Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 24000 & up

SERVICE MANUAL Pallet Trucks 6HBW30

24000 and up

6HBE30

24000 and up

6HBE40 6HBC40

24000 and up

6HBC30 6TB50

24000 and up

24000 and up

00700-CL390 Issued: 4/22/02

24000 and up

O 2002 by Toyota Material Handling, U.S.A., Inc. All rights reserved. N o portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher.

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

Toyota Pallet Truck Service Manual

How To Use This Manual Table of Contents

Table of Contents How to Use This Manual

. . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . .1-2 Manual Design . . . . . . . . . . . . . . . . . . .1-3 START Page . . . . . . . . . . . . . . . . . . . . .1-5

Safety

. . . . . . . . . . . . . . . . . . . . . 2-1

Definitions . . . . . . . . . . . . . . . . . . . . . .2-2 General Safety . . . . . . . . . . . . . . . . . . .2-3 Battery Safety . . . . . . . . . . . . . . . . . . . .2-7 Static Safety . . . . . . . . . . . . . . . . . . . .2-11 Jacking Safety . . . . . . . . . . . . . . . . . .2- 13 Tie-down for Transport . . . . . . . . . . . . 2-15 Towing . . . . . . . . . . . . . . . . . . . . . . . .2-15 Welding Safety . . . . . . . . . . . . . . . . . . 2- 16

Systems Overview

. . . . . . . . . . . . 3-1

Truck Model Identification . . . . . . . . . . 3-2 Vehicle Specifications . . . . . . . . . . . . . . 3-3 General System Data . . . . . . . . . . . . . . 3-4 Programmable Maintenance Tool. . . 3-6 Theory of Operation . . . . . . . . . . . . . . .3-7 Freezer Curtain Bypass . . . . . . . . . . 3-7 Lift/Lower . . . . . . . . . . . . . . . . . . . . 3-7

Scheduled Maintenance

....... 4-1

Introduction . . . . . . . . . . . . . . . . . . . . .4-2 Maintenance Guidelines . . . . . . . . . 4-2 General Truck Operation . . . . . . . . . 4-2 Perform Daily or Every Eight (8) Operating Hours . . . . . . . . . . . . 4-3 Perform Every Two Months or 250 Operating Hours . . . . . . . . . . . . 4-4 Perform Annually or Every 2000 Operating Hours . . . . . . . . . . . . 4-5 Lubrication Points . . . . . . . . . . . . . . 4-6

Troubleshooting

............. 5-1

How to Use This Chapter . . . . . . . . . . . 5-2 Electrical Troubleshooting Guidelines. . 5-3 Checking for Shorts from Battery to Truck Frame . . . . . . . . . . . . . . . 5-4 Checking for Shorts from Components to Truck Frame . . . . . . . . . . . . . 5-4 Hydraulic Troubleshooting Guidelines . 5-6

.

Definitions. . . . . . . . . . . . . . . . . . . . . . 5-7 Electrical Connector Locator Chart . . . 5. 10 . 11 Fault Codes . . . . . . . . . . . . . . . . . . . . 5.

Programmable Maintenance Tool . . . . . 5. 12 Diagnostic History . . . . . . . . . . . . .5. 12 .

Test Mode . . . . . . . . . . . . . . . . . . .5. 14 Special Program Mode . . . . . . . . . .5. 16 Programming . . . . . . . . . . . . . . . . .5. 17 .

Cloning . . . . . . . . . . . . . . . . . . . . 5.20 Pin Descriptions . . . . . . . . . . . . . . .5.2 1 List of Troubleshooting Charts . . . . . . .5.23 Hydraulic Charts . . . . . . . . . . . . . .5.23 Travel Charts . . . . . . . . . . . . . . . . .5.23 .

Wiring Charts . . . . . . . . . . . . . . . . 5.23 Troubleshooting Flowcharts . . . . . . . . .5.25 Component Procedures

....... 6-1

List of Component Procedures . . . . . . . .6.2 Component Locators . . . . . . . . . . . . . . .6.5 Tractor Cover . . . . . . . . . . . . . . . . . . . . 6.7 . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . 6.7 With Battery Gates and Rollers. . . . .6.7 Battery Gates (Optional). . . . . . . . . .6.8 Battery Rollers (Optional). . . . . . . . .6.8 Without Battery Gates and Rollers . . 6.9 Battery Exterior Cleaning . . . . . . . .6. 10 . 11 Charging . . . . . . . . . . . . . . . . . . . 6.

Adding Water . . . . . . . . . . . . . . . . .6. 13 Specific Gravity . . . . . . . . . . . . . . .6. 14 Voltage Check . . . . . . . . . . . . . . . .6.15 Maintenance-Free Batteries . . . . . .6.15 . 15 Storage . . . . . . . . . . . . . . . . . . . . 6.

Power Cables . . . . . . . . . . . . . . . . . . . 6. . 16 Battery/Charger/Truck Connectors . . . 6. 16 . 17 Wiring Harness . . . . . . . . . . . . . . . . . 6.

Diodes . . . . . . . . . . . . . . . . . . . . . . . . 6.19 .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 .

Switches (General). . . . . . . . . . . . . . . .6.2 1 Key Switch . . . . . . . . . . . . . . . . . . . . . 6.22 .

Deadman Switch . . . . . . . . . . . . . . . . 6.23 .

Hydraulic Solenoids . . . . . . . . . . . . . . .6.25 Gauges . . . . . . . . . . . . . . . . . . . . . . . 6.26 .

Hour Meter . . . . . . . . . . . . . . . . . . 6.26 .

Battery Discharge Meter . . . . . . . . .6.27

How To Use This Manual

Toyota Pallet Truck Service Manual

Table of Contents

Combination Hour/Battery Discharge Meter (2) . . . . . . . . . . . . . . . . . 6-28 Control Handle . . . . . . . . . . . . . . . . . . 6-31 Return Spring Adjustment 6HBW30 and 6HBE30 or 6HBE40 . . . . . . . . . . . . . . . . . . . . . . . .6-32 Horn . . . . . . . . . . . . . . . . . . . . . . . . .6-33 Motor Controller . . . . . . . . . . . . . . . . . 6-34 Emergency Reverse Check . . . . . . 6-35 Travel Potentiometer . . . . . . . . . . . 6-36 Contactors . . . . . . . . . . . . . . . . . . . . . 6-39 Rabbit Speed (Field Weakening) Contactor . . . . . . . . . . . . . . . . 6-40 Fonvard/Reverse Travel Contactor 6-44 Brake . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Models 6HBW30.6HBE30. 6HBE40 . . . . . . . . . . . . . . . . . . . . . . . .6-49 Models 6HBC30.6HBC40. and 6TB50 . . . . . . . . . . . . . . . . . . . . . . . .6-50 Motors. General . . . . . . . . . . . . . . . . . 6-53 Motor Brushes . . . . . . . . . . . . . . . 6-53 Motor Brush Spring Tension . . . . . 6-55 Commutator . . . . . . . . . . . . . . . . . 6-56 Terminal Nuts . . . . . . . . . . . . . . . 6-57 Electric Motor Tests . . . . . . . . . . . 6-58 Drive Motor . . . . . . . . . . . . . . . . . . . . 6-61 Drive Unit . . . . . . . . . . . . . . . . . . . . .6-65 Tooth Pattern of Drive Unit . . . . . . 6-70 Drive Unit Vent Plug . . . . . . . . . . . 6-72 Drive Housing Lubrication . . . . . . 6-73 Drive Housing Steering Bearing . . 6-74 Drive Wheel . . . . . . . . . . . . . . . . . 6-75 Casters . . . . . . . . . . . . . . . . . . . . . . .6-79 Load Wheels . . . . . . . . . . . . . . . . . . . . 6-84 Load Wheels. Model 6TB50 . . . . . . . . . 6-85

Pallet Entry Wheels/Sliders 8000 Lb. Models . . . . . . . . . . . . . . . . .6.87 Fork Height Adjustment . . . . . . . . . . .6.88 6000 Lb. Models . . . . . . . . . . . . . .6.88 Long-John Models . . . . . . . . . . . . .6.88 Lift-Limit Switch . . . . . . . . . . . . . . . . .6.9 1 Hydraulic Components . . . . . . . . . . . .6-93 General Guidelines . . . . . . . . . . . .6.93 Hydraulic Fluid . . . . . . . . . . . . . . . . . .6-94 Adjusting Hydraulic Pump Relief Valve .

Pressure . . . . . . . . . . . . . . . . . . . . . . 6.96 Relief Valve Settings . . . . . . . . . . . . 6-96 Check Valve . . . . . . . . . . . . . . . . . .6.98 Hydraulic Ram . . . . . . . . . . . . . . . . . .6.99 Hydraulic Cylinder Seals . . . . . . .6. 103 Hydraulic Unit . . . . . . . . . . . . . . . . . .6-106 Hydraulic Reservoir . . . . . . . . . . .6. 107 Filter Screen and Suction Tube . . 6. 108 Hydraulic Pump . . . . . . . . . . . . . .6. 109 Lift Motor . . . . . . . . . . . . . . . . . . . . .6. 110 General Data . . . . . . . . . . . . . . . .6. 110 Cold Storage Conditioning . . . . . . . . . 6. 112 Classes of Cold Storage . . . . . . . .6-112

Appendix

.................. A-1

Lubrication Equivalency Chart . . . . . . .A-2 Torque Chart . Standard (Ferrous). . . . .A-3 Torque Chart . Metric . . . . . . . . . . . . . .A-4 Decimal Equivalent Chart . . . . . . . . . . .A-5 Standard/Metric Conversions . . . . . . . .A-7 Electrical Schematics . . . . . . . . . . . . . .A-9

Index

...................... 1-1

Toyota Pallet Truck Service Manual

How to Use This Manual

How to Use This Manual

Toyota Pallet Truck Service Manual

How to Use This Manual

Map of the Manual

Map of the Manual

1

How to Use This Manual

Table of Contents

u Map of the Manual

Systems Overview

0 1 Manual Design

I

Vehicle Specifications

Start Page

I

General System

Planned Theory of Operations

Trouble-

Component Procedures

Alphabetical List of Component Procedures

Component Location Photos Appendix

D Index

Toyota Pallet Truck Service Manual

How to Use This Manual Manual Design

Manual Design The Toyota Pallet Truck Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise Anticipate your needs and reduce your decisions regarding maintenance Reduce page flipping through a "one-stop shopping" approach

The two-line running page header at the top of each page tells you: Name of the manual (Toyota Pallet Truck Service Manual) Current Chapter Title (for example, this page How to U s e This Manuall Current topic (for example, this page Manual Design)

We suggest you get in the habit of turning to the START page first when you use this manual.

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

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

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

Systems Overview includes truck specifications and theory of operation information.

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

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

How to Use This Manual Manual Design

Chart "TS1: Start Troubleshooting" on page 5-25 will guide you to the individual troubleshooting symptom chart you need.

When you're familiar with the symptoms listed, you may instead simply find the symptom chart from the "List of Troubleshooting Charts" on page 5-23.

When you complete a troubleshooting procedure, be sure to follow the steps in chart "END1: End of Troubleshooting Procedure" on page 5-28.

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

Find the component in the Component Locators (page 6-5).

Look up the component name in the maintenance manual Index.

Appendix contains reference information such as torque values and lubricants.

Index lists subjects alphabetically.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

H o w To Use This Manual START Page

START Page

How To Use This Manual

Toyota Pallet Truck Service Manual

START Page

(

START:

W h y are you here?

Go to Chapter 2 b

"Safety"

Go to Chapter 3 "Systems Overview"

Yes

Go to Chapter 4 "Planned Maintenance"

Go to Chapter 5 'Troubleshooting"

List of Troubleshooting Charts

Go to Chart STAIYT-2

b

STAIYT Troubleshooting

H o w To Use This Manual

Toyota Pallet Truck Service Manual

START Page

No

Go to the Index Yes

b

How To Use This Manual

Toyota Pallet Truck Service Manual

START Page

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Safety

Safety

Safety

Toyota Pallet Truck Service Manual

Definitions

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

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

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

Toyota Pallet Truck Service Manual

Safety General Safety

General Safety

Do not operate or work on this truck unless you are trained, qualified and authorized to do SO.

Know the truck's controls and what they do.

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

Operate this truck only from the operator's position.

Safety General Safety

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

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

Follow the scheduled lubrication, maintenance and inspection steps.

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Safety General Safety

Do not use an open flame near the truck.

Do not use gasoline or other flammable liquids for cleaning parts.

Clean up any hydraulic fluid, oil or grease that has leaked or spilled on the floor.

Always park this truck indoors.

Safety General Safety

Do not wash this truck with a hose.

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Safety Battery Safety

Battery Safety

As a battery is being charged, an ex losive gas mixture forms within and aroun each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the chargin area. An o en flame or spark can ignite t IS gas, resu tlng in serious damage or injury.

B

a!

p.

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. If any electrolyte comes in contact with our clothin or skin, flush the area imme iately with co d water. If the solution gets on our face or in our eyes, flush the area wit cold water an get medical help immediately.

d

9

d'

1

Wear personal protective equipment to protect eyes, face and skin when checking, handling or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields) and a rubber apron.

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

Safety Battery Safety

A battery gives off explosive gases. NEVER

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

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

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

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Safety Battery Safety

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

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

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

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

Safety Battery Safety

Do not permit cleaning solution, dirt or any foreign matter to enter the cells.

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

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

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Safety Static Safety

Static Safety Electronic circuit boards and devices used on the Toyota pallet truck can be damaged by the discharge of static electricity, called electrostatic discharge.

Static charges can accumulate from normal operation of the truck as well as movement or contact between non-conductive materials (plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups, and so on.)

Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without your seeing or feeling it.

When working on or near static-sensitive electronics, always use static discharge precautions.

1. Place a static discharge wrist strap around

your wrist. Connect the ground lead to the wrist strap connector. See Figure 2-1.

2. Connect the ground clamp to an unpainted, grounded surface on the truck frame.

3. If you will be removing or installing static-

sensitive components, place them on a properly grounded static mat.

4. To transport static-sensitive components, including failed components being returned, place the components in an antistatic bag or box (available from your dealer).

The wrist strap and associated accessories must be tested monthly to verify they are working properly. A defective static discharge wrist band will not alert you that it is bad.

Figure 2-2 shows the components of the Toyota antistatic field service kit, P/N 00590-0484971. The kit includes a wrist strap, ground cord and static-dissipative work surface (mat).

Follow the instructions packaged with this kit.

Safety

Toyota Pallet Truck Service Manual

Static Safety

Figure 2-2:

Anti-Static Kit with Wrist Strap and Mat

A wrist strap tester is available as P/N 00590-04850-71.

Contact your local Toyota Dealer for information.

Toyota Pallet Truck Service Manual

Safety Jacking Safety

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

load.

2. Place all controls in neutral.

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

4. Disconnect the battery connector.

5. Place the jack under the designated jacking points. See Figure 2-4.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while 'acking the truck. After the truck is iacke , place solid blocks beneath it to support it. DO NOT rely on the iack alone to support the truck.

d

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

maximum height.

2. Block the fork section as shown in Figure 2-3. The tractor section will remain on the floor.

3. Lower the forks on the blocks.

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

Figure 2-3:

Blocking the Fork Section

Toyota Pallet Truck Service Manual

Safety Jacking Safety

Tractor 1. Place the jack in the designated jacking position. See Figure 2-4.

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

3. Block that side of the truck in place.

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

5. Block that side of the truck in place.

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

Figure 2-4:

Jacking Tractor Section

Toyota Pallet Truck Service Manual

Safety Tie-down for Transport

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

center of the transport vehicle.

2. Using suitable lifting device, remove the battery. See "Battery" on page 6-7.

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

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

5. Position the chain ends of one chain toward the front of the vehicle bed and the chain ends of the other chain to the rear of the vehicle bed and draw taut.

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

6. Secure the battery according to the battery manufacturer's instructions. If equipped, remove the battery cover or storage tray from the top of the battery and store separately.

Towing To safely tow a Toyota pallet truck: 1. Lower the forks and remove any load.

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

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

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

Safety

Toyota Pallet Truck Service Manual

Welding Safety

Welding Safety

Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors. Prior to performing flame cutting or welding o erations, it is recommended that t e coating be removed in the vicinity where the operation(s)will be performed.

R

Coatin removal may be by mechanical metho s, chemical methods or a combination of methods. Flame cutting and/or weldin operations must be carried out only in we I ventilated areas using local exhaust if necessary.

