00521 -71 00590-00522-71 00590-001 13-71 00590-00462-71

Curtis Battery Meter Curtis Battery Meter Controller Assembly Meter Harness Jumper Stud Weld 1 /4-20 x 1/2 Lockwasher l/4 Hex Nut 1 /4-20

5 6 7 8 9 10

mYmA USED ON B, c A, C, E, G A, B, D, F

D, E 6G

D, E

A= 00590-00514-71 - With Hour Meter B= 00590-00517-71 - With Discharge Meter C= 00590-00519-71 With Hour and Discharge Meter D= 00590-00520-71 - With Battery Meter and Lift lnterrupt E= 00590-00526-71 - With Battery Meter, Hour Meter and Lift Interrupt F= 00590-00527-71 - With Battery Meter and Lift Interrupt G=00590-00529-71 - With B a t t e ~ Meter and Hour Meter

-

List 4-8. Hour Meter/Discharge Indicator Installation - 00590-0051 4-71, 00590-0051 7-71, 00590-0051 9-71, 00590-00520-71,00590-00526-71,00590-00527-71,00590-00529-71 - All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELECTRICAL

mymA

SCHEMATIC

Figure 4-9. Contador Assembly - 00590-00545-71, All Models FIGURE 4-9 ITEM NO. 1 N/S 2 N/S

QTY. 1 1 1 1

PART NUMBER 00590-04510-7 1 00590-04512-71 00590-04510-7 1 00590-04512-7 1

DESCRIPTION Reverse Contador Service Repair Kit Forward Contactor Service Repair Kit

List 4-9. Contador Assembly - 00590-00545-71, All Models

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC

5- 1 5-2 5-3

mYmA

Hydraulic System - 00590-00254-71 - All Models ...........................................................5-3 Purnp/Motor Assembly - 00590-00266-71 - All Models ...................................................5-5 D.A. Cylinder - 00590-04545-71 - All Models ................................................................5-6

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC

Figure 5-1. Hydraulic Sys:em - 0 0 5 9 0 - 0 0 2 5 4 - 7 1 - All Models

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC FIGURE 5-1 ITEM NO. 2 3 7 8 9 10 12

13 14 15 16 17 18 19 20 24 25 26 27

QTY. 1

3 1 1 2 2 1 1 2 1 1 1 1 2 2 2 2 4 4

PART NUMBER 00590-00266-71 00590-00268-71 00590-00275-71 00590-00273-71 00590-00274-71 00590-00270-71 00590-00255-71 00590-00260-71 00590-00272-71 00590-00271 -71 00590-00276-71 00590-00261 -71 00590-00261 -71 00590-04545-71 00590-00262-71 00590-01 445-71 00590-01 446-71 00590-01 444-71 00590-00224-71

mYmA

DESCRIPTION Hydraulic Pump & Motor Assembly- 24 Volt (See Figure 5-2) Hex Head Cap Screw 5/16-18 x 7/8 Male 0 - Ring Connector Swivel Run Tee 90 Degree Swivel Elbow 45 Degree Elbow Hose Assembly Hose Assembly 90 Degree Male Elbow Male Branch Tee Plug 0-Ring Polyflo Tubing (8") Polyflo Tubing (27") Hydraulic Cylinder Assembly (See Figure 5-3) Cylinder Packing Cylinder Retaining Plate Cylinder Retaining Ring Hex Head Cap Screw 5/16-18 Lockwasher 5/16

List 5-1. Hydraulic System - 00590-00254-71 - All Models

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC

Figure 5-2. Pump/Motor PLssembly - 00590-00266-71 - All Models

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC FIGURE 5-2 ITEM NO. 1 2 3 4 5 6 7 8 9 10

QTY. 1 1 1 1 1 1 1 1 1 1

PART NUMBER 00590-04560-71 00590-04781 -71 00590-04562-71 00590-04563-71 00590-04696-71 00590-04697-71 00590-04555-71 00590-04564-71 00590-04557-71 00590-04565-71

DESCRIPTION Motor - 24VDC, 2 Terminal Adapter Block (W/ Check Valve) Reservoir Kit (W/Tubes) Solenoid Release Valve/Coil Flow Control Valve (2 GPM) Adjustable Relief Valve Pump (W/ Coupling, Bolts & Gasket) 90 Degree Elbow Vent Plug (W/ 40 Micron Filter) Solenoid Start Switch

List 5-2. PumplMotor Assembly - 00590-00266-71 - All Models

ToYmA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 HYDRAULIC

mymA

Figure 5-3. D.A. Cylinder - 00590-04545-71 - All Models

FIGURE 5-3 ITEM NO. 1 2 3 4 5 6

QTY. 1 1 1 (N/S) 2 1

DESCRIPTION PART NUMBER NOT SOLD SEPARATELY Head NOT SOLD SEPARATELY Barrel Assembly Piston Rod Assembly 00590-04542-71 NOT SOLD SEPARATELY Sleeve Rod Bearing 00590-00443-71 Seal Replacement Kit - Includes: 00590-04544-71 NOT SOLD SEPARATELY Retaining Ring NOT SOLD SEPARATELY 0 - Ring NOT SOLD SEPARATELY Wear Ring NOT SOLD SEPARATELY Back Up Washer NOT SOLD SEPARATELY Seal NOT SOLD SEPARATELY Lock Ring er NOT SOLD SEPARATELY S l i ~ ~Rina

N/S= Not Shown

List 5-3. D.A. Cylinder - 00590-04545-71 - All Models

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TBSO ELEVATING

mymA

Platform & Rest Assembly - 00590-00969-71, 00590-00970-71,00590-00976-71 All Models .....................................................................................................................

6-3 Entry Roller Installation - 00590-00207-71 - Model 6HBC30 ...........................................6-5 Entry Roller Installation - 00590-00757-71 - Models 6HBE40/6HBC40 ............................6-7 Entry Roller Installation - 00590-00305-71 - Models 6HBW30/6HBE30 ............................6-9 Load Wheel Assembly - 00590-00010-71,0590-00024-71 Models 6HBW30/6HBE30/6HBC30 ............................................................................... 6 1 1 Load Wheel Assembly - 00590-01 621 -71,00590-01 626-71 - Models 6HBE40/6HBC40 .6-13 Load Wheel Assembly - 00590-00095-71 - Models 6HBC40/6HBE40 ............................. 6- 15 Fork And Tractor Sub-assembly - 27" Width - 00590-00242-71,00590-00301-71, 00590-00994-71,00590-01025-71 , 00590-01 031 -71, 00590-01037-71,00590-01043-71, 00590-01 050-7 1,00590-01 055-71, 00590-01 060-71, 00590-01 065-71,00590-01076-71, 00590-01 081 -71,00590-01 087-71, 00590-01 094-71, 00590-01 107-71,00590-01110-71, 00590-01 1 17-71,00590-01124-71 , 00590-01 131 -71, 00590-01 135-71,00590-01142-71 Models 6HBW30/6HBE30/6HBC30 ................................................................................6- 1 7 Fork And Tractor Sub-assembly -24" Wide - 00590-00242-71, 00590-00301 -71, 00590-01 148-71,00590-01155-71,00590-01157-71 , 00590-01 159-71,00590-01161-71 00590-01 163-71,00590-01165-71,00590-01167-71 , 00590-01 169-71,00590-01171-71 , 00590-01 1 73-71,00590-01175-71, 00590-01 177-71, 00590-01 180-71,00590-01183-71, 00590-01186-71,00590-01189-71 , 00590-01 192-71,00590-01195-71,00590-01198-71 Models 6HBW30/6HBE30/6HBC30 ................................................................................6-2 1 Fork And Tractor Sub-Assembly - 22" Wide - 00590-00242-71,00590-00301-71, 00590-01201 -71 00590-01 208-71,00590-01210-71,00590-01212-71,00590-012 14-71, 00590-01 21 6-71,00590-01218-71,00590-01220-71,00590-01222-71, 00590-01 224-71,00590-01226-71 , 00590-01 228-71,00590-01230-71, 00590-01 233-71,00590-01236-71 , 00590-01 239-71,00590-01242-71 , 00590-01245-71,00590-01248-71,00590-01251-71 Models 6HBW30/6HBE30/6HBC30 ................................................................................