!

9

Before working on this truck, make sure that: Fire protection equipment is nearby.

You know where the nearest eyewash station is.

You turn the key switch OFF and disconnect the battery before you attempt to inspect, service or repair the lift truck.

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

Check for shorts to frame as described on page 5-4. If any shorts are detected, remove them before you proceed with the welding operation.

Clean the area to be welded.

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

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

Do not perform any welding operations near the electrical components.

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

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

Toyota Pallet Truck Service Manual

Systems Overview

Systems Overview

Systems Overview

Toyota Pallet Truck Service Manual

Truck Model ldentification

Truck Model ldentification

Model 6HBC30 and Model 6HBC40 Center Rider

Model 6HBW30 Low-Lift Pallet Truck

Model 6TB50 Tow Tractor

Model 6HBE30 and Model 6HBE40 End Rider

Toyota Pallet Truck Service Manual

Systems Overview Vehicle Specifications

Vehicle Specifications

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

Systems Overview

Toyota Pallet Truck Service Manual

General System Data

General System Data Gauge Console

Grab Bar

Load Wheels Tractor

Figure 3- 1:

Model 6HBE30

Toyota Pallet Truck Service Manual

Systems Overview General System Data

Control Handle

Figure 3-2: Model 6HBC30

Systems Overview

Toyota Pallet Truck Service Manual

Programmable Maintenance Tool

Pro rammable Maintenance Too

f

The optional Programmable Maintenance Tool (P/N 00590-01943-71) permits you to test, diagnose, and program the motor controller in this pallet truck.

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

Figure 3-3:

Programmable Maintenance Tool

Toyota Pallet Truck Service Manual

Systems Overview Theory of Operation

Theory of Operation Freezer Curtain Bypass When the truck is traveling tractor-first, and the horn button on the grab rail is pressed, the emergency reverse switch is disabled until the horn button is released.

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

When the battery is plugged in, the key switch is ON and the lift button is pressed: Lift switch closes.

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

Hydraulic fluid is drawn from the reservoir into the lift pump and is forced into the lift cylinders.

Hydraulic pressure in the lift cylinders raises the forks.

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

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

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

Systems Overview

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

Lowering solenoid opens.

Hydraulic fluid in the lift cylinders returns to the hydraulic reservoir through the flow control valve.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Scheduled Maintenance

Scheduled Maintenance

Scheduled Maintenance Introduction

Introduction Maintenance Guidelines A regularly scheduled maintenance program will ensure: Maximum truck performance Maximum truck life Reduction of costly down time Avoidance of unnecessary repairs Scheduled maintenance includes: Cleaning Inspection Lubrication Service Perform all of the scheduled checks and maintenance during the suggested intervals. the intervals given in this guide are based on normal operating conditions. When operating under abnormal or severe conditions, perform these services more often as required to keep the unit in good operating condition.

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

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

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

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

List repairs required.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Scheduled Maintenance Perform Daily or Every Eight (8) Operating Hours

Perform Daily or Every Eight (8) Operating Hours

Check the weight.

Make sure there are solid electrical connections and no damage.

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

Check that the control handle returns to the vertical position when Check that travel is cut out and the brake is applied when the

Inspect the condition of the drive wheel and load wheels. Remove

General Operation

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

Check the steering operation.

Check the lift/lower functions.

Scheduled Maintenance

Toyota Pallet Truck Service Manual

Perform Every Two Months or 250 Operating Hours

Perform Every Two Months or 250 Operating Hours

Contactor Tips

Drive Unit

Check for dielectric grease when cold storage.

General Operation

Hydraulic System

Motor Brushes

Check the condition of cables and hoses.

Toyota Pallet Truck Service Manual

Scheduled Maintenance Perform Annually or Every 2000 Operating Hours

Perform Annually or Every 2000 Operating Hours

Hydraulic System

Scheduled Maintenance

Toyota Pallet Truck Service Manual

Lubrication Points

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

Figure 4- 1 :

Caster Grease Fittings

Figure 4-2:

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

Figure 4-3:

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

Toyota Pallet Truck Service Manual

Scheduled Maintenance Lubrication Points

Figure 4-4:

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

Figure 4-5:

Drive Unit Grease Fittings (21, 180" Apart (front location shown)

Scheduled Maintenance

Toyota Pallet Truck Service Manual

Lubrication Points

This page intentionally left blank

Toyota Pallet Truck Service Manual

Troubleshooting

Troubleshooting

Troubleshooting How to Use This Chapter

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

Use the TS1: Start Troubleshooting on page 5-25 to guide you to the individual symptom chart you need.

When you are familiar with the symptoms listed, you may instead simply look up the symptom chart from the "List of Troubleshooting Charts" on page 5-23.

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

Every time you complete a troubleshooting procedure, be sure to follow the steps in END1: End of Troubleshooting Procedure chart on page 5-28.

If the troubleshooting symptom charts do not isolate the problem, or if the symptoms are not consistent or repeatable, go to the GEN1: General Troubleshooting chart on page 5-26.

This chart will help you approach the problem in a systematic and logical manner.

Each chart starts with a circular or oval-shaped symbol containing the title and symptom.

Charts are identified as H for Hydraulic and T for Travel. The logic generally flows top to bottom and left to right. A symbol shaped like a baseball home plate means the chart is continued on another page, a continuation of the current chart, or a different chart.

Continuation charts have a suffix number added. A continuation chart starts with a circleshaped symbol containing the chart number, including suffx.

For example, look at H-3: No Lower, Lift and Travel OK chart on page 5-36. One logic path is continued on Chart H-3-2, which is the next page. Another logic path from Chart H-3 goes to the END1: End of Troubleshooting Procedure chart on page 5-28.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. Check the electrolyte level and state of charge. See "Battery" on page 6-7. Be sure to block the truck when a troubleshooting procedure requires turning key switch SW1 ON. This will avoid accidents caused by unexpected truck travel.

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

Electrical current can damage the ohmmeter.

Save time and trouble by looking for simple causes first.

Visually inspect all wiring and electrical components for: Loose connections or connectors Loose or broken terminals Damaged terminals, blocks, or strips Broken wiring and shorted conditions (especially those that are close to metal edges or surfaces) Use an ohmmeter to check for wiring continuity.

For information on pin, connector, and harness connections, see "Wiring Harness" on page 6-17.

Troubleshooting Checking for Shorts from Battery to Truck Frame

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

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

3. Attach the voltmeter leads a s follows:

Negative (-) lead to the truck frame Positive (+) lead to the positive battery terminal The voltmeter must show no more than three volts.

4. Now attach the voltmeter leads a s follows:

Negative (-) lead to the negative battery terminal Positive (+) lead to the truck frame The voltmeter must show no more than three volts.

5. If you get more than a 3-volt reading in Step 3 or 4: a. Remove the battery from the truck. See "Battery" on page 6-7. b. Thoroughly clean the battery (see "Battery Exterior Cleaningn on page 6-10) and battery rollers (see "Battery Rollers (Optional)"on page 6-8). c. Reinstall the battery. d. Repeat steps 2 through 4 to see if this has eliminated the problem. e. If excessive voltage is still found, have the battery checked for internal leakage.

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

2. Use an ohmmeter and measure the resistance to frame a t B+, B- and all fuses.

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Checking for Shorts from Components to Truck

3. Remove the battery from the truck. See "Battery" on page 6-7.

4. Connect the battery lead to the truck.

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

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

Troubleshooting Hydraulic Troubleshooting Guidelines

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

When not performing measurements, keep the key switch OFF and the battery connector disconnected.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Definitions

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

Creep Speed Creep speed is activated when a direction is first selected. It is the speed at the minimum throttle setting (minimum Pulse Width Modulation (PWM)).See "Pulse Width Modulation" on page 5-8. The output maintains creep speed until the throttle is rotated out of the throttle minimum setting (10% of throttle).

Creep speed is adjustable from 0-25% PWM duty cycle.

Deadman Switch The deadman switch is located in the truck and must be closed to permit truck operation. It is activated by the control handle position on the 6HBW30 and 6HBE30 or 6HBE40, and the brake levers on the 6HBC30, 6HBC40, and 6TB50. The deadman switch acts to protect against travel while the brake is applied. The handle must be positioned between 10 degrees of vertical and 10 degrees of horizontal in order for the deadman switch to be closed, permitting travel on the 6HBW30 and 6HBE30 or 6HBE40.

High Pedal Disable The high pedal disable (HPD)feature prevents the truck from being started while the throttle is applied. The motor controller is programmed to have HPD based on the deadman switch input. See "Deadman Switch" on page 6-23.

Open Circuit An open circuit is defined as a lack of a continuous path between two or more electrical connections.

Overtemperature (Motor Controller) Overtemperature of the motor controller is from 85" C (185" F) and above. At overtemperature,

Troubleshooting Definitions

the drive current limit is linearly decreased from full set current down to zero. Plug current is not reduced so as to provide full vehicle braking under all thermal conditions.

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

Ramp Shape Ramp shape is the programmable parameter that determines the static throttle map of the motor controller. Change the ramp shape to adjust throttle sensitivity at low speeds.

Eleven preprogrammed ramp shapes are available between 20% and 70%, in 5% steps.

For example, 2096, 2596, 3096, and so on.

The ramp shape number refers to the PWM output a t half throttle, as a percentage of its full range. See "Pulse Width Modulation" on page 5-8. Changing the maximum speed setting or the creep speed setting changes the output range of the controller. See "Creep Speed on page 5-7. Ramp shape output is always a percentage of that range.

Higher settings result in faster starts, lower settings result in slower starts. The factory default value is 50%.

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

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

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Definitions

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

The programmable maintenance tool recognizes different types of SRO. The Toyota pallet truck is Type "1" in the programming mode.

Sequencing Delay This permits the deadman switch to be momentarily opened within a set time and prevents inadvertent activation of high pedal disable (HPD) or static return to off (SRO).See "Static Return to Off' on page 5-9. This feature is useful in applications where the deadman switch may bounce or be momentarily cycled during operation. The delay can be set from 0 to 3 seconds; 0 corresponds to no delay.

Throttle Map The throttle map is the relationship between the speed/directional control rotation and truck response. It is adjustable so you can provide the correct feel for each truck.

The throttle map adjustment is called "ramp shape." See "Ramp Shape" on page 5-8.

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

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

Troubleshooting Electrical Connector Locator Chart

Electrical Connector Locator Chart Refer also to the electrical connector locator photos. See "Component Locators" on page 6-5.

Table 5- 1: Electrical Connector locator Char1

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Fault Codes

Fault Codes An internal microcontroller automatically

checks the function of the motor controller.

When this microcontroller detects a fault, it signals the appropriate fault code through the LED on the bottom of the motor controller. See Table 5-2.

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

Correct faults by following the troubleshooting charts (see "Troubleshooting Flowcharts" on page 5-25).

Figure 5- 1 : Table 5-2: Fault codes

Motor Controller / LED Reference

Troubleshooting

Toyota Pallet Truck Service Manual

Programmable Maintenance Tool

Programmable Maintenance Tool The optional Programmable Maintenance Tool (P/N 00590-01943-71) permits you to test and diagnose the motor controller in a Toyota pallet truck. See Figure 5-2.

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

When the PMT is first plugged into the controller, the PMT displays the controller's model number, date of manufacture, and software revision code. See Figure 5-3.

Following this initial display, the PMT displays a prompt for further instruction.

NOTE: Follow the prompt at the top of the PMT screen, not the blinking icon, to choose the correct setting.

Figure 5-2:

Programmable Maintenance Tool

Diagnostic History You can use the Programmable Maintenance Tool (P/N 00590-01943-71) to access the diagnostic history file of the motor controller.

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

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

A high pedal disable (HPD)or overtemperature fault may be caused by operator habit or overloading.

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

Figure 5-3: Connecting the PMT to the Motor Controller

Toyota Pallet Truck Service Manual

Troubleshooting Access

Access 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Connect the battery and turn the key switch ON.

5. Hold the More Info key, and press the Diagnostics key.

Clear After you have diagnosed and corrected the problem, you must clear the diagnostic history file. This permits the motor controller to accumulate a new file of faults. By checking the new history file at a later date, you can easily determine whether the problem was completely f~ed.

1. Hold the More Info key, and press the Program key. Release the two keys after you enter the Special Program mode.

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

3. Press the More Info key again. The PMT will prompt you to acknowledge or cancel.

4. Press the Value Up key to clear the

diagnostic history. Press the Value Down key to cancel.

Toyota Pallet Truck Service Manual

Troubleshooting Test Mode

Test Mode This section shows you different modes you can use on the PMT to troubleshoot a Toyota pallet truck.

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

2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

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

5. Press the test key on the PMT. 6. Scroll through the line items using the two scroll display keys. See Table 5-3. When the item you want is the top line on the display, press the More Info key for a full screen display.

Table 5-3: Test Modes

input a t PMC3. If truck does not have coast

Toyota Pallet Truck Service Manual

Troubleshooting Test M o d e

The Diagnostics and Special Diagnostics list displays the possible messages you might see when the PMT is operating in the Diagnostic History or the Test mode. See Table 5-4. The messages are listed in alphabetical order for easy reference.

Table 5-4: Diagnostics and Special Diagnostics List

Troubleshooting Special Program Mode

Special Program Mode The chart below shows you line items in the Special Program Mode.

Access 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Connect the battery and turn the key switch ON.

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

6. See Table 5-5. Scroll through the line items using the two Scroll Display keys until the item you want to change is the top line on the display.

7. Press the two Change Value keys until you

reach the value you want.

Table 5-5: Special Diagnostics list

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Troubleshooting Programming

Programming You can change some parameters using the PMT. See Table 5-6. All changes occur in "real time;" the parameters can be changed while the truck is in operation.

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

2. Remove the tractor cover.

3. Connect the PMT to the motor controller.

4. Connect the battery and turn on the key

switch.

5. Press the program key to enter the Program mode.

6. Press the two scroll display keys until the parameter you want is the top line of the display. See Table 5-6.

7. Press the two Change Value keys until the

setting you want is displayed. The parameter is now set at the value you selected.

8. If the display stops changing and you want to go further, press the More Info key. If the

display shows "Min Limit" or "Max Limit." you have reached the factory set limit for that parameter.

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

See "Definitions" on page 5-7

Troubleshooting

Toyota Pallet Truck Service Manual

Programming

Table 5-6: Motor Controller Parameters

Adjust desired PWM output at 50% throttle to adjust throttle sensitivity at low speeds.

See Caution on

See Caution on

See Caution on

Toyota Pallet Truck Service Manual

Troubleshooting Programming

A CAUTION While adjustment of these parameters is possible, settings at values other than those listed below will produce incorrect and unauthorized operational characteristics. DO NOT adjust these parameters to values other than those listed below: Creep SpeedlMin. Duty Cycle must be set to

0% Sequencing Delay may only be adiusted between 0.0 seconds and 0.3 seconds.

Variable Plug must be set to ON.

Troubleshooting

Toyota Pallet Truck Service Manual

Cloning

Cloning With the Programmable Maintenance Tool (PMT),P/N &590-0 1943-71, you can copy or "clone" the parameters and options from one motor controller to another. Cloning only works between controllers with the same model number and software version.

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

2. Turn the key switch ON. 3. Connect the PMT to the motor controller you want to clone. See Figure 5-4.

4. Press and hold the More Info key, then press the Program key. Release the two keys after you enter the Special Program mode.

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

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

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

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

3. Turn the key switch ON.

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

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

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

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

prompt you to acknowledge (load programming settings in controller) or cancel.

Figure 5-4: Connecting the PMT to the Motor Controller

Toyota Pallet Truck Service Manual

Troubleshooting Pin Descriptions

Pin Descriptions An integrated 24-pin low power connector, molded into the front of the motor controller, provides the low power logic control connections.

Pin connections in use are described below:

NOTE: PMC-1 is the same a s pin reference number 1 in Figure 5-5.

PMC-1: key switch input (KS1) PMC-2: brake input PMC-18: forward contactor driver output PMC-19: reverse contactor driver output PMC-22: field weaken contactor PMC-14: travel: pot low PMC-16: travel: pot wiper PMC-10: forward input PMC-11: reverse input PMC-6: emergency reverse input PMC-24: emergency reverse check output PMC-3: high speed

Figure 5-5: Motor Controller / PMC Pin References

Troubleshooting

Toyota Pallet Truck Service Manual

Pin Descriptions

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Troubleshooting List of Troubleshooting Charts

List of Troubleshooting Charts TS1: Start Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 . .

GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 .

MISC: Miscellaneous Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

Hydraulic Charts H-1: No Lift. Lift Motor Does Not Run. Travel is OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29 H-2: No Lift or Slow Lift. Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 H-3: No Lower. Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36

Travel Charts T- 1: No Travel. Lift/Lower OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-2: No Travel in Either Direction. Lift/Lower OK. Fault Code 3.1. . . . . . . . . . . . . . . . . . . . . .

T-3: No Travel in Either Direction. Lift/Lower OK. Fault Code 1.3. . . . . . . . . . . . . . . . . . . . . .

T-4: No Travel in Either Direction. Lift/Lower OK. Fault Code 1.2 . . . . . . . . . . . . . . . . . . . . . .

T-5: No Travel. Fault Code 3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-6: Travel in One Direction Only. Fault Code 3.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-7: No Travel. Fault Codes 2.1 or 2.4 (or both) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

T-9: No Emergency Release. Travel/Lift/Lower OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-10: Slow Travel. Lift/Lower OK. Fault Code 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T- 11: No Rabbit Speed. Travel/Lift/Lower OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-12: No Travel. Fault Code 4.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-13: Slow or No Travel. Fault Code 4.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-14: Slow or No Travel. Fault Code 4.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-15: No Travel. Fault Code 1.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-16: No Travel. Fault Code 2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-17: No Travel. Fault Code 3.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-18: Plugging Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-19: Truck Does Not Accelerate Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Charts W- 1: Truck Functions Partially . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Toyota Pallet Truck Service Manual

Wiring Charts

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

Troubleshooting Flowcharts

( T S1: START TROUBLESHOOTING

functions OK?

No

functions OK?

0

No

v

Go t o Chart

Yes

17 6 Go to Chart

Go t o Chart

Go t o Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

GEN1: General Troubleshooting

1

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

What is the problem?

Eliminate unlikely causes.

Where did it happen?

When did it happen?

What functions are affected?

Select and prioritize the most likely causes.

What conditions trigger the problem?

Talk directly to the operator or foreman.

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

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

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

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

~ I S CMiscellaneous : Problems Not Covered By 0the;\ Charts

problem suspected?

j Go to Chart

+J Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

(END1: End of Troubleshooting Procedure 1 Make sure ALL wires, hoses, and cables that you removed have been re-attached correctly.

Operate the tmck a s it was being operated when the problem occurred.

Ven@the problem does not recur.

Make sure all panels are properly reinstalled.

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

.

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

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

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

( End of Troubleshooting )

I

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

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

Travel is OK.

Using optional lift cutout?

Check Battery.

Procedures

Using schematics a s a guide, check the following switches and associated wiring:

With key switch ON and lift switch depressed, measure voltage between pump contactor coil X and Y terminals.

SWlO lift cutout switch SW12 lift switch SW15* lift switch (rail) M 3 coil *End rider models, with grab bar switches

Go to Chart H-1-4

Yes

With battery plugged in, measure voltage between Band FU1-2.

Is B+ voltage present?

Yes

Go to Chart H-1-2

Replace Fuse FU 1.

6 Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

With key switch ON and lift switch depressed, measure voltage across B- and lift pump motor MP-1 I terminal.

I

With key switch OFF and battery disconnected, check for continuity and wiring shorts between FU 1-2 to pump contactor; pump contactor to pump motor.

With key switch OFF and battery disconnected, check lift motor brushes.

Are cables OK?

No+

Yes

Go to Chart H-1-3

Replace brushes.

No+

Repair or replace.

Replace pump contactor.

0 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

Test pump motor.

See Component F'rocedures.

.

6 Is motor OK?

Replace motor.

Yes

I

With key switch OFF and battery disconnected, remove motor from pump.

See Component Procedures. Turn pump shaft with hand.

Does pump run

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

Go to Chart

No

b

Replace pump.

troubleshoot in^

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

e N o + y q Is wiring OK?

yes

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

With forks lowered, key switch OFF, battery disconnected and lift ccut-out switch closed (normally closed), check for continuity in lift cut-out switch.

Go to Chart H-1-5

0 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

Yes

With key switch OFF, battery disconnected and wires removed, measure resistance oi pump contactor coil.

Yes

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

Go to Chart

6 I

Go to Chart

0 I

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

H-2: No Lift or Slow Lift,

Check for any mechanical binding in lift linkage.

Yes

t With key switch OFF and battery disconnected, check the lift motor and brushes. See Component Procedures.

Yes

6

Check hydraulic pressure. See relief valve settings in Component

I

Go to Chart

I Go to Chart

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

If you return here, go to General Troubleshooting.

.

Go to Chart

.

Toyota Pallet Truck Service Manual

Troubleshooting

Troubleshooting Flowcharts

Adjust lift pressure.

See Component Procedures.

correct pressure?

Yes

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

With key switch OFF, battery disconnected, and forks lowered, remove pressure relief valve and check for signs of damage or contamination.

yes

Yes

Flush system.

Replace hydraulic fluid. See Component F'rocedures.

p Go to Chart

I

Yes

Flush system.

Replace hydraulic fluid. See Component procedures.

0 Go to Chart

I

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

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

With battery connected, key switch ON, while pressing lower switch(es), measure voltage across load holding solenoid 1: SOL1-X to SOL1-Y.

Using schematics a s a guide, check the following switches and associated wiring:

PNO SW 11 Lower switch SW14* lower switch (rail) SOL1 coil

Is B+ present?

(* end rider models with grab

bar switches)

Yes

v

With key switch OFF, battery disconnected, loosen, b u t DO NOT REMOVE, one of the high pressure lines a t the hydraulic pump assembly.

Allow forks to slowly lower. Have rags and drain pan ready to catch fluid.

7 Do forks lower?

A

Repair mechanical binding in lift cylinders or fork Component hocedures.

Yes

I

With key switch OFF and battery disconnected, while pressing switches, check for continuity and shorts across: lift switch and grab bar lift switch* (*end rider models only.)

6 Go to Chart

I I

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

Allow forks to completely lower.

Remove and inspect Solenoid 1 for free movement and for I signs of contamination.

Replace or repair

Clean Solenoid 1.

Remove contamination. Flush hydraulic system, clean filter and install new fluid.

n Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

VeriQ the problem still exists. Repeat H-3.

If you return here, go to General Troubleshooting.

&J Go to Chart

0 Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

T-1: No Travel, Lift/Lower OK. Directional Contactors Do Not Close.

Motor Controller LED is Flashing Once Every 2 Seconds.

Check the battery.

See component procedures.

Charge or replace the battery.

Yes

1

Check the battery terminals and quick disconnect plug.

With key OFF, battery disconnected and control handle in operating position, disconnect wires at deadman switch.

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

See PMT section in Troubleshooting.

Go to Chart T-1-2

'Programmable Maintenance Tool

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

With key OFF and battery disconnected, check for continuity and wiring shorts between: SW1-BAT on key switch (switch closed/on) to SW2-C SW2-NO to M1 -R Terminal X M1 -R Terminal X to M1 -F Terminal X MI-F Terminal X to PMC-2

adiust deadman switch S2 actuator.

With battery connected, key switch ON, and deadman closed, check for B+ at PMC-2.

PMT1 can be used here. See PMT section

'Programmable Maintenance Tool

~

I

Yes

v Go to Chart T-1-3

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

v Go to Chart

I/ Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

f With truck jacked and blocked, battery plugged in, key switch ON and handle in travel position: measure voltage a t PMC10 (with reference to B-) while rotating throttle in forward direction.

PMT1 can be used here.

See PMT section in Troubleshooting.

'Programmable Maintenance Tool

Using schematics a s a guide, check the following switches and associated wiring: Is B+ present?

SW2 brake switch SW3 forward switch SW4 reverse switch

Yes

1 Replace motor controller.

Yes

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

With key switch OFF, battery disconnected and FWD and REV switches alternately closed, check for continuity and wiring shorts between: FWD SW-C to FWD SW NO (SW3) REV SW-C to REV SW NO (SW4)

I

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

u Go to Chart

rJ Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Trowbleshooting Flowcharts

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

A With key switch OFF and battery disconnected, remove connector PMC from motor controller.

Measure resistance, and check for shorts i n wiring harness between: PMC-2 to PMC-18 PMC-2 to PMC-19

f

\

T

Replace motor controller.

6 Go to Chart

With key switch OFF and battery disconnected, remove connector PMC and check for I continuity and wiring shorts I between:

I

PMC-2 to FWD Contactor-X PMC-2 to REV Contactor-X PMC-19 to REV Contactor-Y PMC-18 to FWD Contactor-Y

I

Disconnect and measure resistance of FWD and REV contactor coils.

6 Go to Chart

I Programmable maintenance I tool can be used here. See PMT section in

vNO /

resistance approx. 30

\

Replace coils.

1

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

u Go to Chart

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

(

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

With key switch OFF and battery disconnected, disconnect drive motor cable a t motor controller terminal M-. Connect battery, turn key switch ON.

Yes

V Go to Chart

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

Go to Chart

0 I

Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

T-4: No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 1,2

Replace motor controller.

\I Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

-6: Travel in One Direction Only.

Motor Controller Fault Code 3.1.

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

Measure resistance between: PMC-2 to PMC-18 PMC-2 to PMC-19.

Check for wiring shorts to frame.

'Programmable Maintenance Tool

.

Yes

1

With key switch OFF and battery disconnected, check for continuity and wiring shorts between: PMC-2 to FWD Contactor-X PMC-2 to -REV Contactor-X No+ PMC-19 to REV Contactor-Y PMC-18 to FWD Contactor-Y PMT1 can be used here.

See PMT section in Troubleshooting.

No+

+

Yes

Replace motor controller.

Q Go to Chart

V

Go to Chart

Measure resistance of forward and reverse contactor coils.

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

No+

Repair or replace.

No+

Replace coil(~).

Repair or replace.

& Go to Chart

exists. Repeat T-6.

If you return here, go to General Troubleshooting

Go to Chart

Go to Chart END 1

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

T-7: No Travel. Directional Contactors DO Close.

Motor Controller Fault Codes 2.1 or 2.4 (or Both).

(

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

Measure resistance between PMC-14 to PMC-16 while slowly rotating throttle in both directions.

PMT1 can be used here.

See PMT section in Troubleshooting.

'Programmable Maintenance Tool

7 With key switch OFF and battery disconnected, check for continuity and wiring shorts between: PMC-16 to JP6-4 JP6-4 to VF-2 VF-4 to JP10-6 JP6-5 to PMC-14

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

Repair or replace.

Replace motor controller.

6 0 Go to Chart

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

.

With key switch OFF and battery disconnected, remove connector PMC from motor controller and measure resistance of throttle potentiometer between 7 - 4 to VF-2.

Does from 0-6K ohms i n each

Replace throttle potentiometer.

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

51 Go to Chart

v Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

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

\

+

1

Charge or replace battery.

Verify battery is charged.

No

1 With key switch ON, measure voltage a t PMC-3 (WRT B-) to verify truck is operating in high speed mode.

Programmable maintenance tool can be used here.

Yes

+

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

No

7

Go to Chart

Procedures. Use the maintenance tool

Go to Chart

1 No

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

4 No

Yes

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

Check for continuity and wiring shorts between: PMC-3 and B+ using wiring diagram (schematic) for specific model of truck.

With key switch OFF and battery unplugged, remove connector PMC from motor controller. Measure resistance between PMC-14 to PMC-16 while slowly rotating throttle i n both directions.

PMT1 can be used here.

See PMT section in Troubleshooting.

1

+ v Go to Chart

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

Is wiring OK?

Yes

Go to Chart T-8-5

Go to Chart T-8-3

'Programmable Maintenance Tool

Repair or replace.

Yes

Verify the problem still exists. Repeat T-8. If you return here, go to General Troubleshooting.

With key switch OFF and battery disconnected, check No for continuity and wiring shorts between: PMC-16 to JP6-4 JP6-4 to JP10-5 JP10-5 to VR-2 VR-4 to JP10-6 JP10-6 to JP6-5 JP6-5 to PMC-14.

from 0-6K ohms

No+

Repair wires.

j Go to Chart

V

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

Yes

A With key switch OFF and battery disconnected, check the drive motor brushes. See Component Procedures.

Yes

With key switch OFF, test drive motor. See Component Procedures.

Go to Chart T-8-4

6 Go to Chart

1 I

Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

Is drive motor

drive motor.

Yes

I

I

v

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

Turn the brake drum by hand.

Remove drive motor from drive unit. See Component Procedures.

With key switch OFF, remove brake drum.

See Component Procedures.

No

will the drum

still exists. Repeat T-8. If you return here, go to General Troubleshooting.

armature shaft

armature shaft

Yes

Yes

No

Repair or replace drive motor.

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

.

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

Measure resistance of throttle potentiometer between: JP6-4 to JP6-5.

Verify the problem still exists. Repeat T-8. If you return here, go to General

0 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

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

1 With truck iacked and blocked,-battery connected, key switch ON and handle in travel position; measure voltage a t PMC-6 (with reference to B-) while pushing emergency reverse switch.

PMT can be used here.

See PMTl section in Troubleshooting.

Using the schematics a s a guide, check the following switches and associated wiring: SW2 brake switch SW8 switch SW13* horn switch (rail) #end rider models with grab bar switches

Yes

1 Replace motor controller.

n Go to Chart

Yes

I

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

I

With key switch OFF, I battery disconnected and PMC disconnected; check for continuity of emergency reverse switch (SW7) between: C (Common) and NO (Normally Open) while holding switch closed.

Verify the problem still exists. Repeat T-9.

If you return here, go to General

Q Go to Chart

0 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

.

/ T-10: Slow Travel, Lift/Lower OK. Speed Limited to 151. Motor Controller Fault Code 2.2 ( ~ m e r g e nReverse c~ Circuit Fault).

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

Measure resistance between PMC-24 to PMC-6.

PMT1 can be used here.

See PMT section in Troubleshooting.

Programmable Maintenance Tool

I

With key switch OFF, battery disconnected and PMC disconnected, check for continuity and wiring shorts between: PMC-24 to JP6-8 JP6-8 to (ER) SW7-NO (ER)SW7-NO to JP6-7 JP6-7 to PMC-6.

Yes

I

Yes

Go to Chart

still exists. Repeat T-10. If you return here, go to General Troubleshooting.

j

0 Go to Chart

I

j Go to Chart

\ ) ,

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

1: No Rabbit Speed (Field Weakening), Travel/Lift/Lower OK. No Fault Codes.

NOTES:

/ 1) Rabbit speed only operates in the tractor /

/first (forward) direction.

I

2) End Rider models are equipped with "latched" rabbit speed buttons. Press and release the button to enable rabbit speed.

Rabbit speed is disabled by applying the brake or returning the throttle to neutral.

I

/ 1 / .---------------------------------------------------------/

0 Yes

Go to Chart

I

-

Yes Field weakening will be engaged if: 1) Max speed is set a t 100% 2) Field weakening is enabled in Motor Controller 3)Throttle input is a t 100% 4) Drive motor armature current is less than 150 Amps.

Note: Field weakening will be disengaged if armature current reaches 220 Amps.

Verify conditions 1, 2, and 3*using PMT. See PMT section in Troubleshooting.

* If Programmable Maintenance Tool is not available, see Component Procedures, Throttle Potentiometer.

I

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

C Go to Chart

Yes

Using clamp on Ammeter, verify armature current draw.

current within

No

4 See Component Procedures for motors.

Yes

v

With key switch OFF, battery disconnected, and PMC disconnected, check for continuity and wiring shorts between: PMC-22 to M2-Y M2-X to JP4-6

v JP4-6 to SW16A-4 SW16A-4 to SW16B-4 JP4-7 to SW16A-3 SW16A-3 to SW16B-3 OR JP4-6 to SW17-C JP4-7 to SW17-NO

' ' '

I J P ~ - 7 to PMC-10

GO to Chart

I Grab bar switch o n end rider models Foot bar switch o n center rider models

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

Yes T

With key switch OFF and battery disconnected, disconnect field weakening contactor coil a t M2-X and M2-Y and measure resistance of field weakening contactor coil between: M2-X to M2-Y.

yes

+

With key switch OFF, battery disconnected, PMC disconnected and rabbit switch depressed, check for continuity of rabbit switch between: SW16A-3 to SW16A-4l SW16B-3 to SW 16B-4l or SW17-C to SW17-NO2

Grab b a r switch o n end rider models.

Foot switch on center rider models.

0 Go to Chart

; Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

1 With key switch OFF and battery disconnected, check the field weakening contactor tips. See Component Procedures.

Is contactor OK?

No

or replace + Repair contactor.

Yes

+

With key switch OFF and battery disconnected, check for continuity and wiring shorts i n field weakening resistor R1, b u s bars, and cables between R1 and weakening contactor.

b u s bars, and

No+

Repair or replace.

Yes

1 Replace motor controller.

4

v

v

Go to Chart

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

T-12: No Travel. Motor Controller Fault Code 4,2 Excessive Battery Voltage (Greater than 45 Volts) ,)

VeriQ the correct battery is installed in IV]

Ek

PMT1 red here. See PMT section in Troubleshooting.

F'rogrammable Maintenance Tool

yes

L Never plug charger into truck.

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

6 Go to Chart

Replace with correct

1 Replace motor controller.

b

Q Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

13: Slow or No Travel Motor Controller Fault Code 4,l- Low Battery Voltage (Less than 16 Volts).

Yes

Check the battery terminals and quick disconnect plug.

0 I

Go to Chart

connectors

Yes

Go to Chart T-13-2

3 Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

With key switch OFF and battery disconnected, check for continuity and wiring shorts between:

B-BAT to Motor Controller BB+BAT to FU2-1 FU2-1 to FU2-2 FU2-2 to Motor Controller B+

'

Programmable Maintenance Tool

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

vN 1 ol Are wires and

Yes

Replace motor controller.

Repair oi replace.

0 I

Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

{T- 14: Slow or No Travel.

Motor Controller Fault Code 4,3 - Thermal Cutback.

Check the battery.

See Component Procedures.

< Is battery OK? +Nc Yes

Check for free movement or mechanical binding of load wheels.

5 I

Go to Chart

77 7 Yes

I

Go to Chart T-14-2

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

l With truck jacked and blocked, key switch OFF and battery disconnected, release the brake by pulling the handle down into the operating position.

Turn the brake drum

With key OFF, remove brake drum. See Component Procedures.

armature shaft turn freely?

n Yes

Go to Chart T-14-3

Remove the drive motor from the drive unit. See Component Procedures.

Yes

1 Repair, adjust, or replace the brake.

.,Go to Chart

armature shaft turn freely?

Yes

Repair or replace the drive unit.

\I Go to Chart

Repair or replace the drive motor.

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

operated under conditions extreme for its intended

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

Yes

4 Operate and load within specifications.

correctly?

Yes

Q Go to Chart

1 Replace motor controller.

Go to Chart

6 Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

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

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

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

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

NOI NO^ -

/ Was proper \

I

T

L--Alo

+Lo-

I

apply """"' throttle. u'cLL

.

Yes

With key switch ON and battery plugge in, measure voltage at: PMC-10 and PMC-1 1 (with reference to B-).

PMT1 can be used here.

See PMT section in Troubleshooting.

Yes

1 Go to Chart

j Go to Chart

'

Programmable Maintenance Tool

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

The motor controller is receiving a direction command on Pin PMC-10 or PMC- 1 1, before the handle is lowered.

With key switch OFF, battery disconnected and PMC disconnected from motor controller, check for continuity and wiring shorts between: PMC-11 to JP6-3 JP6-3 to REVERSE SW(SW4)-NO PMC-10 to JPS-4 JPS-4 to JP6-2 JP6-2 to FORWARD SW(SW3)-NO

Go to Chart T-15-3

0 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

With key switch OFF and battery disconnected, measure resistance of FORWARD (SW3)and REVERSE (SW4)switches between: NO to C

ohmmeter read

Yes

Verify that the problem still exists, Repeat T-15. If you return here, go to General Troubleshooting.

Q Go to Chart

No

b

Replace switches.

Q Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

-

Troubleshooting Flowcharts

T-16: No Travel, Motor Controller Fault Code 2,3- High Pedal Disable. ........--------..........-------:Condition: Throttle circuit j :was active prior to the j handle being lowered (brake : j switch closing).

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

followed?

Yes

potentiometer.

See Component I F'rocedures.

Programmable maintenance tool can be used here. See PMT section in Troubleshooting.

Lower handle, then apply throttle.

6 I

Go to Chart

Adjust or replace potentiometer

Go to Chart T- 16-2

potentiometer.

See Component F'rocedures.

6 Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

With key switch OFF and battery disconnected, and PMC disconnected from motor controller, check for continuity and wiring shorts between: PMC-16 to JP6-4 JP6-4 to VF-2 VF-4 to JP6-5 JP6-5 to PMC-14.

Yes

1 Replace motor controller.

Go to Chart

6 Go to Chart

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

T-17: No Travel, Motor Controller Fault Code 3,2 (Directional Contactor Stuck in Closed Position).

C With key switch OFF and battery disconnected, check for continuity and wiring shorts of drive motor cables between: drive motor and directional contactors.

With key switch OFF and battery disconnected, check directional contactor tips. See Component

Are tips OK?

Yes

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

Replace tips or contactor.

0

Yes

Go to Chart

Go to Chart

Q Go to Chart

Yes

3 Go to Chart

0 I

Toyota Pallet Truck Service Manual

Troubleshooting Troubleshooting Flowcharts

6 1 8 : Plugging Does Not Operate Properly.

Truck Travels OK i n Forward and Reverse.

With key switch OFF, check brushes and motor.

See Component

Yes

6 Go to Chart

p Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

T-19: Truck Does Not Accelerate Proper

Check to see if the battery is charged.

QN0qq Charge or replace

Yes With key switch OFF and battery disconnected, check throttle potentiometer adjustment. See Component

Yes

a I

Go to Chart

I

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

With key switch OFF and battery disconnected, check for a mechanical reason for slow acceleration.

(Draggingbrake, defective wheel bearing, bad load wheel, etc.)

1 Repair as required.

v Go to Chart

With key switch OFF and battery disconnected, check motor and brushes.

See Component F'rocedures.

Toyota Pallet Truck Service Manual

.

Troubleshooting

Troubleshooting Flowcharts

{1

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

Visually check the wiring in the handle and where the wiring leaves the handle.

Look for damage to the wiring.

\

Yes

I

Use a DVM and check for continuity of wires per the schematic.

Use a DVM and check for continuity of wires in the handle per the schematic.

continuity measurements

Repair or replace

Yes

I

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

Yes

wiring and connectors in the area of the motor controller.

0 I

Go to Chart

Q Go to Chart

Go to Chart

Troubleshooting

Toyota Pallet Truck Service Manual

Troubleshooting Flowcharts

This page intentionally left blank

Toyota Pallet Truck Service Manual

Component Procedures

Component Procedures

Toyota Pallet Truck Service Manual

Component Procedures List of Component Procedures

List of Component Procedures

Assembly. Casters . . . . . . . . . . . . . . . . . . 6-81

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Adding Water . . . . . . . . . . . . . . . . . . . 6-13 Charging . . . . . . . . . . . . . . . . . . . . . . 6-11 Exterior Cleaning . . . . . . . . . . . . . . . . 6- 10 Gates . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 Gates and Rollers . . . . . . . . . . . . . . . . . 6-7 Maintenance Free. . . . . . . . . . . . . . . . 6-15 Rollers . . . . . . . . . . . . . . . . . . . . . . . . .6-8 Specific Gravity . . . . . . . . . . . . . . . . . 6- 14 Storage . . . . . . . . . . . . . . . . . . . . . . . 6-15 Voltage Check . . . . . . . . . . . . . . . . . . 6-15 Without Gates and Rollers . . . . . . . . . . 6-9 Battery/Charger/Truck Connectors . . . . . 6-16 Brake. . . . . . . . . . . . . . . . . . . . . . 6-49 to 6-52

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Assembly . . . . . . . . . . . . . . . . . . . . . . 6-81 Wheel Replacement . . . . . . . . . . . . . . 6-79 Cold Storage . . . . . . . . . . . . . . . . . . . . . 6-112 Commutator . . . . . . . . . . . . . . . . . . . . . . 6-56 Contactors . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Forward/Reverse Travel . . . . . . . . . . . 6-44 Rabbit Speed . . . . . . . . . . . . . . . . . . . 6-40 Control Handle . . . . . . . . . . . . . . . . . . . . 6-31 Covers Tractor . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Deadman Switch . . . . . . . . . . . . . . . . . . . 6-23 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

E Emergency Reverse Check . . . . . . . . . . . . 6-35

Filter Screen . . . . . . . . . . . . . . . . . . . . . 6-108 Fork Height Adjustment . . . . . . . 6-88 to 6-90 6000 Lb. . . . . . . . . . . . . . . . . . . . . . . 6-88 8000 Lb. . . . . . . . . . . . . . . . . . . . . . . 6-90 Long-John Models . . . . . . . . . . . . . . . 6-88 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Hydraulic Components General . . . . . . . . . . . . . . . . . . . . . . . 6-93 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 6-94 Hydraulic Pump . . . . . . . . . . . . . . . . . . 6-109 ~ G d r a u l i cRam . . . . . . . . . . . . . 6-99 to 6- 102 Hydraulic Reservoir. . . . . . . . . . . . . . . . 6-107 Hydraulic Solenoids . . . . . . . . . . . . . . . . 6-25 Hydraulic Unit . . . . . . . . . . . . . . . . . . . 6-106

Key Switch . . . . . . . . . . . . . . . . . . . . . . . 6-22

Lift Limit Switch . . . . . . . . . . . . . . . . . . . 6-91 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 6-110 Load Wheels . . . . . . . . . . . . . . . . . . . . . . 6-84 Model 6TB50 . . . . . . . . . . . . . . . . . . . 6-85

M Maintenance Free Batteries . . . . . . . . . . . 6-15 Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Motor Controller . . . . . . . . . . . . . . . . . . . 6-34 Motors Brush Spring Tension . . . . . . . . . . . . 6-55 Brushes . . . . . . . . . . . . . . . . . . . . . . 6-53

Toyota Pallet Truck Service Manual

Component Procedures List of Component Procedures

Commutator . . . . . . . . . . . . . . . . . . . .6-56 Drive . . . . . . . . . . . . . . . . . . . . . . . . .6-61 General . . . . . . . . . . . . . . . . . . . . . . .6-53 Lift . . . . . . . . . . . . . . . . . . . . . . . . . .6-110 Tests . . . . . . . . . . . . . . . . . . . . . . . . .6-58

Solenoids Hydraulic . . . . . . . . . . . . . . . . . . . . . . 6-25 Suction Tube . . . . . . . . . . . . . . . . . . . . . 6-108 Switches Deadman . . . . . . . . . . . . . . . . . . . . . . 6-23 General . . . . . . . . . . . . . . . . . . . . . . . 6-21 Key . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 Lift Limit . . . . . . . . . . . . . . . . . . . . . . 6-91

Pallet Entry Wheels/Sliders . . . . . . . . . . . 6-87 Power Cables . . . . . . . . . . . . . . . . . . . . . .6- 16

Relief Valve . . . . . . . . . . . . . . . . . . . . . . .6-96 Return Spring Adjustment . . . . . . . . . . . . 6-32

Seals Hydraulic Cylinder . . . . . . . . . . . . . . 6-103 Sliders Pallet Entry . . . . . . . . . . . . . . . . . . . .6-87

Terminal Nuts . . . . . . . . . . . . . . . . . . . . . 6-57 Tractor Cover . . . . . . . . . . . . . . . . . . . . . . 6-7 Travel Potentiometer . . . . . . . . . . . . . . . . 6-36

Wheels Caster . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Load . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Pallet Entry . . . . . . . . . . . . . . . . . . . . 6-87 Wiring Harness . . . . . . . . . . . . . . . . . . . . 6-17

Component Procedures

Toyota Pallet Truck Service Manual

List of Component Procedures

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Component Procedures Component Locators

Component Locators

II

II

Contactors Page 5-39

L\

Drive Wheel Page 5-75

Figure 6- 1:

Inside Tractor, Model 6HBE30/6HBE40 Shown

I

Component Procedures

Toyota Pallet Truck Service Manual

Component Locators

Lift Motor '

Page 5-110

Relief Valve

' Page 5-96

Fill/Vent Plug

Lift Limit

Page 5-94

Switch Page 5-9

:iller Port 'age 5-94

Hydraulic Reservoir Page 5- 107

Figure 6-2:

H y draulic Components

Toyota Pallet Truck Service Manual

Component Procedures Tractor Cover

Tractor Cover Remova 1 To take off the tractor cover, remove the two screws from the top of the cover and the two screws from the bottom of the cover. Lift the cover slightly outward and upward from the truck to avoid the handle assembly.

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

A CAUTION Before working on the battery, review Battery Safety, starting on Page 2-7.

Batteries may weigh more than 1,000 pounds (454 kg). Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

The Toyota pallet truck may be equipped with optional battery rollers and side gates for ease of battery removal and replacement.

With Battery Gates and Rollers Remova 1 1. Drive the truck to the battery exchange location and a s close to the battery replacement device a s possible.

2. After the truck is stopped and the handle is returned to the full up (brake on) position, turn the key switch OFF.

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

Component Procedures Battery Gates (Optional)

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

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

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

Installation 1. With a fully charged and tested battery on

the replacement device, position the replacement device at the truck in accordance with the manufacturer's recommendations.

2. Position the battery in the compartment. Be sure the battery has no more than 0.50 inch (12.7 mm) of "free play" movement in the battery compartment.

3. Install the side gate. See "Battery Gates (Optional)"on page 6-8. Move the lifting

device from the area.

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

Baltery Gates (Optional) Inspection Inspect the battery gates for bending or cracks.

Replace if necessary.

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

Toyota Pallet Truck Service Manual

Component Procedures

Toyota Pallet Truck Service Manual

Without Battery Gates and Rollers

Without Battery Gates and Rollers Remova1 1. Drive the truck to the battery exchange location and as close to the battery lifting device a s possible.

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

4. Position the battery lifting device in

accordance with the manufacturer's recommendations.

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

6. Remove the battery by lifting straight up.

7. Place the discharged battery on the charging stand.

Installation Figure 6-3:

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

2. Lower the battery and position it in the compartment. Be sure the battery has no more than 0.50 inch (12.7 mm) of "free play" movement in the battery compartment.

3. Move the hoist from the area.

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

operation.

Removing Battery with Hoist

Component Procedures

Toyota Pallet Truck Service Manual

Battery Exterior Cleaning

Battery Exterior Cleaning 1. Inspect the battery.

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

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

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

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

Figure 6-4:

Battery Filler Plugs and Vent Holes

Toyota Pallet Truck Service Manual

Component Procedures Charging

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

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

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

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

1. Familiarize yourself with:

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

3. Consult your battery and battery charger

manufacturer's manual for specific charging procedures.

4. Wear personal protective equipment. See "Battery Safety" on Page 2-7.

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

Component Procedures Charging

6. Inspect the battery.

7. Check the electrolyte level in each cell.

Electrolyte must cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. See "Adding Water" on page 6- 13.

Electrolyte level will increase during charging.

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

9. Check and record the voltage of each cell.

10. To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged will decrease battery life. At maximum recommended discharge, the specific gravity must read 1.150 or less.

11. Make sure that filler plugs are clean and vent holes are open. Tighten all filler plugs.

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

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

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

14. If, after charging, the electrolyte level is below the cells, add water to put it above the splash plate about 1/8 in. See "Adding Water" on page 6-13. Do not overfill the cells or permit electrolyte to spill on the battery case.

In general, a lead-acid battery may be charged at any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 110° F (430 C).

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Adding Water

Temperatures of 1200 F (490 C) are permitted only for short periods of time.

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

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

Before charging, make sure battery plates are covered with electrolyte. Add water, if necessary, only to cover the splash plate by 1/8 in.

Electrolyte level increases during charging.

To avoid overflow, add water after charging, and after hydrometer and voltmeter readings are taken, to about 1/8 in. above the splash plate.

Keep the outside of the battery case clean and dry.

Component Procedures Specific Gravity

Specif ic Gravity Specific gravity readings for lead-acid batteries with electrolyte temperatures at 80° F (270 C) change with the state-of-charge. See Table 6-1.

Table 6- I : Specific Gravity

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

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

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

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

3. Leave the hydrometer nozzle in the battery

and read the specific gravity of the cell.

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

Charge the battery, then take readings.