6-25 Fork And Tractor Sub-Assembly -27" Width- 00590-00242-71,00590-00301-71, 00590-01 627-71,00590-01637-71,00590-01640-71,00590-01644-71 , 00590-01 648-71, 00590-01 651 -71,00590-01 655-71, 00590-01 658-71 Models 6HBE40/6HBC40 ...............................................................................................6-28

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

Figure 6-1. Platform & Rest Assembly - 00590-00969-71,00590-00970-71,00590-00976-71

6-2

myaA

- All Models

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FIGURE 6-1 ITEM NO. 1 2 3 5

6 7 8

QTY. 1 4 4 1 1 2 4 4

PART NUMBER 00590-0003 1 -71 00590-00029-71 00590-00004-71 00590-00971 -71 00590-00977-71 00590-00913-71 00590-00030-71 00590-00005-71

DESCRIPTION

myiA USED ON

Front Rest Weldment Hex Head Cap Screw 3/8- 14 x 1-1/2 Flat Washer 3/8 Backrest Frame - 48" Backrest Frame - 60" Hex Head Cap Screw 3/8-16 x 1 Non Locking Hex Nut 3/8- 16 Lockwasher 3/8

A= 48" Backrest

B= 6 0 Backrest List 6-1. Platform & Rest Assembly - 00590-00969-71, 00590-00970-71, 00590-00976-71 - All Models

A B

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

Figure 6-2. Entry Roller Installation - 00590-00207-71 - Model 6HBC30

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FIGURE 6-2 ITEM NO. 1 2 3 4 5 N/S 7

QN. 1 1 3 3 3 2 2

PART NUMBER 00590-01 440-71 00590-0021 3-71 00590-002 10-71 00590-00211-71 00590-0021 2-71 00590-00208-71 00590-002 1 2-71

DESCRIPTION Entry Roller Assembly: Includes Entry Roller Bracket Roller Bolt 3/8-16 x 1.75 Lock Nut 3/8- 1 6 Flat Head Cap Screw 3/8-16 x 3/4 Lock Nut 3/8- 16

N/S= Not Shown

List 6-2. Entry Roller Installation - 00590-00207-71 - Model 6HBC30

myiA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

Figure 6-3. Entry Roller Installation - 00590-00757-71 - Models 6HBE40/6HBC40

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING FIGURE 6-3 ITEM NO. 1

2 3

QTY. 1 1 4 4 4 2 2

PART NUMBER 00590-00758-71 00590-00759-71 00590-0021 0-71 00590-0021 1-71 00590-0021 2-71 00590-00 1 9 1 -71 00590-00306-71

myiA

DESCRIPTION Entry Roller Assembly: Includes Entry Roller Bracket Roller Bolt 3/8-16 x 1.75 Lock Nut 3/8- 16 Flat Head Countersink Screw 3/8-24 x 1 GR8 ESNA Light Nut 3/8-24

List 6-3. Entry Roller Installation - 00590-00757-71 - Models 6HBE40/6HBC40

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

Figure 6-4. Entry Roller Installation - 00590-00305-71 - Models 6HBW30/6HBE30

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING FIGURE 6-4 ITEM NO. 1 2 3 4 5 7 8

PART NUMBER QTY. 1 00590-00307-71 1 00590-00308-71 4 00590-002 10-71 4 00590-0021 1-71 4 00590-0021 2-71 2 00590-001 91 -71 2 00590-00306-71

mymA

DESCRIPTION Entry Roller Assembly: Includes Entry Roller Bracket Roller Bolt 3/8- 16 x 1.75 Lock Nut 3/8-16 Flat Head Screw 3/8-24 x 1 GR8 ESNA Light Nut 3/8-24

List 6-4. Entry Roller Installation - 00590-00305-71 - Models 6HBW30/6HBE30

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

mymA

Figure 6-5. Load Wheel Assembly - 0055%-00010-71,0590-00024-71 - Models 6HBW30/6HBE30/6HBC30

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FIGURE 6-5 ITEM NO. 1 2

3 4 5 6 7 8 9 10

mymA

1

I USED

1 QTY. 1 I

1 1 1 1 1 1 1

2 2 2 2 1 2

PART NUMBER 100590-00021-71 00590-0001 3-71 00590-00025-71 00590-01 618-71 00590-01 620-71 00590-00020-71 00590-000 1 7-71 00590-0001 2-71 00590-00015-71 00590-0001 8-71 00590-0001 4-71 00590-0001 9-71 00590-0001 1-71

DESCRIPTION

I ON

ITrail Mechanical Fork Load Wheel - Medium Poly - Tan Load Wheel -Hard Poly - Neutral Load Wheel - Medium Poly - Tan (With Aluminum Hub) Load Wheel - Hard Poly - Neutral (With Aluminum Hub) Wheel Shaft Spirol Pin Shielded Bearing Flat Washer - 1 " Grease Fitting Sleeve Bearing Grease Fitting Non-Shielded Bearing

A= Assembly - 00590-00010-71 (High Temperature Applications) B= Assembly - 00590-00024-71 (Overall Applications)

List 6-5. Load Wheel Assembly - 00590-0001 0-7 1,0590-00024-71 Models 6HBW30/6HBE30/6HBC30

B A B A

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

mymA

Figure 6-6. Split Load Wheel Assembly - 00590-01 621 -71,00590-01 626-71 - Models 6HBE40/6HBC40

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FIGURE 6-6 ITEM NO. 1

2 3 4 5 7 8 9 10 11 12 13 14

QTY. 4 4 4 4 2 8 AR 2 1

2 2 2 4 6 4 AR

PART NUMBER 00590-00894-71 00590-00898-71 00590-00897-71 00590-00901 -71 00590-00895-71 00590-0001 2-71 00590-0001 5-71 00590-0001 8-71 00590-01 623-71 00590-01 622-71 00590-01 469-71 00590-0001 5-71 00590-01 624-71 00590-00423-71 00590-00633-71 00590-00359-71

DESCRIPTION Load Wheel - Medium Poly - Neutral Load Wheel - Hard Poly - Tan Load Wheel - Hard Poly - Black Load Wheel - Soft Poly - Yellow Wheel Shaft Bearing Shield Flat Washer - 1 " Grease Fitting Trail Mechanical Fork Flanged Bushing Rework Bushing Grease Fitting Tandem, Pivot Weld Grease Fitting Pin: 1/4 x 1 3/4 Spacer

mymA USED ON B A A B

A= Assembly 00590-01 621 -71 (High Temperature Applications) B= Assembly 00590-01626-71 (Overall Applications)

List 6-6. Split Load Wheel Assembly - 00590-01 62 1-71,00590-01626-71 - Models 6HBE40/6HBC40

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

Figure 6-7. Load Wheel Assembly - 00590-00095-71 - Models 6HBC40/6HBE40

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FIGURE 6-7 ITEM NO. 1 2

3 4 5 6 7 8 9

QTY. 2 2 2 2 2 1 1 4 3 2 2 2

PART NUMBER 00590-0002 1-71 00590-0051 1 -71 00590-00506-71 00590-00509-71 00590-0051 3-71 00590-00507-71 00590-0001 7-71 00590-0001 2-71 00590-00015-71 00590-0001 8-71 00590-0001 4-71 00590-00423-71

mymA

DESCRIPTION Trail Fork Split Load Wheel - Hard Poly - Tan Split Load Wheel - Medium Poly - Tan Split Load Wheel - Hard Poly - Black Split Load Wheel - Soft Poly - Yellow Wheel Shaft Spring Pin Shielded Bearing Flat Washer - 1 " Grease Fitting Sleeve Bearing Grease Fitting - Straight

List 6-7. Load Wheel Assembly - 00590-00095-71 - MODELS 6HBC40/6HBE40

USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

mymA

Figure 6-8. Fork And Tractor Sub-assembly - 27" Width - 00590-00242-71,00590-00301-71,00590-00994-71, 00590-01 025-71,00590-01031-71,00590-01037-71,00590-01043-71,00590-01050-71,00590-01055-71, 00590-01 060-71,00590-01065-71,00590-01076-71,00590-01081-71 , 00590-01087-71,00590-01094-71 , 00590-01 107-71,00590-01110-71 , 00590-01117-71, 00590-01 124-71,00590-01131-71 , 00590-01 135-71, 00590-01 142-71 - Models 6HBW30/6HBE30/6HBC30

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

DESCRIPTION Box & Fork Weldment - 27" Bell Crank Sub-Assembly - Right Hand: Includes Sleeve Bearina Sleeve Bearing Right - Hand Bell Crank Machining 65 Dearee Grease Fittina - 1. /8 Socket Head Cap Screw 5/16- 1 8 UNC x 1 /2 Bell Crank Sub-Assembly - Left Hand: Includes Sleeve Bearing Sleeve Bearina Left Hand Bell Crank Machining 65 Degree Grease Fitting 1/23 ~ o c k e t ~ e Cap a d ~ c r e w 5 / 1 6 - 1 8UNC x 1/2 Pull Rod Sub-Assembly: Includes Bushing Sleeve Bearing Pull Rod Machining 65 Degree Grease Fitting - 1/8 Grease Fitting - 1 /4-28 Sleeve Bearing Front Fork Shaft Load Wheel Assembly (See Figure 6-5) Load Wheel Assembly Figure 6-5) . (See .