5. Record the specific gravity reading on the battery chart.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Voltage Check

Voltage Check Take a voltage check on each cell after performing the specific gravity check on page 6-14. Connect the leads of a voltmeter to the positive and negative terminals of each cell. Voltage readings will change with the state-of-charge. See Table 6-2.

Table 6-2: Voltage Readings

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

Maintenance-Free Batteries Your truck may be equipped with a maintenance-free battery, in that case, the specific gravity need not be checked. Please follow manufacturer's recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery must be kept clean and dry and may be washed to remove any accumulated foreign matter. See "Battery Exterior Cleaning" on page 6-10.

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

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

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

Component Procedures Power Cables

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

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

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

Battery/Charger/Truck Connectors Connectors must be checked for: Cracks Damage Worn Contacts Repair or replace any defective components a s required.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Wiring Harness

Wiring Harness Terminology The term "connector JW means a mated connector consisting of two connector halves.

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

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

For example, connector JP2 is the mated connector in the control handle. 52 represents the jack connections. P2 represents the pin connections.

See Table 6-3 to locate the electrical connectors on the truck.

Table 6-3: Electrical Connector Locator Chart

Component Procedures Wiring Harness

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

Carefully mate and unmate all connectors.

Do not pry apart connectors with unspecified tools.

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

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

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

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

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

There must be a wire marker at each termination. If the marker is missing or unreadable, remark the wire to permit easier identification.

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Diodes

Diodes A CAUTION Use the correct precautions against electrostatic discharge. See "Static Safety" on page 2-1 1.

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

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

Electrical current can damage the ohmmeter.

Replace the entire assembly if defective diodes are found.

Positive lead (+) Negative lead 4-1 Simpson 260 Multimeter Reading Digital Multimeter Reading

Anode Cathode 8-30 ohms

Cathode Anode Infinity

0.3 - 1.O V

Infinity

Component Procedures

Toyota Pallet Truck Service Manual

Fuses

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

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

Use an ohmmeter set to R x l scale and measure the resistance across the fuse. The resistance must be less than one ohm.

Figure 6-5: Fuse location

Toyota Pallet Truck Service Manual

Component Procedures Switches (General)

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

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

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

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

Component Procedures Key Switch

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

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

the two terminals of the switch.

2. Disconnect the battery; test the key switch with an ohmmeter after removing the wires from the switch terminals. In the OFF position, the ohmmeter must read greater than one megohm, and in the ON position, the ohmmeter must read less than one ohm. If not, replace the switch.

Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Remove the mounting nut from the stem of

the key switch.

4. Remove the key switch.

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

Installation 1. Connect the wires to the terminals.

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

3. Reconnect the battery connector and check key switch operation.

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

5. Install tractor cover.

6. Reconnect the battery connector.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Deadman Switch

Deadman Switch Adjustment The deadman switch is located near the brake adjusting rod, above the drive motor. See Figure 6-6.

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

2. Remove the tractor cover.

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

Figure 6-6:

Deadman Switch, 6HBW30 and 6HBE30 or

6 HB €40

4. Using the nuts on the barrel of the deadman switch, adjust the switch so that power is disconnected when: For 6HBW30 and 6HBE30 or 6HBE40 models, the handle is approximately 10 degrees from fully raised or fully lowered. See Figure 6-6.

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

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

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

5. Test operate the truck.

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

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

Figure 6-7:

Deadman Switch, PMCR30 or PMCR40 and

PM 190

Component Procedures Deadman Switch

Remova1 1. Lower the forks completely.

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

3. Remove the tractor cover.

4. Disconnect the wires on the deadman switch.

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

6. Remove the deadman switch.

Installation 1. Mount the deadman switch to the mounting

bracket.

2. Connect the wires to the deadman switch.

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

5. Adjust switch if necessary. See "Deadman Switch on page 6-23.

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

7. Install the tractor cover.

8. Reconnect the battery connector.

Toyota Pallet Truck Service Manual

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Solenoids

Hydraulic Solenoids Remova1 1. Make sure that the forks are fully lowered.

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

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

4. Remove the nut holding the solenoid coil to

the solenoid valve.

5. Lift the solenoid coil off the solenoid valve.

6. Remove the solenoid valve from the manifold.

Installation 1. Inspect the seat where the solenoid seals

against the manifold. The sealing surface must be completely clean and free from any nicks or damage.

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

3. Thread the solenoid valve into the manifold.

Torque the solenoid valve to 25 ft. lb. (35 Nm).

4. Install the solenoid coil on the solenoid valve and tighten the nut.

5. Connect the wires to the terminals.

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

7. Turn the key switch OFF. Disconnect the

battery.

8. Install any covers that were removed.

Figure 6-8:

H y draulic Solenoids

Component Procedures Gauges

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

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

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

If the meter does not log hours, verify that B+ is present on pin 3 when the deadman is closed (the handle is in drive position). If voltage is not present, use the schematic in the Appendix and trace B+ to the source (deadman switch).

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

Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Remove the wires from the rear of the gauge

and make careful note of their orientation.

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

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Battery Discharge Meter

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

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

3. Connect the wires to the correct terminals.

4. Reconnect the battery connector and test operation.

5. Install the tractor cover.

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

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

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

Remova1 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the wires from the rear of the meter and make careful note of their orientation.

4. Remove the two mounting nuts and slide off

the mounting bracket.

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

Component Procedures Combination Hour/Battery Discharge Meter (2)

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

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

3. Connect the wires to the correct terminals.

4. Reconnect the battery connector and test operation.

5. Install the tractor cover.

Combination Hour/Battery Discharge Meter (2) Low Battery Lift Cut-out (optional) The Toyota pallet truck may be equipped with a low battery lift cut-out feature as part of the battery discharge/hour meter package. This feature prevents the forks from being raised when the battery reaches a programmable level of discharge. This feature maintains a minimum (reserve)level of battery charge to enable the truck to return to the battery area for charging or replacement of the battery.

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

Hour Meter

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

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Combination Hour/Battery Discharge Meter (2)

Battery Discharge Meter

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

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

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

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

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

Component Procedures Combination Hour/Battery Discharge Meter (2)

Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Remove the connector from the rear of the

meter.

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

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

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

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

3. Plug the connector in the meter.

4. Reconnect the battery connector and test

operation.

5. Install the tractor cover.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Control Handle

Control Handle Figure 6-9 and Figure 6-10 shows the control handle assembly for the various models.

Figure 6-9:

Control Handle Assembly, Models 6HBW30 and 6HBE30 or 6HBE40

Figure 6-1 0: Control Handle Assembly, Models 6HBC30 or 6HBC40 and 61650

Toyota Pallet Truck Service Manual

Component Procedures Return Spring Adjustment 6HBW30 and 6HBE30 or 6HBE40

Return Sprin Adjustment 6HBW30 an 6HBE30 or 6HBE40

3

Handle Pivot

Trucks Without Coast

\ i

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

r

Trucks With Coast Coast spring cannot be adjusted. Adjust preload on handle return spring so the brake does not drag with the coast control engaged.

This must provide enough preload for the handle to return to the vertical position when released from any position.

piut &# LOC~

8,s

8,s

8,s

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

I

-\

Handle Return Spring Adjusting Screw

Figure 6- I I : Return Spring Adjustment

Component Procedures

Toyota Pallet Truck Service Manual

Horn

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

Remova1 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the two wires from the horn.

See Figure 6- 12.

4. Remove the horn mounting bolt. See Figure 6-12.

Installation 1. Attach the horn to the tractor frame and tighten the mounting bolt. See Figure 6-12.

2. Attach the two wires.

3. Reconnect the battery connector and test operation.

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

5. Install the tractor cover.

6. Reconnect the battery connector.

Figure 6- 12: Horn Location

Component Procedures

Toyota Pallet Truck Service Manual

Motor Controller

Motor Controller

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

Cleaning 1. Turn the key switch OFF and disconnect

the battery connector.

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

Figure 6- 13: Motor Controller Connections

3. Remove any dirt or corrosion from the bus bar area. Wipe the controller with a moist rag. Permit it to dry before connecting the battery.

4. Make sure the bus bars are tight. Use two wrenches to avoid stressing the bus bars and putting undue strain on internal connections.

Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Push the locking tab and disconnect the PMC connector (control wires) from the motor controller.

4. Disconnect the cables from the M- terminal on the motor controller. Use two wrenches to avoid stressing the bus bars. See Figure 6- 13.

5. Disconnect the three bus bars (terminals B+, B-, and A2) on the motor controller. Use two wrenches to avoid stressing the bus bars. See Figure 6- 13.

6. Remove the four hex head cap screws securing the motor controller to the truck frame, and pull the controller out. See Figure 6-14.

Figure 6-14: Removing the Motor Controller

Toyota Pallet Truck Service Manual

Component Procedures Emergency Reverse Check

Installation 1. Secure the motor controller to the truck frame with the four previously removed hex head cap screws. See Figure 6-14 on page 6-34.

2. Connect the three bus bars on the motor controller terminals B+, B-, and A2.

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

3. Connect the power cable to the M- terminal on the motor controller. Use two wrenches to avoid stressing the bus bars. See Figure 6-13 on page 6-34.

4. Connect the PMC connector (control wires) to the motor controller.

5. Connect the battery connector and turn the key switch ON. 6. Test operation. See "Programmable Maintenance Tool" on page 5-12.

7. Disconnect the battery connector and turn the key switch OFF. 8. Install the tractor cover.

9. Connect the battery connector.

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

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

See "Wiring Harness" on page 6-17.

Component Procedures

Toyota Pallet Truck Service Manual

Travel Potentiometer

Travel Potentiometer The travel potentiometer is a two-wire potentiometer that connects between the 6,500 ohm-0/0-5,000 ohm pin (PMC-16)and the Pot Low pin (PMC-14). Zero speed corresponds to 0 ohm and full speed corresponds to 6,500 ohms.

Figure 6- 15 shows the potentiometer connections.

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

2. Jack and block the truck. See "Jacking Safety" on page 2-13.

3. Disconnect the handle harness connector

(JPCG)at the bottom of the handle prior to adjustment. This will ensure that feedback from other circuitry in the truck will not effect ohmmeter readings.

4. Remove the four screws from switch cover on the underside of the handle/arm assembly. Lay back the cover to access the 5. To electrically center the potentiometer, place the control assembly handle in the neutral position and disengage the potentiometer gear from the actuator cam assembly gear.

6. Connect the ohmmeter to pins VR-2 and VR-4. Measure potentiometer resistance while rotating the potentiometer gear until the ohmmeter reads as close to zero ohms as possible. A paint dot, if present on the shaft and bushing, must line up for reference.

7. Engage the potentiometer gear with the

actuator cam assembly gear.

Figure 6- 15: Travel Potentiometer Connections

Toyota Pallet Truck Service Manual

Component Procedures Travel Potentiometer

8. With the ohmmeter still connected, verify that the forward and reverse positions have the same comparative potentiometer resistance, by rotating the control assembly handle fully in the two directions. Record the maximum resistance value in the two directions. The difference between the two readings must be 200 ohms or less. An example follows:

If the difference between the two readings is greater than 200 ohms, check to be sure the potentiometer is electrically centered (refer to step 6).

9. Reconnect the JPC6 connector. Reconnect

the battery connector. Turn the key switch ON. NOTE: The remaining steps of this procedure permit a final check of the potentiometer and to make adjustments if necessary, before the switch cover is installed.

10. While holding the actuator cam assembly in place, slowly rotate the assembly to activate a directional switch and contactor.

11. Slowly rotate the actuator cam assembly in the opposite direction. Again, observe the brake drum rotation. If the potentiometer is properly centered, the brake drum rotation must be nearly the same in the two directions. If no further adjustments are needed, go to step 15.

NOTE: If there is noticeable difference in the rotation (speed)in the two directions, further potentiometer adjustment is necessary.

Component Procedures Travel Potentiometer 12. Pull down gently on the actuator cam

assembly, enough to disengage the gear from the potentiometer gear.

13. Turn the potentiometer gear one tooth, in

relation to the mating gear of the actuator cam assembly.

14. Re-engage the two gears by holding the

actuator cam assembly in place and rotating the control handle assembly just enough to activate a directional contactor.

Check the brake drum rotation for the two directions.

NOTE: This may require repeating until you are sure as to which way to turn the potentiometer. It may even require rechecking with the meter.

15. Reattach the switch cover on the underside of the handle/arm assembly.

NOTE: Jack the truck and remove the blocking.

16. Test the truck's operation.

17. Turn the key switch OFF and disconnect

the battery connector.

18. Install the tractor cover.

19. Reconnect the battery connector.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Contactors

Contactors Tip Inspection When you inspect contactor tips, follow these guidelines (see Figure 6-16): Darkened points do not indicate burning.

Burning indicates a loss of contact point material.

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

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

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

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

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

Figure 6- 16: Severely Pitted Contactor Tips

Component Procedures

Toyota Pallet Truck Service Manual

Rabbit Speed (Field Weakening) Contactor

Rabbit Speed (Field Weakening) Contactor Models 6HBE30,6HBE40,6HBC30,6HBC40 and 6TB50 Assembly Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires on the X and Y terminals. Note the location for the correct installation later. See Figure 6-17.

Figure 6- 17: Rabbit Speed Contactor

4. Remove the nuts holding the bus bar and cable to the contactor. See Figure 6-18.

Figure 6- 18: Disconnecting Bus Bar From Contactor

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

Figure 6- 19: Removing Contactor Assembly From Frame

Toyota Pallet Truck Service Manual

Component Procedures Rabbit Speed (Field Weakening) Contactor

Tip Removal 1. Remove the contactor assembly. See

"Assembly Removal" on page 6-40.

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

Lift out the moving contact assembly from the magnet frame assembly. See Figure 6-20.

Figure 6-20: Disassembling Contactor Assembly

Figure 6-2 1 : Removing Brass Lock Nuts

5. Remove the lock washer.

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

Figure 6-22: Removing Fixed Contacts

Component Procedures

Toyota Pallet Truck Service Manual

Rabbit Speed (Field Weakening) Contactor

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

2. Install the lock washer and M 8 brass lock nut and torque to 70 to 84 in-lbs (8 to 9.5 Nm).

A CAUTION Using more torque than 84 in. Ib. (9.5 Nm) may damage contactor.

Figure 6-23: Installing the Fixed Contacts

3. Insert the moving contact assembly into the coil and frame.

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

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

6. Test coil resistance.

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

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

2. Remove the tractor cover.

3. Disconnect the two wires from the contactor. These wires are marked with an X and Y.

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

5. The reading must be 28.5 to 30.5 ohms.

Figure 6-24: Rabbit Speed Contactor Components

Toyota Pallet Truck Service Manual

Component Procedures Rabbit Speed (Field Weakening) Contactor

Assembly Installation

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

Figure 6-25: Installing Rabbit Speed Contactor

2. Secure the bus bar and cable to the contactor with the nuts. See Figure 6-26.

Figure 6-26:

Securing Bus Bar to Contactor

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

See Figure 6-27.

4. Install the tractor cover.

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

Figure 6-27: Connecting Wires to Contactor

Component Procedures

Toyota Pallet Truck Service Manual

Forward/Reverse Travel Contactor

Forward/Reverse Travel Contactor Assembly Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires from the X and Y terminals on the contactor coils. Note the location of the wires for correct installation later. See Figure 6-28.

4. Remove the four bolts securing the bus bars and cables to the contactor. Note the location for assembly later. See Figure 6-28.

Figure 6-28: Disconnecting FWD/REV Travel Contactor

5. Remove the two screws holding the contactor assembly to the frame. See Figure 6-29.

Tip Removal 1. Remove the contactor assembly. See "Assembly Removal" on page 6-40.

Figure 6-29:

Removing Contactor Assembly

2. Loosen and remove the three top cover screws. See Figure 6-30.

3. Hold the contactor together so that it does not fall apart. Turn it upside down and place it on a work bench so it rests on its f ~ e contacts. d

Figure 6-30: Removing Top Cover

Toyota Pallet Truck Service Manual

Component Procedures Forward/Reverse Travel Contactor

4. Separate the magnet frame assembly from the top cover assembly. See Figure 6-31.

Figure 6-3 1 : Separated Contactor Assembly

5. Remove the normally-closed fixed contact insulator and the pegs from the top cover assembly. See Figure 6-32.

6. Remove the normally-closed fixed contact from the top cover assembly. This will permit the moving contacts to lift up on one side and expose the return springs. See Figure 6-33.

Figure 6-32: Removing the Fixed Contact

7. Insert a thin screwdriver or similar

instrument into the coils of the return spring and depress the spring to take the pressure off the moving contact.

8. This permits you to remove the moving contact sideways from the top cover assembly.

Figure 6-33: Accessing the Return Springs

Component Procedures

Toyota Pallet Truck Service Manual

Forward/Reverse Travel Contactor

9. Remove the two return springs from the top cover assembly. See Figure 6-34.

Tips Installation 1. Place the top cover assembly upside down

on a work bench so it rests on its fixed contacts.

2. Place the two return springs into the recesses in the top cover.

3. Use a thin screwdriver or similar instrument to depress the return spring.

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

Figure 6-34: Return Springs and Moving Contacts

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

4. Repeat step 3 with the other moving contact assembly.

5. Place the normally-closed fxed contact in its correct position in the inverted top cover.

See Figure 6-35.

6. Place the normally-closed fxed contact insulator into the top cover assembly, and add the two pegs in the insulator and the normally-closed fxed contact.

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

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

Figure 6-35: Assembling Top Cover Assembly

Toyota Pallet Truck Service Manual

Component Procedures Forward/Reverse Travel Contactor

8. With the top cover positioned on the coil frame, position the contactor assembly with the coil frame down. See Figure 6-36.

Figure 6-36: Assembling the Contactor

Insert the three screws into the top cover and tighten to 16 to 20 in. lb. (1.8 to 2.3 Nm). See Figure 6-37.

A CAUTION not over-tighten the screws.

Make sure the moving contacts are sitting d firmly on the normally-closed f ~ e contact and there is sufficient spring pressure.

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

12. Test the coil resistance.

Figure 6-37: Securing Top Cover Assembly

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

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

2. Remove the tractor cover.

3. Disconnect the two wires from the contactor. These wires are marked with an X and Y.

4. Connect one lead of the ohmmeter to the X terminal of the contactor. Connect the other lead to the Y terminal of the contactor. See Figure 6-38.

5. The reading must be 28.5 to 30.5 ohms.

Figure 6-38: Testing Coil Resistance

Component Procedures

Toyota Pallet Truck Service Manual

Forward/Reverse Travel Contactor

Assembly Installation 1. Secure the contactor assembly to the frame with the two screws. See Figure 6-39.

2. Install the cap screw securing the bus bar to the motor controller.

3. Install the bolts and cables to the bus bars

on M1-2 and M1-3.

A CAUTION More than 84 in. Ib. (9.5 Nm) of torque may damage the contactor.

4. Install the bus bar connected to the field

weakening contactor.

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

6. Install the tractor cover.

7. Connect the battery connector and turn the key switch ON. 8. Test operation of the truck.

Figure 6-39: Installing the FWD/REV Contactor

Toyota Pallet Truck Service Manual

Component Procedures Brake

Brake Models 6HBW3Ol6HBE30, 6HBE40

A CAUTION Permit the brake to cool completely before servicing.

I

(

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

2. Loosen lock nuts on each side of the brake rod. See Figure 6-40.

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

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

5. Adjust the spring screw if necessary. See Figure 6-40. The compressed length of spring when brakes are on (handle vertical) must be 1.94 in. (49 mm).

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

Lock Nut

Remova1 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the control handle.

A CAUTION Do not stick any objects in the drive motor fan.

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

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

6. Remove brake rod.

Figure 6-40:

Brake Adjustment

Lock Nut

Component Procedures

Toyota Pallet Truck Service Manual

Models 6HBC30, 6HBC40, and 6TB50

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

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

9. Remove the shoe springs. See Figure 6-41.

10. Remove the brake shoes. See Figure 6-41.

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

Springs

12. Remove the brake assembly.

Installation 1. Install the brake using the five mounting bolts to the drive motor assembly. Apply thread-locking compound to the mounting bolts. ~ o r ~bolts u e to 13 ft. lb. (17.6 ~ m ) . -

Bolts

Figure 6-4 1 :

Brake Shoes and Springs

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

3. Install the brake shoes.

4. Install the shoe springs.

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

6. Install the control handle.

7. Adjust the brake. See "Brake" on page 6-49.

8. Test operate the truck.

Models 6HBC30,6HBC40, and 6TB50 Adjustment 1. Loosen the adjusting nut on the brake adjustment. See Figure 6-42.

2. Squeeze one of the brake handles approximately 75% closed.

3. While holding the brake in position, turn the brake adjusting nut until the brake contacts the brake drum. See Figure 6-42.

4. Tighten the lock nut securely against the bracket. See Figure 6-42.

5. Release the brake handle.

6. Test the brake.

NOTE: Use a maximum rated load when you measure the stopping distance. The

Lock Nut Figure 6-42:

Brake Adjustment

Component Procedures

Toyota Pallet Truck Service Manual

Models 6HBC30,6HBC40, and 6TB50 truck must stop within approximately 6 feet (1.83 meters).

Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

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

See Figure 6-43.

4. Remove the brake cable from the cable mount.

5. Disconnect the handle harness (JP6).

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

Figure 6-43:

Brake Cable and Clevis Pin

Nut

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

See Figure 6-44.

Figure 6-44:

Brake Drum With Control Handle Removed

Figure 6-45:

Brake Puller

8. Remove the brake drum. It may be necessary to use a puller. See Figure 6-45.

Component Procedures

Toyota Pallet Truck Service Manual

Models 6HBC30, 6HBC40, and 6TB50

9. Remove the shoe springs. See Figure 6-46.

10. Remove the brake shoes. See Figure 6-46.

11. Remove the five bolts holding the brake assembly to the drive motor assembly. See Figure 6-46.

12. Remove the brake assembly.

Figure 6-46:

Brake Shoes and Springs

Installation Vut

1. Secure the brake assembly to the drive motor assembly using the five mounting bolts. See Figure 6-46.

2. Install the brake shoes. See Figure 6-46.

3. Install the shoe springs. See Figure 6-46.

4. Install the brake drum using the 3/4-16 nut. See Figure 6-47.

5. Install the control handle. See "Control Handle" on page 6-31.

6. Connect the handle electrical harness (JP6).

Figure 6-47:

Brake Drum With Control Handle Removed

7. Insert the brake cable into the cable mount.

See Figure 6-48.

8. Connect the brake cable clevis to the brake arm using the clevis pin and brake arm return spring. See Figure 6-48.

9. Adjust the brake. See "Brake" on page 6-49.

10. Install the tractor covers.

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

Brake Cable

Figure 6-48:

Clevis

Clevis Pin

Brake Cable and Related Components

Toyota Pallet Truck Service Manual

Component Procedures Motors, General

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

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

Inspection 1. Inspect the brushes for wear and for correct contact with the commutator.

See Figure 6-49. Record the level of wear on the brushes. This history will give you an indication of whether a brush must be changed or if it can wait until the next inspection. Refer to page 6-55 for acceptable brush length and general motor information.

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore, you must take this into account when considering brush replacement.

2. Check brush spring tension. See "Motor Brush Spring Tension" on page 6-55.

3. Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. Do not use lubricants of any kind on or around the commutator.

4. Check brush holders for solid connection to the mounting support. Tighten the mounting screws as necessary.

5. Check the cap screws holding the brush cross connectors to the brush holder body.

6. Make sure the motor terminals are secured tightly to the motor frame. Be careful not to strip the threads or crush the insulating parts.

Figure 6-49:

Motor Brush, Typical Location

Component Procedures Motor Brushes

7. Check all the cap screws around the frame for tightness.

8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

Replacement If one brush needs replacement, always replace the entire set of brushes.

Use only genuine Toyota replacement brushes.

Using another type of brush could damage the commutator or cause excessive brush wear.

If the end of the brush is not already contoured to fit the commutator, seat the brush to the commutator:

NOTE: If the motor commutator is not accessible, form the brush contour using a brush-seating stone.

1. Move the motor brush springs out of your

way.

2. Wrap a piece of 00 sandpaper around the commutator. DO NOT use emery cloth to

seat brushes.

3. Move the brushes back down in their holders until they seat against the sandpaper.

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

5. Remove the sandpaper.

6. Blow any dust out of the motor with clean,

compressed air at a maximum of 30 psi (207 kPa).

Toyota Pallet Truck Service Manual

Component Procedures

Toyota Pallet Truck Service Manual

Motor Brush Spring Tension

Motor Brush Spring Tension Inspection 1. Turn the key switch OFF, and disconnect the battery connector.

2. Remove the tractor cover.

3. Slide the brush up slightly in its holder.

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

5. Place a small leather loop around the coil spring for the brush. If the brush spring has a loop at the brush, hook the spring scale directly to the spring. See Figure 6-50. .eather Loop

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

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

8. When the paper strip starts to move freely,

the spring scale will read the spring brush tension.

9. Refer to table below for correct spring tension.

Pull paper i n Direction of Rotation Figure 6-50:

Motor

Minimum Brush Length

9/16 inch F ( l 4 m m ) Motor

1 / 2 inch (13 mm)

1

spring Tension

30 to 36 ounces (842 to 1016 grams) 32 to 40 ounces (909 to 1136 grams)

10. Repeat steps 3 through 9 for the remaining brushes. If tension is not within the range given for any brush, replace the complete set of springs.

1

Motor Brush Spring Tension Inspection

Component Procedures

Toyota Pallet Truck Service Manual

Commutator

Commutator Inspection The commutator must be inspected for surface condition and high mica.

The commutator must be smooth and clean to provide maximum brush wear. When commutators are not properly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature.

MI ce

High Mica Most armatures have the mica undercut. If the armature on your motor does not, do not attempt to cut it. The decision to undercut or not is determined by the type and grade of brush used in that particular motor. The mica must be undercut to a depth equal to the width of the mica (usually 1/32 inch, but may change in some motors). See Figure 6-51.

Servicing If the commutator requires service, you will need to remove the armature from the motor.

Do not use a stone to even out high and low spots on the commutator. Use only a suitable abrasive rubber polisher.

Servicing a motor for an abnormal commutator surface condition and high mica or mica undercutting requires special equipment a t a motor rebuilding facility.

SEGMENTS

GOOD

UNDERCUT

SEGMENTS

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

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, the motor must be removed for servicing.

MICA

MICA

BAD UNDER C U T

Figure 6-51:

Mica

SEGMENTS

Toyota Pallet Truck Service Manual

Component Procedures Terminal Nuts

Terminal Nuts When you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor.

Use a second wrench on the stud terminal securing nut to avoid twisting the stud. Check these torques each time you check motor brushes.

Stud terminal securing nuts (3/8 inch [MlO]) must be torqued to 140 to 160 in. lb. (15.8 to 18.1 Nm) and Motor Cable Securing Nuts to 100 to 120 in. lb. (11.2 to 13.6 Nm).

Figure 6-52:

Motor Terminal Nuts

Component Procedures

Toyota Pallet Truck Service Manual

Electric Motor Tests

Electric Motor Tests Motor Types See Figure 6-53.

A shunt-wound motor, such as the drive motor, has four external connections: two armature (A) and two field (S).

A series-wound motor, such as the lift motor, has only two external connections because the armature and field windings are connected internally.

Shunt-Wound or Series-Wound Motors Shunt-Wound Motor

NOTE: Shunt-wound and series-wound motors for European markets may have the field connections labeled (E) instead of (S).

Series-Wound Motor

Open Circuit Motor Test An open circuit is one in which the electrical circuit within the motor has been broken. This can be caused by:

Bad brushes or brush springs A broken wire in the field or armature winding A loose or bad connection See Figure 6-53.

1. Isolate the motor from the truck circuit by

removing the power cables. Use two wrenches to avoid twisting the terminal stud.

2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor. See Table 6-4.

Table 6-4: Motor Resistance Measurements

Figure 6-53:

Motor Circuits

Toyota Pallet Truck Service Manual

Component Procedures Electric Motor Tests

3. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor.

4. If an open circuit is found in a

series-wound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

Grounded Motor Test In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused by direct contact or through conductive foreign material.

The ground may be caused by: Insulation breakdown Brush leads touching the motor housing Build-up of carbon dust or other materials To test a motor for grounds: Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal studs.

Attach one lead of a megohmmeter or a digital ohmmeter to a motor terminal and the other lead to an unpainted surface of the motor housing. Set the ohmmeter to the highest scale.

If the ohmmeter reads resistance of less than 100,000 ohms, the motor is grounded. Clean,

repair or replace the motor as necessary.

Short-circuited Winding A short-circuited winding is one in which the insulation on the field or armature has broken down at two or more points. The breakdown creates a low resistance path, permitting current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire.The result is a decrease in total resistance of the motor winding and an increase in the current flow.

The severity of the short circuit depends on its location.

Component Procedures Electric Motor Tests A shorted motor may be indicated by:

Slow or sluggish operation Operating faster than normal Overheating Blowing a power fuse Severe burning or discoloring on one or two commutator segments every 90" of rotation These symptoms can be caused by problems other than the motor itself: Brake too tight or dragging Wheel bearings too tight Faulty transmission Binding in an attached pump Testing a motor for short-circuited windings requires special equipment at a motor rebuilding facility.

Short-circuited Armature A short-circuit in the armature will cause

heating, which will probably result in burning of: Armature coil Brush wires Commutator segments Visual inspection may reveal this condition.

Positive determination of a short-circuited armature requires special equipment at a motor rebuilding facility.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Drive Motor

Drive Motor Remova1 1. Turn key switch OFF and disconnect the battery connector.

2. Remove the tractor cover.

3. Remove the control handle assembly.

4. Remove the brake assembly from the top of the drive motor as described on page 6-49.

5. Unscrew the deadman switch wires. See "Deadman Switch" on page 6-23.

6. Remove the four hex head nuts and drive motor power cables. Use two wrenches to avoid twisting the motor stud.

7. Remove the hex head bolts securing the

mounting plate to the main case of the drive unit. See Figure 6-54. Use a steel jack handle in the control handle frame to rotate the drive unit for access to all seven mounting plate bolts. Remove the bolts.

A CAUTION Due to the weight of the drive motor and the attached com~onents,it is recommended that YOU use a hokt to lift'the motor from the truck.

Figure 6-54:

Drive Unit Mounting Plate Bolts

Component Procedures

Toyota Pallet Truck Service Manual

Drive Motor

8. Lift out the drive motor, control handle frame, and drive unit mounting plate.

9. Remove pinion gear lock nut and pinion gear. Remove the seven mounting bolts securing the motor to the drive unit mounting plate. See Figure 6-55.

Drive Motor Mounting Bolts (7)

10. Remove the bolts mounting the control handle frame to the drive motor. Separate the motor from the handle frame.

Pinion Gear Figure 6-55:

Drive Unit, Pinion Gear

Figure 6-56:

~ e c aon l Mounting plate

Installation 1. Position the control handle frame on brush end of drive motor and attach with four hex head cap screws. Apply thread-locking compound (P/N 00590-0 1931-7 1) and torque to 25 to 30 ft. lb. (35 to 42 Nm). See Figure 6-56.

When installing the hex head bolts that secure the mountin plate, torque the hex bolts to the specifie 25 to 30 ft. Ib. (35 to 42 Nm). Failure to torque these bolts properly may cause the braking and steering to fail.

See the decal to the right and on the mounting plate on the truck.

3

2. Position the drive unit mounting plate on the opposite end of motor and secure with seven hex head cap screws. Torque to 120 to 150 in. lb. (13.5 to 16.9 Nm).

3. Install pinion gear and lock nut on armature shaft. Torque to 50 ft. lb. (67.8 Nm).

Toyota Pallet Truck Service Manual

Component Procedures Drive Motor

4. Using a gasket scraper, remove any gasket material from the mating surfaces of the drive unit mounting plate and main case.

5. Apply a coating of gasket compound (P/N 00590-00438-71) to the drive unit case and drive unit mounting plate.

6. With a suitable hoist, position the assembled motor and mounting plate on the drive unit. Install hex head cap screws and torque to 50 ft. lb. (67.8 Nm).

7. Attach power cables with four hex head bolts. Torque to 100 to 120 in. lb. (11.2 to 13.6 Nm). Use a second wrench on the stud terminal securing nut to avoid twisting the motor stud. See "Terminal Nuts" on page 6-57.

8. Reattach the deadman switch and wires.

9. Reattach brake and brake linkage and adjust as described on page 6-49.

10. Install control handle.

11. Connect wiring harness connectors and install new cable tie straps in original locations from which they were removed.

12. Before testing operation, move handle from extreme left to right and back several times.

Check for any wire and cable interference.