Flat Washer 3/4 Eccentric Pin Lockwasher 5/8 Hex Nut 5/8-18 Socket Head Cap Screw 5/16- 18 x 1/2 Rear Fork Shaft Clevis Mach Hex Head Cap Screw 1/2-13 x 1 -1/4 Lockwasher 1/2 Switch Actuator Rear Link Shaft Socket Head Cap Screw 1/4-20 x 1 /2 Fork and Platform Weldment - 27" Cylinder Pivot Pin Truck Link Shaft Cup Point Socket Head Cap Screw 5/16-18 x 5/8 Grease Fitting 1/4-28 STR Pivot Cylinder Shim 1 /4 Pivot Cylinder Shim 1/8 Snap Ring Washer Roller

PART NUMBER QTY. SEE CHART 1 1 N/S 00590-01004-71 2 00590-01 002-71 1 00590-00673-71 1 00590-01005-71 I I I 1 100590-00018-71 1 00590-00628-71 1 N/S 00590-01001 -71 2 N/S 100590-01002-71 I 1 N/S 100590-00673-71 1 N/S 00590-01 003-71 1 N/S 00590-0001 8-7 1 1 N/S 00590-00628-71 SEE CHART 2 1 00590-00666-71 1 N/S 00590-01008-71 1 SEE CHART 1 00590-00018-71 2 00590-00019-71 2(N/S) 00590-00669-71 00590-00998-71 2 REF 00590-00010-71 REF 00590-00024-71 00590-00632-71 8 2 00590-01 006-71 2 00590-00997-71 00590-00995-71 2 4 00590-00628-71 2 00590-00999-71 00590-00252-71 2 4 00590-00243-71 4 00590-00246-71 1 00590-00253-71 00590-01000-71 2 00590-00628-71 2 1 SEE CHART 2 00590-00251 -71 2 00590-00248-71 2 00590-00244-71 2 00590-0001 9-71 00590-00249-71 AR AR 00590-00250-71 00590-00247-71 4 4 00590-00245-71 2 00590-00626-71

ITEM NO. 1 4 4A 4B 4C

4D 4E 5 5A 5B 5C 5D 5E 6 6A 6F 68 6D 6E 6C 7 8

-

-

1

-

f

9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33

-- -

mymA

--

- Item 5 is oppostte side - not shown.

- The Assembly Port Numbers In The Below Chart Represent The Fork Assemblies Part Numbers Only.

- The First Two Part Numbers Shown On The Illustrotton Page Are The Tractor Assemblies.

N/S= Not Shown

List 6-8. Fork And Tractor Sub-assembly - 27" Width - Models 6HBW30/6HBE30/6HBC30

ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

ASSEMBLY P/N

MODEL NO.& FORK LENGTH

00994

6HBW30 36"

01010

01 007

01045

01 097

07025

6HBW30 - 42"

01 028

01 026

01052

01 108

01031

6HBW30 4 8

01034

01 032

01 057

01113

01 040

01038

01062

01120

01 046

01 044

01 089

01 127

01 053

01051

01 067

01 132

-

ITEM 1 P/N

ITEM 6 PIN ITEM 6B P/N ITEM 22 P/N

01050

6HBW30 - 60" 6HBE30 - 36" 6HBE30 - 42"

01055

6HBE30 - 4 8

01 058

01 056

01096

01 138

01060

6HBE30 - 60"

01 063

01061

None

01 145

01 065

6HBE30 84"

01 068

01 066

01 112

01 178

01076

6HBE30 - 96"

01 077

01 066

01119

01 181

01 081

6HBE30 103"

-

01 084

01 082

01 144

01 184

01087

6HBE30 - 84"'

01 090

01 088

01126

01 187

01 094

6HBC30 - 36"

01 104

01 095

01 009

01 190

01107

6HBC30/ - 42"

01 114

01061

01 027

01 193

01 110

6HBC30 - 4 8

01 121

01111

01 033

01 196

01117

6HBC30 - 6 0

01 128

01118

01 039

01 199

01124

6HBC30- 84"

01 133

01 125

01 083

01231

01131

6HBC30 - 9 6

01 139

01 125

01 137

01 234

01135

6HBC30 - 103"

01 146

01136

None

01 237

01142

6HBC30 84"'

01 109

01 143

None

01 240

01037 01043

-

-

myaA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

THIS PAGE INTENTIONALLY LEFT BLANK

ToyIlA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

mymA

Figure 6-9. Fork And Tractor Sub-assembly -24" Wide - 00590-00242-71,00590-00301-71,00590-01148-71, 00590-01 155-71,00590-01157-71,00590-01159-71,00590-01161-71 00590-01 163-71,00590-01165-71, 00590-01 167-71,00590-01169-71,00590-01171-71,00590-01173-71,00590-01175-71,00590-01177 00590-01 180-71,00590-01183-71,00590-01186-71,00590-01189-71,00590-01192-71,00590-0119~ 00590-01198-71 - Models 6HBW30/6HBE30/6HBC30

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING FIGURE 6-9 ITEM NO. 1 4

QTY. 1 1

4A 4B 4C 4D 4E

2 1 1 1 1

00590-0 1002-7 1 00590-00673-71 00590-0 1004-71 00590-00018-71 00590-00628-71

5* 5A 58 5C 5D 5E

1 2 N/S 1 N/S 1 N/S 1 N/S 1N/S

00590-01001 -7 1 00590-01002-71 00590-00673-71 00590-01 001 -71 00590-0001 8-71 00590-00628-71

6 6A 6F 6B 6D 6E 6C 7 8

2 1 1 N/S 1 1 2 2 (N/S) 2 REF

9 10 11 12 13 14 16 17 18 19 20 21 22 23 25

8 2 2 2 4 2 2 4 4 1 2 2 1 2 2

SEECHART 00590-00666-71 00590-01 008-71 SEE CHART 00590-0001 8-71 00590-0001 9-71 00590-00669-71 00590-00998-7 1 00590-00010-71 00590-00024-7 1 00590-00632-7 1 00590-01 006-71 00590-00997-71 00590-00995-71 00590-00628-71 00590-00999-71 00590-00252-71 00590-00243-71 00590-00246-71 00590-00253-71 00590-0 1 000-7 1 00590-00628-71 SEE CHART 00590-00251 -71 00590-00244-7 1

27 28 29

2 2 AR

00590-00302-71 00590-0001 9-7 1 00590-00249-71

-

PART NUMBER SEE CHART 00590-0 1 004-7 1

mymA

DESCRIPTION Box & Fork Weldment - 24" Bell Crank Sub-Assembly - Right Hand: lncludes Sleeve Bearing Sleeve Bearing Right Hand Bell Crank Machining 65 Degree Grease Fitting 1/8 Socket Head Cap Screw 5/16-18 UNC x 1/2 Bell Crank Sub-Assembly - Left Hand: Includes Sleeve Bearing Sleeve Bearing Left Hand Bell Crank Machining 65 Degree Grease Fitting 1/8 Socket Head Cap Screw 5/16- 18 UNC x 1 /2 I Pull Rod Sub-Assembly: Includes Sleeve Bearing Sleeve Bearing Pull Rod Machining 65 Degree Grease Fitting - 1/8 Grease Fitting - 1/4-28 Sleeve Bearing Front Fork Shaft Load Wheel Assembly (See Figure 6-5) Load Wheel Assembly (See Figure 6-5) Fiat Washer 3/4 Eccentric Pin Lockwasher 5/8 Hex Nut 5/8-18 Socket Head Cap Screw 5/16-18 x 1 /2 Rear Fork Shaft Clevis Mach Hex Head Cap Screw 1 /2-13 x 1 -1/4 Lockwasher 1/2 Switch Actuator Rear Link Shaft Socket Head Cap Screw 1 /4-20 x 1/2 Fork and Platform Weldment - 24" Cylinder Pivot Pin Cup Point Socket Head Cap Screw 5/16- 18 x 5/8 Truck Link Shaft Grease Fitting 1/4-28 STR Pivot Cylinder Shim 1 /4 --

USED ON

---

-* Item 5 1s oppos~teside - not shown.

- The Assembly Part Numbers In The Below Chart Represent The Fork Assemblies Part Numbers Only.

- The Flrst Two Part Numbers Shown O n The lllustrat~onPage Are The Tractor Assemblies.