Repair or adjust a s necessary.

13. Reconnect battery connector.

14. Test operation.

15. Disconnect battery and install tractor cover.

Drive Motor Data Lubrication

None required. Sealed ball bearings are used at the two ends of the motor.

Armature Test

These armatures have standard winding connections and can be tested on a growler using a metal strip or hacksaw blade to locate shorted windings.

Commutator

Replace the armature when the commutator has worn to the minimum diameter of 2.9 inches (73.0 mm).

Brush Replacement

Replace brushes when they have worn to the minimum length of 9/16 inch (14 mm).

Spring Tension

Check that the spring tension of new brushes is 20 oz. (568 grams).

Component Procedures

Toyota Pallet Truck Service Manual

Drive Motor

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Component Procedures Drive Unit

Drive Unit Remova 1 1. Lower the forks. Turn the key switch OFF

and disconnect the battery connector.

Remove the tractor cover.

2. Remove the drive unit fill plug (Figure 6-57) and drain plug (Figure 6-59). Permit the gear oil to drain.

Figure 6-57:

Drive Unit Fill Plug

3. Jack the truck and block the frame. See Figure 6-58.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while 'acking the truck. After the truck is jacke , place solid blocks beneath it to support it. DO NOT rely on the iack alone to support the truck.

d

For details, see "Jacking - Safety" on page 2- 13.

Figure 6-58: Jacking Tractor

4. Remove the control handle assembly.

5. Unscrew the deadman switch wires. See "Deadman Switch" on page 6-23.

6. Remove the four hex head nuts holding the drive motor power cables. Use two wrenches to avoid twisting the motor stud.

-

7. Remove the control handle assembly. See "Control Handle" on page 6-31.

8. Remove the brake assembly from the top of the drive motor as described on page 6-49.

Drive Unit Drain Plug

Figure 6-59:

Drive Unit Drain Plug

Component Procedures

Toyota Pallet Truck Service Manual

Drive Unit

9. Unscrew the deadman switch wires. See "Deadman Switch" on page 6-23.

Remove the four hex head nuts holding the drive unit to the main case cover. See Figure 6-60.

Remove the socket head cap screws which secure the drive unit to the frame. See Figure 6-60.

Secure hoisting straps through the control handle frame. Remove the drive unit, drive motor, and control handle frame using a hoist with at least one-ton capacity.

To separate the drive unit from the drive motor, you must first separate the drive unit plate from the drive unit main case.

14. Remove the hex head bolts securing the drive unit plate to the main case. See Figure 6-60.

15. Remove the pinion gear nut and pinion gear from the underside of the drive unit plate.

Remove seven hex head bolts mounting the motor to the drive unit plate.

See Figure 6-61.

Figure 6-60:

Drive Unit Mounting

Drive Bolts

Disassembly 1. Remove the six hex head cap screws [29] which secure the cover plate [4]to the main case [3]of the drive unit for access to the gear assembly. Refer to Figure 6-62 for numbers in [brackets].

2. Remove the lock nut [24]from the wheel drive shaft 181. Use a suitable press to remove the wheel shaft assembly from the case.

3. Remove the spiral gear and bearing assembly.

4. Remove the lock nut [22]from the helical gear [I].Use a suitable press to remove the pinion shaft assembly from the case.

5. Remove the helical gear and bearing assembly from the case.

Figure 6-6 1:

Drive Unit mounting to Drive Motor

Toyota Pallet Truck Service Manual

Component Procedures Drive Unit

LEGEND: 28. Vent Plug

10. Pipe Plug

19. Shim 3.5 OD

2. Spiral Gear and Pinion Set

1 1. Bearing Cup/Cone

20. Shim 3.5 OD

29. Hex Head Cap Screw

3. Main Case

12. Bearing Cup/Cone

21. Shim 3.5 OD

30. N/A

4. Cover Plate

13. Bearing Cup/Cone

22. Lock Nut, 3/4-16

3 1. Flat Washer

5. Bearing Filler Plug

14. Shim 2.0 OD

23. Ring Set-Kit

32. N/A

1. Helical Gear and Pinion Set

6. Hex Plug

15. Shim 2.0 OD

24. Lock Nut, 1 3/8-18

33. Grease Fitting

7. Ball (34), 1/2 in. dia.

16. Shim 2.0 OD

25. Ball (35), 9/16 in. dia.

34. Spirol Pin

8. Drive Wheel Shaft

17. Shim 2.0 OD

26. Lock Washer (6)

35. Helical Gear and Pinion Set

9. Ring

18. Shim 3.5 OD

27. Seal-Oil

Figure 6-62:

Drive Unit, Cross-Sectional View

Component Procedures Drive Unit

Assembly NOTE: Refer to Figure 6-62 for numbers in [brackets].

1. To determine the correct shim pack [14-171: a. Press the bearing cone [1 11 on the pinion shaft 121. b. Place the pinion, bearing cone, and matching bearing cup on a flat surface to check the total length of the bearing assembly and pinion head. c. Locate the Mounting Distance [MD] stamped on the housing. d. Locate the Setting Distance [SD]etched on the pinion head. e. Subtract the total length of the pinion head assembly and Setting Distance from the Mounting Distance. This will be your required shim pack [14-171.

MD - (Length + SD) = shim 2. Place the shim pack [14-171 in the case [3] and draw the bearing cup into position.

3. Place the case [3]in a fabricated assembly base and press the remaining bearing cup [ l l ]into the case.

4. Insert the pinion shaft [2]through the bottom of the case [3]and position it in place.

5. Press the bearing cone [ l11 into place in the main case 131. Permit approximately 0.005 inch (0.127 mm) end play.

6. Place the helical gear [ l ]on the spline of the pinion shaft 121.

7. Install and tighten the lock nut 1221 to adjust the end play of the pinion shaft (0.000 to 0.002 in.) (0.000 to 0.050 mm).

8. Press the bearing cone [ 121 on the spiral gear [2].

9. Place the shim [18-211 (approximately 0.020 to 0.030 in.) (0.508 to 0.762 mm) in the bearing cup bore and then insert the bearing cup [12]in place. The cup must be a slip fit. Tap it in place with a soft face hammer.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Drive Unit

10. Prevent the helical gear [ l ]from turning by inserting a 1/8 in. bolt through the pipe plug hole [28].Engage the bolt with gear teeth.

11. Place the spiral gear [2]into position. Check the backlash while you press the gear down into the bearing cup [ 121. The required backlash is 0.003 to 0.005 in. (0.076 to 0.127 mm). Add to or subtract from the shim pack [18-211to achieve the correct backlash. Check the tooth pattern. See 'Tooth Pattern of Drive Unit" on page 6-70.

12. Press the bearing cup [13]in the case. Place the bearing cone in the cup, and press the seal [27]into the case.

13. Insert the wheel drive shaft [8]through the seal and bearing while you align the spline of the shaft with the spiral gear [2].Press the shaft through until it is seated.

14. Install the lock nut 1241 and torque to 55 ft. lb. (77 Nm) and obtain a setting of 0.000 to 0.001 in. (0.000 to 0.025 mm) preload. e ~ threadClean and apply ~ o c t i t 271 locking compound before assembly.

15. Place the complete drive wheel assembly on the wheel drive shaft.

16. Install cover plate (with 'T"visible). Apply sealant (85 gram tube 00590-04851-71 or 300 ml cartridge P/N 00590-04852-71) in continuous bead around all holes and perimeters of mating parts. Use six hex head cap screws 1291 and lock washers 1261.

Torque to 18 ft. lb. (25.2 Nm).

17. Install the hex plug [6],pipe plug [lo],and vent plug [28]into the unit using anti-seize compound.

18. Install the drive motor. See "Drive Motor" on page 6-61.

Checking the Gears 1. Clean the pinion and spiral gear [2].Apply a small amount of red lead on the teeth of the pinion gear.

2. Rotate gear several times to right and left.

3. Check the tooth contact pattern on the spiral and pinion gear. See "Tooth Pattern of Drive Unit" on page 6-70.

Toyota Pallet Truck Service Manual

Component Procedures Tooth Pattern of Drive Unit

Tooth Pattern of Drive Unit Mount the gear sets according to the instructions in this chapter. Adjust the shim packs to the correct tolerances. Adjust incorrect tooth patterns as shown in the chart below; the degree of change depends on the position of the patterns on the teeth.

TOOTH PATTERN ON RING GEAR CONCAVE FLANK D R I WEN CONCfiUE

FLANK

CONVEX FLANK

CORRECT PATTERN

BY CHANGING THE SHIMS IN THE DIRECTION SHOWN

BY THE ARROWS

D R I U I NG CONVEX FLANK

No Adjustment Needed

\d !

I

IDEQL P Q T T E R N

P A T T E R N AT T I P

P A T T E R N AT ROOT

T O E PATTERN

J

HEEL P A T T E R N Figure 6-63:

Drive Unit Gear Tooth Pattern

Toyota Pallet Truck Service Manual

Component Procedures Tooth Pattern of Drive Unit

Installation

A CAUTION Be sure the key switch is OFF, and the battery connector disconnected before you begin.

Position the drive unit mounting plate on the opposite end of motor and secure with seven hex head screws. Torque to 120 to 150 in. lb. (13.5 to 16.9 Nm) See Figure 6-64.

Install pinion gear and lock nut on armature shaft and torque to 50 ft. lb.

(67.8 Nm). See Figure 6-65.

Using a gasket scraper, remove any gasket material from the mating surfaces of the drive unit mounting plate and the main case.

4. Apply a generous coating of gasket compound (P/N 00590-00438-71) to the drive unit case and the drive unit mounting plate.

Figure 6-64:

Drive Unit Mounting to Drive Motor

Figure 6-65:

Drive Unit Mounting

5. With a suitable hoist, position the assembled motor and mounting plate on the drive unit. Install hex head screws and torque to 50 ft. lb. (67.8 Nm).

See Figure 6-65.

6. Using the hoist, lift the drive unit, drive motor, and control handle frame into place on the truck frame.

7. Align the drive unit to the truck frame.

8. Install the six socket head screws in the steering bearing. Apply thread-locking compound to the screws and torque them to 80 ft. lb. (108 Nm). See Figure-6-65.

A CAUTION Do not remove the hoist until the cap screws are in place and torqued to 8 0 ft. Ib. (1 08 Nm).

9. Remove the hoist and install the brake. See "Brake" on page 6-49.

10. Mount the control handle.

Component Procedures

Toyota Pallet Truck Service Manual

Drive Unit Vent Plug

11. Connect the wiring harness.

12. Connect the drive motor cables. Torque to 100 to 120 in. lb. (11.2 to 13.6 Nm). Use a second wrench on the stud terminal securing nut to avoid twisting the motor studs.

13. Attach the deadman switch wires. See "Deadman Switch" on page 6-23.

Drain Plug

14. Install drain plug. See Figure 6-66.

Ensure the drive unit is filled to the correct level with gear oil. Install fill plug. See Figure 6-67.

15. Reconnect the battery connector and turn the key switch ON. 16. Check the controls for correct operation.

Figure 6-66:

Drive Unit Drain Plug

Figure 6-67:

Drive Unit Fill Plug and Vent Plug

Drive Unit Vent Plug Make sure the drive unit vent plug is clean and open to keep pressure from building up in the housing. Extra pressure could force lubricant out of the shaft seals. See Figure 6-67.

Cleaning 1. Remove the vent plug from the top cover of the drive housing. See Figure 6-67.

2. Wash it in a suitable cleaning solvent.

3. Dry it with compressed air to make sure it is not clogged.

4. Install the vent plug and tighten it securely.

Component Procedures

Toyota Pallet Truck Service Manual

Drive Housing Lubrication

Drive Housing Lubrication Gear Oil Level 1. Remove the level plug. See Figure 6-68.

2. Check oil level. When truck is level, the oil must be up to the bottom of the level plug opening.

3. If necessary, add the specified oil through the plug opening, but do not overfill.

4. Install the level plug securely.

Figure 6-68:

Drive Unit Level Plug

Changing Gear Oil 1. Remove the drain plug from the bottom of

the gear housing cover and permit the oil to drain. See Figure 6-69.

2. Remove and clean the vent plug. See "Cleaning" on page 6-72.

3. After the oil has drained completely, flush the housing with a suitable solvent and permit it to drain.

\

4. Install the drain plug. See Figure 6-69.

5. Fill the drive housing with the specified gear oil through the pipe plug opening in the top cover of the transmission. The drive housing will hold 2.9 qts. (2.75 liters) of gear oil. Do not overfill.

Drain Plug

Figure 6-69:

Drive Unit Drain Plug

Component Procedures Drive Housing Steering Bearing

Drive Housing Steering Bearing Remova1 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the drive unit fill plug and drain plug and permit gear oil to drain. See Figure 6-67 and Figure 6-69.

3. Remove the drive unit as described on page 6-65.

4. Remove the spirol pin 1341 and bearing filler plug [5] (see Figure 6-62). Remove 34 (qty) 1/2 inch steel ball bearings [7]and 35 (qty) 9/ 16 inch steel ball bearings 1251 through the filler plug opening. Separate the ring from the main case, then remove the ring set 1231.

Installation 1. Install the bearing four-piece ring set 1231.

2. Insert 34 (qty) 1 /2 inch steel ball bearings [7]and 35 (qty)9/16 inch steel ball bearings [25]through the filler plug opening. Alternate 1/2 inch and 9/16 inch steel balls during installation.

3. Use a hoist to replace the drive unit. See "Installation" on page 6-71.

A CAUTION Do not remove the hoist until the cap screws are in place and torqued to 80 ft. Ib. (1 08 Nm).

4. Replace the drain plug.

5. Replace the gear oil.

6. Replace the fill plug.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Drive Wheel

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

2. Turn the control handle all the way to the left.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while 'acking the truck. After the truck is iacke , place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck.

d

Figure 6-70:

Jacking Tractor End

Figure 6 -71:

Drive Wheel a n d Tire

For details, see "Jacking Safety" on page 2-13.

3. Jack and block the truck under the tractor frame. See Figure 6-70.

4. Remove drive wheel mounting bolts. See Figure 6-71.

5. Remove the drive wheel.

Component Procedures

Toyota Pallet Truck Service Manual

Drive Wheel

Cushion Tire Replacement Any misalignment of the tire and hub while the tire is being pressed on the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire's metal insert. The chamfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

OUTSIDE O F HUB AND TIRE ASSEMBLY

A CAUTION To prevent damage, the hub must be installed on the circular ram with the chamfered side UP* 1. Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert.

2. Place a circular ram on the press table. See Figure 6-72. The length of the ram must be longer than the width of the old tire to permit complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert ofthe tire, but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

3. If the outside edge of the hub is not flush

with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightlysmaller in diameter that the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the correct amount of recession.

4. Position the hub assembly with the old tire

on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire on the wheel. The chamfered edge must always be the leading edge when a tire is pressed on the hub.

PRE SS TAB L E

Figure 6-72:

Cushion Tire Replacement

Toyota Pallet Truck Service Manual

Component Procedures Drive Wheel

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

6. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

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

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

8. Release the press. Remove the wheel, tire assembly and the old tire from the press table. Inspect the wheel and tire assembly.

9. Install the wheel and tire assembly on the drive axle of the truck. Torque the mounting hub bolts to 120 to 150 ft. lb.

(162.8 to 203.5 Nm).

Component Procedures

Toyota Pallet Truck Service Manual

Drive Wheel

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Component Procedures Casters

Casters Casters are used on Models 6HBW30 and 6HBE30 or 6HBE40, and 6HBC30 or 6HBC40 and 6TB50.

Remova1 1. Turn the key switch OFF and disconnect the battery.

Figure 6-73:

Removing Caster

Figure 6-74:

Removing Tension Pin

Figure 6-75:

Removing Axle Shaft

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while 'acking the truck. After the truck is iacke , place solid blocks beneath it to support it. Do NOT rely on the iack alone to support the truck. See "Jacking Safety" on page 2-13.

d

2. Jack and block the tractor.

The casters are very heavy. DO not place hands under the casters when removing the four bolts.

3. Remove the four bolts and washers from the mounting plate. See Figure 6-73.

Wheel Replacement 1. Remove the caster assembly if required.

2. With a hammer and pin punch, drive the tension pin out of the axle shaft. See Figure 6-74.

3. With hammer and brass drift pin, drive out the axle shaft. See Figure 6-75.

Component Procedures

Toyota Pallet Truck Service Manual

Casters

4. Remove the wheel and shims.

See Figure 6-76.