N/S= Not Shown

List 6-9. Fork And Tractor Sub-Assembly - 24" Wide - Models 6HBW30/6HBE30/6HBC30

6-2 1

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

THIS PAGE INTENTIONALLY LEFT BLANK

mylA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

mymA

Figure 6-1 0. Fork And Tractor Sub-Assembly - 22" Wide - 00590-00242-71,00590-00301-71,00590-01201-71 00590-01 208-71,00590-01210-71,00590-01212-71 ,00590-01 21 4-71,00590-01216-71,00590-01218-71 , 00590-01 220-71,00590-01222-71,00590-01224-71,00590-0 1226-71,00590-01228-71,00590-01230-71, 00570-01233-71,00590-01236-71,00590-01239-71 ,00590-01 242-71,00590-01245-71,00590-01248-71 , 00590-01 25 1 -71 - Models 6HBW30/6HBE30/6HBC30

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATlNG

FIGURE 6-10 ITEM NO. 1 4 4A 4B 4C 4D 4E 5* 5A 5B 5C 5D 5E 6 6A 6F

68 6D 6E 6C 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 28 29 30 31 34

QTY. 1 1 2 1 1 1 1 1 N/S 2 N/S 1 N/S 1 N/S 1 N/S 1 N/S 2 1 1 N/S 1 1 2

PART NUMBER SEE CHART 00590-01 004-71 00590-01 002-71 00590-01 004-71 00590-01 005-71 00590-0001 8-71 00590-00628-71 00590-01 001 -71 00590-01 002-71 00590-00673-71 00590-01 001 -71 00590-0001 8-71 00590-00628-71 SEE CHART 00590-00666-71 00590-01 008-71 SEE CHART 00590-0001 8-7 1 00590-0001 9-71 2 (N/S) 00590-00669-71 2 00590-00998-71 REF 00590-0001 0-71 00590-00024-71 8 00590-00632-71 2 00590-01 006-71 2 00590-00997-71 2 00590-00995-71 4 00590-00628-71 2 00590-00999-71 2 00590-00252-71 4 00590-00243-71 4 00590-00246-71 1 00590-00253-71 2 00590-01 000-71 2 00590-00628-71 1 SEE CHART 2 00590-00251 -71 00590-00248-71 2 2 00590-00244-71 2 00590-0001 9-71 AR 00590-00249-71 AR 00590-00250-71 4 00590-00247-71 4 00590-00996-71

myiA

DESCRIPTION Box & Fork Weldment - 22" Bell Crank Sub-Assembly - Right Hand: Includes Sleeve Bearing Sleeve Bearing Right Hand Bell Crank Machining 65 Degree Grease Fitting 1 /8 Socket Head Cap Screw 5/16-18 UNC x 1/2 Bell Crank Sub-Assembly - Left Hand: Includes Sleeve Bearing Sleeve Bearing Left Hand Bell Crank Machining 65 Degree Grease Fitting 1 /8 Socket Head Cap Screw 5/16- 18 UNC x 1/2 Pull Rod Sub-Assembly: Includes Sleeve Bearing Sleeve Bearing Pull Rod Machining 65 Degree Grease Fitting - 1/8 Grease Fitting - 1/4-28 Sleeve Bearing Front Fork Shaft Load Wheel Assembly (See Figure 6-5) Load Wheel Assembly (See Figure 6-5) Flat Washer 3/4 Eccentric Pin Lockwasher 5/8 Hex Nut 5/8- 18 Socket Head Cap Screw 5/16- 18 x 1/2 Rear Fork Shaft Clevis Mach Hex Head Cap Screw 1/2-13 x 1-1 /4 Lockwasher 1 /2 Switch Actuator Rear Link Shaft Socket Head Cap Screw 1/4-20 x 1 /2 Fork and Platform Weldment - 22" Cylinder Pivot Pin Truck Link Shaft Cup Point Socket Head Cap Screw 5/16-18 x 5/8 Grease Fitting 1/4-28 STR Pivot Cylinder Shim 1/4 Pivot Cylinder Shim 1 /8 Snap Ring Spacer

USED ON

-* Item 5 is opposite side - not shown.

- The Assembly Part Numbers In The Below Chart Represent The Fork Assemblies Part Numbers Only.

- The First Two Part Numbers Shown O n The Illustration Page Are The Tractor Assemblies.

N/S= Not Shown

List 6-1 0. Fork And Tractor Sub-Assembly - 22" Wide -Models 6HBW30/6HBE30/6HBC30

6-25

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

ASSEMBLY P/N

MODEL NO. & FORK LENGTH

ITEM 1 P/N

ITEM 6 P/N

ITEM 68 P/N

ITEM 22 P/N

01 201

6HBW30 - 36"

01518

01007

01 045

01 097

01 208

6HBW30 - 42"

01519

01026

01 052

01 108

01210

6HBW30 - 60" 6HBE30 - 36" 6HBE30 - 42"

01520

01032

01057

01 113

01521

01038

01062

01 120

01522

01044

01089

01 127

01523

01051

01067

01 132

01212 01214 01216

6HBW30 4 8

01218

6HBE30/6HBE40 - 48"

01524

01056

01096

01 138

01220

6HBE30 - 60"

01525

01061

None

01 145

01 222

6HBE30 - 84"

01 526

01066

01112

01 178

01 224

6HBE30 - 96"

01527

01 066

01119

01 181

01 226

6HBE30 - 103"

01528

01082

01144

01184

01228

6HBE30 - 84"'

01529

01088

01126

01 187

01 230

6HBC30 36"

01 530

01095

01 009

01 190

01 233

6HBC30 - 42"

01532

01061

01027

01 193

01 236

6HBC30 - 4 8

01533

01111

01 033

01 196

01 239

6HBC30 - 60"

01 534

01118

01039

01 199

01 242

6HBC30/ 84"

01535

01125

01083

01231

01 245

6HBC30 - 96"

01536

01125

01 137

01 234

01 248

6HBC30 - 103"

01 537

01 136

None

01 237

01251

6HBC30 - 84"'

01531

01143

None

01 240

-

-

ToYaA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

myiA

Figure 6-1 1. Fork And Tractor Sub-Assembly -27" Width- 00590-00242-71, 00590-00301 -71, 00590-01 627-71, 00590-01 637-7 1,00590-01 640-7 1,00590-01 644-71,00590-01648-71,00590-01651-7 1,00590-01 655-71, 00590-01 658-71 - Models 6HBE40/6HBC40

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

FlGURE6-11 ITEM NO. QTY.

1 4 48

4C 4D 4E 5* 5B 5C 5D 5E 6 6A

6B 6C 6D 6E 6F 6G 7 8 9 10 13 14 16 17 18 19 20 22 23 24 25 28 29 30 31 32 33 34 35 36

-

PART NUMBER SEE CHART

1 1 5 1 1 1

00590-00675-71 00590-00673-71 00590-00675-71 00590-001 18-71 00590-00628-71 1 N/S 00590-00672-71 5 N/S 00590-00673-71 1 N/S 00590-00672-71 1 N/S 00590-0001 8-71 1 N/S 00590-00628-71 2 SEE CHART 2 00590-00666-71 1 SEE CHART 1 00590-0001 8-71 2 N/S 00590-00668-71 2 00590-00670-71 2 00590-00669-71 1 00590-00667-71 2 00590-00634-71 00590-01621-71 4 4 100590-01626-71 AR (00590-00632-71 2 00590-01 608-71 4 00590-00628-71 2 00590-00635-71 2 00590-00252-7 1 4 00590-0091 4-71 4 00590-00246-71 1 00590-00253-7 1 2 00590-00636-71 1 SEECHART 2 00590-00251 -71 2 00590-00248-71 2 00590-00244-71 2 00590-0001 9-71 AR 00590-00249-71 AR 00590-00250-71 4 00590-00247-71 4 00590-00245-71 4 00590-00626-71 AR 00590-00631 -7 1 2 00590-00627-71 4 00590-00682-7 1 1

DESCRIPTION Box & Fork Weldment - 24V, 27" Bell Crank Sub-Assembly - Right Hand: Includes Sleeve Bearing Right Hand Bell Crank Machining 65 Degree Grease Fitting 1/8 PTF Socket Head Cap Screw 5/16- 18 UNC x 1 /2 Bell Crank Sub-Assembly - Left Hand: Includes Sleeve Bearing Left Hand Bell Crank Machining 65 Degree Grease Fitting 1/8 PTF Socket Head Cap Screw 5/16-18 UNC x 1/2 Pull Rod Sub-Assembly: Includes Sleeve Bearing Pull Rod Machining 65 Degree Grease Fitting - 1/8 PTF Pull Rod Fork Assembly: Includes Grease Fitting Bushing Pull Rod Fork Machining Front Fork Shaft Load Wheel Assembly , (See Fiaure 6-61 Load Wheel Assembly (See Figure 6-6) Flat Washer 3/4 Pull Rod Pin Socket Head Cap Screw 5/16-18 x 1 /2 Rear Fork Shaft Clevis Mach Hex Head Cap Screw 1/2-13 UNC x 1-1/4 Lockwasher l/2 Switch Actuator Rear Link Shaft Fork and Platform Weldment - 27" Cylinder Pivot Pin Truck Link Shaft Cup Point Socket Head Cap Screw 5/16-18 x 5/8 Grease Fitting 1/4-28 STR Pivot Cylinder Shim 1/4 Pivot Cylinder Shim 1/8 Snap Ring Washer Roller Washer Socket Head Cap Screw 1/4-20 x 1/2 Tandem Pivot Weldment %

Item 5 is opposite side - not shown.

- The Assembly Part Numbers In The Below Chart Represent The Fork Assemblies Port Numbers Only.

- The First Two Part Numbers Shown O n The Illustration Page Are The Tractor Assemblies.

N/S= Not Shown

List 6-1 1. Fork And Tractor Sub-Assembly -27" Width- Models 6HBE40/6HBC40

6-28

mymA USED ON

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING FIGURE 6-1 1 ITEM NO. PART NUMBER QTY. 37 8 00590-00633-71 38 00590-00630-71 2 2 39 00590-00664-71 40 2 00590-00629-71 4 45 00590-00423-71 2 46 00590-00677-71 47 2 00590-00680-71 48 8 00590-002 18-71 49 AR N/ 00590-0001 5-71

mymA USED ON

DESCRIPTION Pin 1/4 x 1 -1/2 Nut Pull Rod Adjuster Hex Nut 1 -3/8 - 12 Grease Fitting Trail Fork Assembly Cover Plate Cap Screw 1 /4-20 x 1/2 Spacer

s

50

AR N/ 00590-00359-71 S

Spacer

- * Item 5 is opposite side - not shown.

- The Assembly Port Numbers In The Below Chart Represent The Fork Assemblies Part Numbers Only.

- The First Two Part Numbers Shown O n The Illustration Page Are The Trador Assemblies.

N/S= Not Shown

List 6-1 1. Fork And Trador Sub-Assembly -27" Width- Models 6HBE40/6HBC40

P/N

MODEL NO./ FORK LENGTH

ITEM 1

ITEM 22

ITEM 6

ITEM 6B

W/O ITEM

01627

6HBE40 - 84"

01631

None

00665

00667

22

01637

6HBE40 - 96"

01 638

None

00690

00691

22

01 640

6HBC40 - 84"

01 642

01 641

00693

00691

1

01 644

6HBC40 96"

01 656

01645

00712

00713

1

01648

6HBE40 - 84"

01 646

None

00690

00691

22

01651

6HBC40 84"

01 660

01659

00712

00713

1

01655

6HBE40 - 103"

01 649

None

00738

00739

22

01 658

6HBC40 - 103"

01 653

01652

00771

00742

1

-

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ELEVATING

THIS PAGE INTENTIONALLY LEFT BLANK

mymA

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ALPHABETICAL INDEX A Actuator Switch ....................................................3-5, 6-1 7, ............... 6-21,6-25, ............... 6-28 Adapter ......................................................... 5-5 Motor ..................................................... 3-3 Adapter Block (W/ Check Valve) ..................... 5-5 Adjuster Pull Rod .................................................. 6-29 Arm .............................................................. 1-13 Arm Wiring - Cold Storage ............................. 2-3 Armature ...................................................... 3- 1 7 Assembly ....................................................... 6-5 Armature & Fan ...................................... 3-1 5 Axle W/ Grease Fitting (Cold Storage) ...... 1 - 1 7 Axle W/ Grease Fitting (Regular) .............. 1-1 7 Battery Connector - 24V .......................... 4-6, 4-1 2 Bell Crank Sub - L.H. .............................. 6-21, 6-25 Bell crank Sub - L.H. ............................... 6-28 Bell Crank Sub - R.H. .............................. 6-21,6-25, ............... 6-28 Bell Crank Sub, L.H. ................................ 6-1 7 Bell crank Sub, R.H. ................................ 6-1 7 Brake .................................................... 3-3, 3-5 Brush Plate & Box .................................... 3- 15, 3- 1 7 Caster (Heavy Duty) ................................ 1-9, 1-1 1 Caster (Standard) .................................... 1-9, 1 - 11 Controller ............................................... 4-25 Drive Unit ............................................... 3-3 Drive Unit Sub ........................................3-3, 3-5 Drive Wheel ............................................ 3-1 1 Emergency Reverse Module ..................... 4-6, 4- 1 2 Entry Roller ............................................. 6-5, 6-7, 6-9 Final ..................................................... 1-3 Foot Switch (Cold Storage) ...................... 4-21, 4-23 Foot Switch (Standard) ............................. 4-21, 4-23 Handle ................................................... 1-3, 2-7 Heater .................................................... 4- 19 High Power Cable ................................... 4-6, 4- 12 Hose ...................................................... 5-3 Load Wheel ........................................ 6-1 7,6-21, ............... 6-25, 6-28 Motor Sub - All Other Models .................. 3-1 1 Motor Sub Model 6HBW30 ................... 3-1 1 Piston Rod ........................................ 5-6 Pivot Arm ................................................ 1- 15 Pull Rod Fork .......................................... 6-28 Pull Rod Sub ........................................... 6-1 7,6-21, ............... 6-25, 6-28 Rail ........................................................ 1-3 Shroud ................................................... 1-1 7 Spacer ................................................... 4-6, 4- 12 Steering Bearing ..................................... 3-7, 3-9 Suppressor ............................................. 4-7 Switch .................................................... 4-1 9 Switch Bracket ........................................ 4-1 5 Swivel Head ............................................ 1- 15 Tansmission - Model 6HBW30 ................. 3-1 1 Terminal & Lead ..................................... 3-15, 3-17 Trail Fork ................................................ 6-29

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mYmA

Transistor Control .................................... 2-3 Transistor Controller ................................ 2-5 Transmission . All Other Models ...............3-11 Turtle Speed Module ................................ 1-29 Wire Snubber .......................................... 4 7 4-1 3 Yoke ....................................................... 1-13 Axle Oilite Bushing Leg ................................... 1-15 Pivot ....................................................... 1-15 Wheel ..................................................... 1.13

B Backrest 48" ......................................................... 1-33 60" ......................................................... 1-33 Mounting Angle ....................................... 1-37 Backrest Frame . 48" ......................................1-35 Backrest Frame . 60" ...................................... 1-35 Ball ............................................................... 2-7 Ball Joint Brake ...................................................... 2-7 Base Plate Kit W/ 2-5/8" x 3-5/8" Bolt Center ................1-17 W/ 3" x 5" Bolt Center ..............................1-17 Bearing ......................................................... 3.7.3.9. ................3-1 3.3.15. ................6-11 Ball (11/16 Dia.) ..................................... 3-9 Ball (3/4" Dia.) ........................................ 3-9 Flanged Sleeve ........................................ 4. 15 Non-Shielded .......................................... 6-11 Rod ........................................................ 5-6 Shielded ................................................. 6 1 1. 6-1 5 Sleeve ..................................................... 6 1 1.6.15. ................6-1 7.6.21. ................6.25. 6-28 Thrust ..................................................... 1-15 Wheel ................................................... 1 .17 Bearing Cone ................................................ 1-15 Bearing Cup .................................................. 1-15 Block Brake ...................................................... 2-3 Bracket .......................................................... 2 7 4-1 5 Control Moduel ....................................... 4-12 Control Module . All Other Models ........... 4-12 Control Module (All Other Models) ...........4-6 Control Module (Model 6HBW30 Only) ....4-6 Entry Roller .............................................. 6 66.7. - 9 Handle Mounting .................................... 2-7 Switch ..................................................... 4 7 4-1 3 Switch Mounting ...................................... 4-19 Brake Drum Cold Storage ........................................... 3 3 . 3-5 Standard ................................................. 3-5 Brake Drum . Standard .................................. 3-3 Brake Shoe .................................................... 2-9 Brush ............................................................. 3-15 Brush Set ....................................................... 3-17 Brush Spring .................................................. 3-15 Brush Spring Set .............................................

3-17 Bumper .........................................................1-27 Bushing ......................................................... 2-7

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ALPHABETICAL INDEX

TOYrnA

Flanged .................................................. 6- 13 Oilite ...................................................... 1-13 Rework ................................................... 6- 13 Button Horn ....................................................... 4 1 5, 4-1 9 Lift .......................................................... 4-15, 4-19 Lower ..................................................... 4-15, 4-19 Plug ........................................................ 4-25 Rabbit ..................................................... 4-1 9 Safety ..................................................... 4- 15

Operating .............................................. 1-1 9.1.21. ............... 1.23. 1-25 Tow Tractor Warning ............................... 1-1 9.1.21. ............... 1.23. 1-25 9. 1 .21.

Toyota .................................................... 1 - 1 ............... 1.23. 1-25 Turtle Speed ........................................... 1-1 9.1.21. ............... 1.23. 1-25 Warning ................................................. 1-1 9.1.21. ............... 1.23. 1-25

Cable 2-3 Brake ......................................................

Cam ..............................................................2-9 Cam Follower ................................................2-7 Cast Clevis ..................................................... 3-3 Caster Wheel Kit ............................................ - 15 Chain #2 . 24" ................................................. 1-3 1 Channel Brake Handle .......................................... 2-3 Clamp Cable .................................................... 4-21, 4-23 Hose ....................................................... 4-6 Clip ............................................................... 2-9 Coast Installation ........................................... 1-3 Connector Male-0-Ring ........................................... 5-3 Contador Forward .................................................. 4-26 Reverse ................................................... 4.26 Triple Set . 6HBW30 Only ........................ 4-1 2 Triple Set . All Other Models .................... 4-1 2 Triple Set (6HBW30) ................................ 4-6 Triple Set (All Other Models) ..................... 4-6 Controller Motor ............................................... 4 - 6 4- 12 Cover Steering, Machining ................................. 4-1 5 Switch ..................................................... 4 - 1 5 4-19 Top ......................................................... 3-1 3 Cover Channel .............................................. 2-3 Cylinder Hydraulic ................................................ 5-3 Cylinder Packing ............................................ 5-3 Cylinder Retoing Ring ..................................... 5-3 Cylinder Retaining Plate .................................. 5-3 D Decal Coast Safety ............................................ 1-1 9, 1.2 1, ................ 1 .23.1.25. ................ 1-27 Danger ................................................... - 19.1.21. ................ 1.23. 1-25 Emergency Disconnect ............................. 1-1 9.1.21. ................ 1.23. 1-25 Motor Specification ..................................1.1 9.1.21. ................ 1.23. 1-25 N o Riding (9" Black) ................................. 1-1 9.1.21. ................ 1.23. 1-25

E Elbow 45 Degree ............................................. 5-3 90 Degree .............................................. 5-5 90 Degree Male ...................................... 5-3 90 Degree Swivel .................................... 5-3 Entry Roller Installation ................................... 1-3 F Fan ............................................................... 3.15. 3-17 Filler Dash ...................................................... 1-7 Fitting Grease ................................................... 1-1 5. 1.1 7. ............... 3.7.3.9. ............... 6-1 1.6.13. ............................................................. 6-1 5.6.28. ............................................................... 6-29 Grease . 1/4-28 ..................................... 6-1 7.6.21. ............... 6-25 Grease . 1 /4-28 (Straight) ....................... 6-1 7.6.21. ...............6-28 Grease . 65 Degree. 1 /8 ........................ 6-1 7.6.21. ............................................................... 6-25 Grease . 65 Degree. 1/8 PTF .................. 6-28 Grease. 65Degree. 1/8 ......................... 6-17 Grease (Straight) ..................................... 6-15 Foot .............................................................. 4-6 Foot Switch Installation (Cold Storage) ............ 4-12 Foot Switch lnstallation (Cold Storage) (Model 6TB50) 4-6 Foot Switch lnstallation (Cold Storage) (Models 6HBC30 & 6HBC40).... 4-6 Foot Switch Installation (Standard) ................... 4-12 Foot Switch lnstallation (Standard) (Model 6TB50) 4-6 Foot Switch lnstallation (Standard) (Models 6HBC30 & 6HBC40) ......... 4-6 Fork Trail ....................................................... 6-15 Trail Mechanical ..................................... 6-1 1. 6-1 3 Frame Backrest . 48" ......................................... 6-3 Backrest . 60" ......................................... 6-3 Fuse . 15 Amp ............................................... 4.6. 4-12 Fuse . 150 Amp ............................................. 4.6. 4-12 Fuse . 250 Amp ............................................. 4.6. 4-12 G Gear Helical Pinion .......................................... 3.7. 3-9 Potentiometer ......................................... 4-15 Grip Extension ................................................2-5 Hand ..................................................... 1.3. 2.3. 2-5

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ALPHABETICAL INDEX Guard Spring .................................................2-7 H Handle .......................................................... 1-3 Handle Mounting and lnsta11.(6HBW30/6HBE30) 1-3 Harness Contro ................................................... 2-3 Control Arm . Cold Storage ..................... 2-5 Control Arm . Standard ........................... 2-5 Control Arm Wiring . Standard ................ 2-3 Controler . Model 6TB50 (Cold Storage) .. 4- 15 Controler . Models 6HBW30/6HBE30/6HBEW40 4-15 Controller . Models 6HBC30/6HBC40 ..... 4-1 5 Controller (Cold Storage) Models 6HBC30/6HBC40 ............................................................... 4-15 Controller (Cold Storage) Models 6HBW30/6HBE30/6HBE40 ..................... 4- 15 Controller (Standard) Model 6TB50 .........4-1 5 Foot Wiring ............................................ 4.21, 4-23 Main Wiring (Cold Storage) ..................... 4.6. 4-1 2 Main Wiring (Standard) ........................... 4-6 Maine Wiring (Standard) ......................... 4-1 2 Meter ................................................. 4-25 Rail Control ............................................ 4- 19 Helical Gear and Pinion Set ........................... 3.7, 3-9 Hook 5" .......................................................... 1-3 1 Horn .......................................................... 4-1 2 24 Volt ................................................... 4- 12 Horn . 24V .................................................... 4-6 Housing Switch .................................................... 4- 19 Hub Wheel ................................................... 3-1 1 Hydraulic Pump & Motor Assembly . 24 Volt ... 5-3 Hydraulic Sy.tem ........................................... 1-3 I Installation Entry Roller ............................................. 1-3 Foot Switch ............................................. 1-3 Insulator ....................................................4- 15 J Jumper ........................................................ 4-25 K Keyswitch 2 Position ............................................... 1-29 3 Position ............................................... 1-29 Kit Field Coil ............................................... 3- 15 Seal Replacement ................................... 5-6 Spring (Service) ....................................... 1.17 Knob Butterfly .................................................. 2.3. 2-5 Knuckle Guard Machine ................................. 2-5 Knuckle Guard Machining .............................. 2-3 L Latch Flexable ................................................. 4- 12 Lever .............................................................2-9 Parking .................................................. 2-3 Return .................................................... 4-1 5

TOYmA

Load Backrest . 48" ........................................ 1-37 Load Backrest. 60" ........................................ 1-37 Load Wheel Cool . Medium Poly (Tan) ........................6-11 Hard poly (Neutral) ................................. 6-11 Medium Poly (Neutral) ............................. 6-13 Medium Poly (Tan) ................................... 6-11 Split . Hard poly . Black ........................... 6-15 Split. Hard poly (Tan) ............................. 6-15 Split -Soft Poly. Yellow ............................ 6-15 Load Wheel . Hard Poly . Black ...................... 6-13 Load Wheel . Hard Poly . Tan ......................... 6-13 Load Wheel . Soft Poly . Yellow ....................... 6-13 M Machine Brake Lever ............................................. 2-7 Bushing ..................................................2-7 Machining Handle .................................................. 2 3 2-5 L.H. Bell Crank ........................................ 617,6.21, ................6.25, 6-28 Main Case .............................................. 3 7 3-9 Pull Rod .................................................. 617,6.21, ................6.25, 6-28 Pull Rod Fork ........................................... 6-28 R.H. Bell Crank .......................................617,6.21, ................6.25, 6-28 Meter Cudis Battery ........................................... 4-25 Discharge ............................................... 4-25 Hour ....................................................... 4-25 Microswitch .................................................... 3 3 3-5 Module Control .................................................. 4 6 4- 1 2 Horn ...................................................... 4 6 , 4- 12 Motor ............................................................ 3-13 24V DC . 2 Terminal ............................... 5-5 P Pad ............................................................... 2 7 3-3 Back ....................................................... 1.19,1.21, ................1.23, 1-25 Bumper ................................................... 2-7 Leg Guard .............................................. 1.19,1.21, ................1.23, 1-25 Platform .................................................. 1 -1 9, 1.2 1, ............................................................... 1.23, 1-25 Pin ................................................................ 1-1 3,1.27, ...................................................................... 1.31.3.3. ................6-11 1/4 x 1 3/4 ............................................. 6-13 1/ 4 ~.11 /2 ............................................... 6-29 Between Arms ......................................... 1.15 Between Legs .......................................... 1-15 Clevis ..................................................... 2-3 Cotter ..................................................... 3-5 Cylinder Pivot .......................................... 6 1 7.6.21. ............................................................... 6 2 5 6-28 1 1 Eccentric ................................................. 6 -7. 6.2 ...............................................................6-25 Hinge (Cold Storage) ...............................1-17 Hinge (Regular) ....................................... 1-17

.

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ALPHABETICAL INDEX Oilite Bushing Leg ...................................1-1 5 Pull Rod .................................................. 6-28 Roll ........................................................ 2 3 2-7 Spirol ...................................................... 1.31.3.7. 3-9 Spring ..................................................... 4 1 5. 6.1 1. ................ 6-15 Pivot Shaft Handle ...........................................2-7 Plate 2-9 Backing ..................................................

Brake Actuator ........................................2-3 Cover ..................................................... 3 3 9 6-29 Low Lift Spec ...........................................1.19.1.21. ................1.23. 1-25 Top ......................................................... 1-15 Tow Spec ................................................ 1.19.1.21. ................1.23. 1-25 Plug ............................................................... 2 3 2-5 Vent ........................................................ 3 7 3-9 Pocket Manual ................................................... 1 .19.1.21. ................ 1.23. 1-25 Pump ............................................................. 5-5 R Race Inner Bearing .......................................... 3-9 Repair Kit Service .................................................... 4-26 Reservoir ........................................................5-5 Reservoir Kit (Wflubes) ...................................5-5 Ring Retaining ................................................ 1.15 Snap ....................................................... 1.31.3.7. ................ 3.9.3.13. ............................................................... 6 7.6.22. ............................................................... 6 2 5 6-28 Rod Brake Adiusting ....................................... 2-7 Roller ............................................................. 6 5 6.7. 6-9

s

Seal Metal ...................................................... 1.15 Oil .......................................................... 3 - 7 3 9 3-1 3 0-Ring ................................................... 1-15 Seat

Platform (Left Hand) ................................. 1.19. 1.2 1. ............................................................... 1.23. 1-25 Platform (Right Hand) .............................. 1.19. 1.2 1. ................ 1.23. 1-25 Shaft Actuator .................................................. 4- 15 Brake Lever ............................................. 2-7 3-9 Drive Wheel ............................................ 3 Front Fork ........................................ 6 1 7.6.21. ............................................................... 6 2 5 6-28 Rear Fork ................................................ 617.6.21. ...............................................................6 2 6-28 Rear Link ................................................- 1 7.6.21. ...............................................................6 2 5 6-28 Truck Link ........................................6 7.6.25.

TOYrnA

Truck link ................................................ 6-21 Wheel .................................................... 6-1 1.6.13. ............................................................... 6-15 Shield Bearing .................................................. 6-13 Shim Caster .................................................... 1 .9. 1.11 Heavy Duty Caster .................................. 1-11 Pivot Cylinder . 1/4 ................................. 6-1 7.6.21. ............... 6.25. 6-28 Pivot Cylinder . 1/8 ................................. 6-1 7.6.22. ............... 6-25 Pivot Cylinderr . 1/8 ................................6-28 Shim . 2.0 OD ........................................ 3.7. 3-9 Shim . 3.5 OD ............................................... 3.7. 3-9 Shunt Variable Resistor ..................................... 4.6. 4-12 Solenoid ........................................................ 5-5 Solenoid Release Valve/Coil ........................... 5-5 Spacer .......................................................... 1.13.1.15. ..................................................................... 4.7.4.12. ............... 6.13.6.17. .................................................................... 6.22.6.25. .................................................................... 6-29 Hex ........................................................ 4-15 Pull Rod .................................................. 6-22 Spring .................................................... 1-1 5. 2-7 Spiral ............................................................ 3-9 Spiral Gear ................................................... 3.7. 3-9 Spiral Gear and Pinion Set ............................. 3.7. 3-9 Spiral Pinion .................................................. 3.7. 3-9 Spring ........................................................... 1.13.1.15. ..................................................................... 1.27. 3-3 Compression .......................................... 4- 15. 4-19 Cup ....................................................... 1-27 Handle Return ......................................... 2-7 Return .................................................... 2.9. 3-5 Torsion ................................................... 1 .31. 4-1 5 Stop Disk ....................................................... 2-7 Strap Retainer .................................................. 3-11 Sub ............................................................... 1-3 Sub-Assembly Fork and Tractor ..................................... 1-3 Switch ........................................................... 4-1 5.4.21. ..................................................................... 4-23 Emergency Reverse ................................. 4-15 Foot ....................................................... 4-2 1. 4-23 Lift Brake (Standard) ................................ 4-12 Lift Break (Standard) ................................ 4-6 Push Button Control ................................ 4-15 Solenoid Start ......................................... 5-5 T Tee Male Branch ........................................... 5-3 Swivel Run ........................................ 5-3 Tire Poly (Hard/Black) .................................... 3-11 Rubber (Black) ........................................3-11 Tubing

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 ALPHABETICAL lNDEX Polyflo. 27" ...........................................5-3 Polyflo. 8" ..............................................5-3 Ty-Mount Self Adhesive .......................................... 4-12 Ty-Rap Self Locking ........................................... 4.6, 4-12

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Valve Adjustable Relief ..................................... 5-5 Flow Control ........................................ 5-5 Variable Resistor ............................................ 4-15 Vent Plug ....................................................... 5-5 W Weld Tandem. Pivot ......................................... 6-13 Weldment Box & Fork . 24V (24") ............................ 6-21 Box & Fork . 24V. 22" ............................. 6-25 Box & Fork . 24V. 27" ............................. 6-1 7. 6-28 Coast Mount ........................................... 1-27 Coupler .................................................. 1-31 Coupling (Eye & Pin) ............................... 1-31 Fork & Platform . 22" .............................. 6-25 Fork & Platform . 24" .............................. 6-21 Fork & Platform . 27" .............................. 6-1 7. 6-28 Front Rest ............................................... 1.35. 6-3 Latch .................................................... 1-31 Lever ...................................................... 2-3 Link Lever ............................................... 2-3 Sub. Coupling ........................................ 1-31 Swivel ..................................................... 1-27 Tandem Pivot .......................................... 6-28 Tractor Cover ......................................... 1.7 Yoke ................................................... 1-17 Wheel ...................................................... 1.13. 1-17 Woodruff Key ................................................ 3.5. 3-13 #607 ....................................................3-3

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC PART NUMBER INDEX Numerics 00590-00145-71 ............ 4- 15 00590-00002-71 ............ 1.9. 1-1 1 00590-001 46-71 ............ 4-1 5 00590-00006-71 ............ 1-9 00590-001 47-71 ............ 4-15 00590-00008-71 ............1-9 00590-0001 0-71 ............ 6-1 7.6.21 6-25 00590-00011-71 ............ 6-1 1 00590-0001 2-71 ............ 1-1 7.6.1 1 6-1 3. 6-1 5 00590-0001 3-71 ............ 6-1 1 00590-00014-71 ............ 6-1 1. 6-1 5 00590-0001 5-71 ............ 6-1 3. 6-29 00590-0001 7-71 ............ 6-1 1. 6-1 5 00590-0001 8-71 ............ 6-1 1.6.13 6.15. 6.17 6.21. 6.25 6-28 00590-0001 9-71 ............ 6-1 1.6.17 6-2 1.6.25 6-28 00590-00020-71 ............ 6- 1 1 00590-00021 -71 ............ 6-1 5 00590-00024-71 ............ 6-1 7 00590-00025-71 ............ 6- 1 1 00590-00031 -71 ............ 1.35. 6-3 00590-00035-71 ............ 1 -3 1 00590-00040-71 ............1-31 00590-00041 -71 ............ 1-3 1 00590-00042-71 ............ 1-3 1 00590-00043-71 ............ 1-3 1 00590-00044-71 ............ 1-3 1 00590-00045-71 ............ 1-3 1 00590-00050-71 ............ 1-3 1 00590-00051 -71 ............ 1-3 1 00590-00052-71 ............ 1-31 00590-00054-71 ............ 1-3 1 00590-00055-71 ............ 1 -3 1 00590-00060-71 ............ 1-31 00590-00084-71 ............ 3- 11 00590-00085-71 ............ 3- 11 00590-00086-71 ............ 3- 1 1 00590-00087-71 ............ 3-1 1 00590-00088-71 ............ 3- 11 00590-00100-71 ............ 1 .3.2.3. 2.5 00590-00109-71 ............ 2-3 00590-001 14-71 ............ 2.3. 2-5 00590-001 16-71 ............ 2-3 00590-001 17-71 ............ 2-3 00590-001 1 8-71 ............ 6-28 00590-001 21-71 ............ 4- 15 00590-001 22-71 ............ 4-1 5 00590-001 23-71 ............ 4-1 5 00590-00135-71 ............ 4-15 00590-00136-71 ............ 4-15 00590-00137-71 ............ 4-15 00590-001 38-71 ............ 4-15. 4-1 9 00590-00139-71 ............ 4-15 00590-00140-71 ............ 4-15 00590-001 41 -71 ............ 4-15 00590-001 42-71 ............ 4-1 5 00590-00 144-71 ............ 4- 15

00590-001 48-71 ............ 4-15 00590-00 149-71 ............ 4- 15 00590-00150-71 ............ 4.15. 4-19 00590-001 51 -71 ............4-1 5 00590-00154-71 ............ 2-3 00590-001 59-71 ............2-3 00590-001 60-71 ............ 2-3 00590-001 61 -71 ............2-3 00590-00162-71 ............ 2-3 00590-00163-71 ............ 2-3 00590-001 67-71 ............ 2.3. 2-5 00590-001 68-71 ............ 2-3 00590-00169-71 ............ 2.3. 3-5 00590-001 70-71 ............ 2.3. 2-5 00590-001 71 -71 ............2-3 00590-001 72-71 ............2-3 00590-001 93-71 ............ 4-1 5 00590-00196-71 ............ 4-1 5 00590-00197-71 ............ 4-1 5 00590-001 98-71 ............ 2-5 00590-00199-71 ............ 2-5 00590-00205-71 ............ 2-5 00590-00207-71 ............ 1-3 00590-0021 0-71 ............ 6.5.6.7. 6.9 00590-0021 4-71 ............ 1.3. 1-5 00590-002 15-71 ............ 2-7 00590-002 16-71 ............ 2-7 00590-00221 -71 ............ 2-7 00590-00222-71 ............2-7 00590-00224-71 ............ 2-7 00590-00225-71 ............ 2-7 00590-00229-71 ............2-7 00590-00230-71 ............2-7 00590-00231 -71 ............ 2-7 00590-00233-71 ............ 2-7 00590-00234-71 ............ 2-7 00590-00235-71 ............2-7 00590-00237-71 ............ 2-7 00590-00238-71 ............ 2-7 00590-00239-71 ............2-7 00590-00240-71 ............2-7 00590-00241 -71 ............ 2-7 00590-00242-71 ............ 1.3. 1-5 00590-00247-71 ............ 6-1 7.6.22 6.25. 6-28 00590-00248-71 ............6- 17. 6.25 6-28 00590-00249-71 ............ 6.21. 6.25 6-28 00590-00250-71 ............ 6-1 7.6.22 6.25. 6-28 00590-00251 -71 ............ 6-1 7. 6.21 6.25. 6-28 00590-00252-71 ............6-1 7.6.25 6-28 00590-00253-71 ............ 6- 17. 6.2 1 6.25. 6-28 00590-00254-71 ............ 1-3

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 PART NUMBER INDEX 00590-00574-71 ............ 4.6. 4-1 2 00590-00584-71 ............ 4.6. 4- 12 00590-00590-71 ............ 4-6 00590-00592-71 ............ 4-7 00590-00595-71 ............ 4.6. 4- 12 00590-00598-71 ............ 4.6. 4-1 2 00590-00626-71 ............ 6- 17.6.22 6-28 00590-00628-71 ............ 6-28 00590-0063 1-71 ............ 6-28 00590-00633-71 ............ 6-13. 6-29 00590-00634-71 ............ 6-28 00590-00635-71 ............ 6-28 00590-00636-71 ............ 6-28 00590-00664-71 ............6-29 00590-00666-71 ............ 6- 1 7. 6.2 1 6.25. 6-28 00590-00667-71 ............ 6-28 00590-00668-71 ............ 6-28 00590-00669-71 ............ 6- 1 7. 6.2 1 6.25. 6-28 00590-00670-71 ............ 6-28 00590-00672-71 ............ 6-28 00590-00673-71 ............ 6-1 7. 6.21 6.25. 6-28 00590-00675-71 ............ 6-28 00590-00677-71 ............ 6-29 00590-00680-71 ............ 6-29 00590-00682-71 ............ 6-28 00590-00752-71 ............ 1-37 00590-00753-71 ............ 1-37 00590-00755-71 ............ 1-37 00590-00757-71 ............ 1-3 00590-00758-71 ............ 6-7 00590-00759-71 ............ 6-7 00590-00890-71 ............ 6-1 3 00590-00894-71 ............ 6- 13 00590-00895-71 ............ 6-13 00590-00897-71 ............ 6- 13 00590-00901 -71 ............ 6- 13 00590-00971 -71 ............1.35. 6-3 00590-00977-71 ............ 1.35. 6-3 00590-00983-71 ............ 1-33 00590-00985-71 ............ 1-33 00590-00996-71 ............ 6-1 7. 6.22 6-25 00590-00998-71 ............ 6-1 7. 6.21 6-25 00590-00999-71 ............ 6-1 7. 6.21 6-25 00590-01000-71 ............ 6-1 7. 6.21 6-25 00590-01001 -71 ............ 6-1 7. 6.21 6-25 00590-01002-71 ............ 6-1 7. 6.21 6-25 00590-01 003-71 ............ 6-1 7 00590-01 004-71 ............ 6-1 7. 6.21 6-25 00590-01005-71 ............ 6-1 7. 6-25 00590-01006-71 ............ 6-1 7.

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MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 PART NUMBER INDEX 00590-01 345-71 ............ 2-3 00590-04557-71 ............ 5-5 00590-01 346-71 ............ 2-7 00590-01 347-71 ............ 2-3 00590-01 348-71 ............ 2-7 00590-01 349-71 ............ 2-3 00590-01 350-71 ............ 4-15 00590-01 351 -71 ............ 2-7 00590-01 352-71 ............ 2-3 00590-01 353-71 ............ 4- 15 00590-01 359-71 ............ 4.7. 4-1 2 00590-01 360-71 ............ 4.6. 4-1 2 00590-01361 -71 ............ 4-1 2 00590-01370-71 ............ 1.3. 4-6 00590-01 374-71 ............ 4-6 00590-01 377-71 ............ 4.6. 4-1 2 00590-01 379-71 ............ 4.6. 4-1 2 00590-01 383-71 ............ 4-6 00590-01 388-71 ............ 4-6 00590-01 421 -71 ............ 2-5 00590-01 423-71 ............ 2-5 00590-01 429-71 ............ 4-6 00590-01 440-71 ............ 6-5 00590-01 441 -71 ............ 6-5 00590-01 445-71 ............ 5-3 00590-01 446-71 ............ 5-3 00590-01 467-71 ............ 1-7 00590-01 468-71 ............ 1-7 00590-01469-71 ............ 6-1 3 00590-01 538-71 ............ 6-1 1 00590-01 539-71 ............ 3-3 00590-01 554-71 ............ 1.11 00590-01 556-71 ............ 1-1 1 00590-01 587-71 ............ 4.6. 4- 12 00590-01 59571 ............. 4- 12 00590-01 597-71 ............ 4- 12 00590-01 599-71 ............ 4- 12 00590-01 600-71 ............ 4-23 00590-01 603-71 ............ 4-23 00590-01 604-71 ............ 4-23 00590-01 608-71 ............ 6-28 00590-01 61 8-71 ............ 6-1 1 00590-01621 -71 ............ 6-28 00590-01 622-71 ............ 6-1 3 00590-01 623-71 ............ 6-13 00590-01624-71 ............ 6-1 3 00590-01 626-71 ............ 6-28 00590-0451 0-71 ............ 4-26 00590-0451 2-71 ............ 4-26 00590-0451 3-71 ............ 4-15 00590-045 1 5-71 ............ 4- 15 00590-0451 8-71 ............ 2-9 00590-0451 9-71 ............ 2-9 00590-04520-71 ............ 2-9 00590-04521 -71 ............ 2-9 00590-04522-71 ............ 2-9 00590-04523-71 ............ 2-9 00590-04531 -71 ............ 3.7. 3-9 00590-04534-71 ............ 1.19. 1 -25 00590-04544-71 ............ 5-6 00590-04545-71 ............ 5-3 00590-04555-71 ............ 5-5

00590-04560-71 ............ 5-5 00590-04562-71 ............ 5-5 00590-04563-71 ............ 5-5 00590-04564-71 ............ 5-5 00590-04565-71 ............ 5-5 00590-04566-71 ............ 3-15 00590-04567-71 ............ 3-1 5. 3-1 7 00590-04573-71 ............ 3- 13 00590-04574-71 ............ 3-1 5. 3-1 7 00590-04576-71 ............ 3-13 00590-04584-71 ............ 1-15 00590-04585-71 ............ 1.15 00590-04589-71 ............ 1-15 00590-04590-71 ............ 1-15 00590-04591 -71 ............ 1-15 00590-04592-71 ............ 1-1 3. 1-1 5 00590-04593-71 ............ 1-1 3. 1-1 5 00590-04594-71 ............ 1-13 00590-04595-71 ............ 1-1 3. 1-15 00590-04596-71 ............1.15 00590-04597-71 ............ 1-13 00590-04598-71 ............1-13 00590-04600-71 ............ 1-13 00590-04601 -71 ............1-1 3. 1-15 00590-04602-71 ............ 1-1 3. 1-15 00590-04603-71 ............ 1-1 3. 1-1 5 00590-04604-71 ............ 1.13 00590-04624-71 ............ 1-25 00590-04694-71 ............ 1.13 00590-04696-71 ............ 5-5 00590-04697-71 ............ 5-5 00590-0471 5-71 ............ 3-15 00590-0471 6-71 ............ 3-1 5 00590-0471 8-71 ............ 3- 15 00590-04720-71 ............ 3-1 5 00590-04721 -71 ............ 3-1 5. 3-17 00590-04755-71 ............ 1.17 00590-04756-71 ............ 1.17 00590-04766-71 ............ 1.17 00590-04768-71 ............ 1-1 7 00590-04769-71 ............1-1 7 00590-04770-71 ............ 1 -17 00590-04771 -71 ............ 1-1 7 00590-04776-71 ............ 1-1 7 00590-04780-71 ............ 1.17 00590-04781 -71 ............ 5-5 00590-04787-71 ............ 1-1 5 00590-04788-71 ............ 1 - 1 5 00590-04791 -71 ............ 1- 1 5 00590-04792-71 ............ 1-15 00590-04793-71 ............ 1-15 00590-04794-71 ............ 1.15 00590-04797-71 ............ 1.15 00590-04798-71 ............ 1-15 00590-04803-7 1 ............ 1.17 00590-04826-71 ............ 1-1 7 009590-0001 0-71 .......... 6- 17

MODEL 6HBW30/6HBE30/6HBE40/6HBC30/6HBC40/6TB50 PART NUMBER INDEX

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