Figure 6-76:

Removed Wheel and Shims

Figure 6-77:

Compressing Caster Springs

Figure 6-78:

Relieving Pivot Tension

Caster Disassembly

Do not remove the pivot in until the springs are compressed in the fo lowing step.

I'

1. Install two 1/4-20 x 3 inch bolts and several washers through the caster frame and into the springs. See Figure 6-77.

NOTE: Use washers as spacers. Allow the bolt to thread into the spring 4-5 turns before it starts to compress springs.

2. Tighten the bolts against the washers compressing the spring until the tension is relieved from the pivot. See Figure 6-78.

Component Procedures

Toyota Pallet Truck Service Manual

Casters

Remove the pivot pin retainer screw. See Figure 6-79.

Figure 6-79:

Removing Pivot Pin Retainer Screw

Figure 6-80:

Removing Pivot Pin

4. Use a hammer and pin punch to drive out the pivot pin and washers. See Figure 6-80.

5. If necessary, replace the springs. If spring replacement is not necessary, leave springs compressed for reassembly.

Caster Assembly 1. Lubricate the pivot pin with white lithium grease.

2. Align the washers on each side of the wheel carrier and insert the pivot pin.

3. Secure the pivot pin with the shaft retainer screw.

Figure 6-8 1: Separated Caster

Toyota Pallet Truck Service Manual

Component Procedures Casters

4. Remove the bolts and washers compressing the springs. See Figure 6-82.

Figure 6-82:

Removing Bolts From Springs

Figure 6-83:

Installing New Wheel

Figure 6-84:

Installing Axle Shaft

Wheel Installation 1. Turn the caster assembly on its side. See Figure 6-83.

2. Align the new wheel with spacers on each side and insert the axle shaft. Tap lightly with a hammer while aligning the tension pin holes. See Figure 6-84.

Toyota Pallet Truck Service Manual

Component Procedures Casters

Drive the tension pin in the axle shaft. See Figure 6-85.

Lubricate with the grease fittings.

Figure 6-85:

Installing Tension Pin

Figure 6-86:

Caster, Shims and Mounting Bolts

Figure 6-87:

Securing Caster To Tractor

Caster Installation 1. Secure the shims and caster assembly to the truck with the four bolts and washers (see Figure 6-86 and Figure 6-87).

2. Lubricate via grease fittings.

3. Remove block and jack.

Component Procedures

Toyota Pallet Truck Service Manual

Load Wheels

Load Wheels Replacement 1. Lift the forks to maximum height and block them. See "Jacking Safety" on page 2-13.

2. With a hammer and pin punch, drive out the tension pin. See Figure 6-88.

Figure 6-88:

Removing Tension Pin

Figure 6-89:

Removing Axle From Load Arm Casting

Figure 6-90:

Removed Load Wheel and Components

3. Drive the axle out of the load arm casting with a hammer and brass drift pin. See Figure 6-89.

4. Push the load wheel out. Note the location of the washers and pin. See Figure 6-90.

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

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

7. Place the new load wheel upright on a flat

surface. Position the bearing over the load wheel. Place a flat metal plate over the bearing, and hammer the bearing in place with a plastic mallet. Make sure the bearing is fully seated in the load wheel.

8. Align the load wheel and washers with the holes in the load arm casting.

9. Drive the axle through the load arm casting, load wheel and washers. Make sure the pin hole in the axle aligns with the housing.

10. Install the tension pin.

11. Lubricate the grease fittings.

Toyota Pallet Truck Service Manual

Component Procedures Load Wheels Model 6TB50

Load Wheels Model 6TB50 Remova1 1. Turn the key switch OFF and disconnect

the battery connector.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while 'acking the truck. After the truck is jacke , place solid blocks beneath it to support it. DO NOT rely on the iack alone to support the truck.

d

2. Jack and block the operator compartment.

See "Jacking Safety" on page 2- 13.

3. Remove the load wheels by first removing the external snap ring and thrust washer from the each end of the load axle.

4. Remove the wheel assembly.

5. Support the load axle on blocks to prevent it from dropping a s the fasteners are removed.

6. Remove the four bolts securing the axle to the operator compartment.

7. Remove the load axle from underneath the operator compartment.

Installation 1. Inspect the load wheel axle and snap ring groove for wear. If either area shows signs of wear, replace the axle.

2. Position the load axle under the operator compartment supported on blocks.

3. Apply ~octite@ (#603green) to the bolts previously removed, then secure the load axle to the operator compartment. Torque bolts to 30 ft. lbs. (40.7 Nm).

4. Inspect the load wheels for wear or damage prior to installation.

Component Procedures Load Wheels Model 6TB50

5. Slide the load wheel onto the axle, install the thrust washer then secure with the snap ring.

NOTE: Verify that the snap ring is properly seated into the snap ring groove.

6. Remove the blocking and return the truck to service.

Toyota Pallet Truck Service Manual

Component Procedures

Toyota Pallet Truck Service Manual

Pallet Entry Wheels/Sliders 8000 Lb. Models

Pallet Entry Wheels/

Sliders 8000 Lb. Models Entry Wheel Replacement 1. Raise the forks and block them in the raised position. See "Jacking Safety" on page 2-13.

2. Remove the lock nut and bolt from sides of the entry roller bracket. See Figure 6-91.

3. Replace the roller(s).

4. Insert the bolt through the entry roller bracket and roller. Secure with the lock nut. See Figure 6-91.

Slider Replacement 1. Raise the forks and block them in the raised position. See "Jacking Safety" on page 2-13.

2. Remove the lock nut and bolts (2) from the bottom of the entry slider bracket.

See Figure 6-91.

/

Entry Roller Bracket

Bolt

Roller

Pallet Entry Wheel Replacement

3. Replace the slider.

4. Insert the bolts through the entry slider bracket and slider. Secure with the lock nuts. See Figure 6-91.

Slider

Bolt

Pallet Entry Slider Replacement

Figure 6-9 1 :

Replacing Pallet Entry Wheels/Sliders

Component Procedures

Toyota Pallet Truck Service Manual

Fork Height Adjustment

Fork Height Adjustment 6000 Lb. Models To adjust the lowered fork height for new load wheels, refer to Figure 6-92.

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

2. Loosen the nut [3] on the eccentric pin [ 11.

Rotate the hex head of the eccentric pin until the top of the trail-fork touches the bottom side of the fork surface a t 'A'.

3. Tighten the nut for the eccentric pin.

4. Remove the blocks and lower the forks completely. Check the fork height at 'B'.

The lowered fork height must be 3-1 /4 in. (83mm).

To adjust the lowered fork height for worn load wheels: 1. Lower the forks completely. Measure the distance from the floor to the top of the fork at 'B'. The lowered fork height must be 3-1 /4 in. (83mm).

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 [3]on the eccentric pin [ 11.

Rotate the hex 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.

Long-John Models Upper Bell Crank Adjustment Adjust the lowered fork height at the upper bell crank to make sure that 6K and 8 K trucks with long-john forks enter and exit pallets correctly: 1. Lower the forks completely. Measure the fork height a t the load wheel and in front of the battery compartment. Record the dimensions. Fork height at the load wheel must be between 3-1/4 in. and 3-5/16 in.

(83-84 mm) Fork height at the battery

Figure 6-92:

Fork Height Adjustment, 6000 Lb.

Toyota Pallet Truck Service Manual

Component Procedures Long-John Models

compartment must be set between 3-3/8 in. and 3-1/2 in. (89-92 mm).

Subtract the battery compartment dimension from the load wheel dimension.

If this answer is negative, add the desired down slope (1/8 in. to 1 /4 in.) to the result to determine the shim stack height to put the forks to the desired slope. If the answer is positive, within the desired slope, leave it alone. If the answer is positive but not within the desired slope, add a 1 /8 in. shim to put the forks to the desired slope. See Figure 6-93.

Raise the forks. Place blocks under the forks at the battery compartment and the fork tips. Lower the forks until the forks are resting on the blocks. Loosen the bolts that fasten the lift cylinder clevis to the cylinder support plate.

4. Release lift pressure and loosen the bolts until the shim stacks will slide between the lift cylinder clevis and the cylinder support plate.

5. Remove the bolts from one side at a time and insert the shim stack. Replace and tighten the bolts in one side before removing bolts from the other side to insert the other shim stack.

6. Raise the forks and remove blocks. Check fork height to validate the correct slope.

7. Torque bolts to 75 ft. lb. (102 Nm).

8. Readjust the trail fork acentric pin to

permit the fork to lower fully a t the load wheel.

Figure 6-93:

location of shim stacks

Component Procedures

Toyota Pallet Truck Service Manual

Long-John Models

Lower Bell Crank Adjustment Adjust the lowered fork height for new load wheels at the lower bell crank (Figure 6-94).

1. Lower the forks completely and measure the fork height at the load wheel and in front of the battery compartment. Record the dimension(+ The fork height at the load wheel must be between 3-1/4 in. and 3-5/ 16 in. (83-84 mm). The fork height at the battery compartment must be between 3- 1 /2 in. and 3-5/8 in. (89-92 mm).

2. Remove the hex head bolt that captivates the fork height adjustment eccentric pin.

3. Slide the eccentric pin out 112 in. (13 mm).

Use a slide hammer to loosen the eccentric pin if necessary.

4. Rotate the eccentric pin to adjust the fork height. The indicator mark on the pin is the standard setting for the pin.

5. Slide in the eccentric pin and replace the hex head bolt.

6. Raise and lower the forks a few times then measure the fork height at the battery compartment and load wheels. Continue to adjust the eccentric pins until the fork height measurements are correct (see step 1).

7. Adjust the two forks evenly so the forks hit

the lower stops at the same time.

To adjust the lowered fork height for worn load wheels: 1. Lower the forks completely. Measure the distance from the floor to the top of the fork at the load wheel. The lowered fork height must be 3-1 /4 in. (83mm).

2. Remove the hex head bolt. See Figure 6-94.

Slide the eccentric pin out 1/2 in. (13 mm) and rotate as necessary to adjust the fork height. The indicator mark on the pin is the standard setting for the pin.

3. Make sure that the two wheels are adjusted to share the load equally.

4. Slide in the eccentric pin and replace the hex head bolt.

Figure 6-94:

Fork Height Adjustment at Lower Bell Crank

Toyota Pallet Truck Service Manual

Component Procedures Lift-Limit Switch

Lift-Limit Switch When the forks are fully raised, the lift-limit switch shuts off power to the lift contactor (M3), which turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure 6-95.

Adjustment 1. Remove the tractor cover.

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

3. Turn the key switch OFF and disconnect

the battery connector.

4. Loosen the bolt, then slide the switch bracket up or down to activate (cut power off)when the lift is 1/2 to 1 inch (12.7 to 25.4 mm) before its fully raised position.

5. Tighten the bolt.

6. Reconnect the battery connector and turn the key switch ON. Lower then raise the forks until they reach their fully-raised position. The lift-limit switch must cut power off to the pump when the lift cylinders reach 1/2 to 1 inch (12.7 to 25.4 mm) before their upper limit.

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

8. Install the tractor cover.

Figure 6-95:

lift-limit Switch

Component Procedures

Toyota Pallet Truck Service Manual

Lift-Limit Switch

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Components

Hydraulic Components General Guidelines To prolong the life of your Toyota pallet truck, adhere to the following guidelines: Keep all fittings and connections tight to prevent leaks. Be careful not to tighten brass fittings too much or they may become damaged or distorted.

Before you remove any component from the hydraulic system, wash the component and surrounding area with cleaning solvent to prevent foreign matter from entering the system. Cap and plug all openings immediately.

When you remove a fitting with a pipe thread, use a sealing compound on the outside of the threads before you reinstall the fitting. (Never use ~eflon@ tape.) Make sure all parts are clean.

When you install a hose assembly, make sure it isn't twisted when the fittings are tightened. Always use two wrenches on a swivel-type fitting-one to hold the fitting and the other to tighten the hose.

Keep hose clamps tight to prevent hoses from chafing and to avoid leaks.

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Fluid

Hydraulic Fluid Correct Level To prevent air from entering the lines, the fluid level (with the forks fully lowered) must be filled and visible to the bottom of the fill plug elbow.

Add the specified fluid if necessary. See "Lubrication Equivalency Chart" on page A-2.

Changing Store and handle the hydraulic fluid with extreme care to prevent moisture and foreign matter from entering the hydraulic system.

Contaminated hydraulic fluid is the major cause of hydraulic system failures. Any service equipment, such as containers, funnels and hand pumps, must be kept clean at all times.

Cover them when not in use.

1. Lower the forks.

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

3. Remove the tractor cover.

Figure 6-96:

H y draulic Unit

Figure 6-97:

H y draulic Connections

4. Remove one of the lift cylinder hoses from the fitting at the hydraulic pump. See Figure 6-97.

5. Connect a drain hose (high pressure) to the open fitting on the pump and tighten. (A pressure gauge hose is acceptable.) Place the hose in a waste fluid container.

Fluid will be under pressure and ma spra or s lash. Point hose away from bo y an holCPfirmly in waste fluid container.

i dY

6. Connect the battery connector and turn the key switch ON. 7. Operate the hydraulic pump by pressing the lift button until all the hydraulic fluid is pumped from the system.

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Fluid

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

9. Remove the drain hose and connect the lift cylinder hose.

10. Remove the vent plug and fill the reservoir to the bottom of the filler port with the recommended hydraulic fluid. See "Lubrication Equivalency Chart" on page A-2. Replace vent plug.

11. Connect the battery connector and turn the key switch ON. 12. Raise and lower the forks several times to purge air from the system.

13. Return the forks to the lowest position and recheck the fluid level. Add fluid if necessary.

14. Install the tractor cover.

15. Dispose of waste fluid properly.

Component Procedures

Toyota Pallet Truck Service Manual

Adjusting Hydraulic Pump Relief Valve Pressure

Adjustin Hydraulic Pump Relief Va ve Pressure

9

The hydraulic system is protected by a relief valve located in the adapter body. See Figure 6-98. The relief valve is set by the manufacturer to open at a specified pressure.

Relief Valve Seth'ngs Table 6-5: Truck Pressure levels

Figure 6-98:

Check Setting 1. Adjust the lift-limit switch so the switch will

not shut the pump down when the forks reach their upper limit.

2. Retract the lift cylinders completely.

Remove the 90" elbow. Install a female tee with a 1 /8" NPT 0 to 3,000 psi (0 to 20684 kPa) pressure gauge in place of the elbow.

See Figure 6-98.

3. Turn the key switch ON. Leave the control

handle in the neutral (vertical)position.

4. Press the lift button and observe the indicator on the pressure gauge. When the forks reach the upper lift limit, the pump will make a high pitched squeal indicating the relief valve is opening.

5. If the relief valve opens at a lower or higher pressure than the specified pressure, adjust the relief valve.

Relief Valve Adjustment 1. Remove the lock nut covering the relief valve adjustment screw.

Checking Relief Valve Pressure

Toyota Pallet Truck Service Manual

Component Procedures Relief Valve Settings

2. As you depress the lift button, turn the adjusting screw inward to increase the pressure setting or outward to decrease the pressure setting.

3. Monitor the pressure gauge indicator. After the relief valve is properly set, release the lift button.

4. Reinstall the hex cap.

5. Check the relief valve setting.

6. Lower the forks completely. Turn the key switch OFF. 7. Remove the pressure gauge. Replace the elbow.

8. Turn the key switch ON. Raise the forks.

Inspect all hoses and fittings for leaks.

9. Adjust the lift-limit switch to shut down the pump when the forks reach their upper limit. See "Lift-Limit Switch" on page 6-91.

Remova1 1. Clean the surface around the valve.

2. Disconnect the wires from the terminals on the coil, then loosen and remove the nut.

Remove the coil.

3. Using a wrench on the flat surface, loosen and remove the tube subassembly unit.

Remove, inspect, and clean or replace the strainer a s required.

Installation 1. Inspect and clean the valve cavity as

required.

A CAUTION Do not bend or apply pressure to center stud or hold cartridge body any place but on the flat sides of the subassembly.

2. Confirm that the O-ring and ~eflon@ ring are in position. Apply a small amount of clean grease on the two rings. Verify that the strainer is in position.

Component Procedures Check Valve

3. Hand screw the subassembly in position and tighten to a maximum of 35 ft. lb.

(49 Nm).

4. Assemble the coil on the spool assembly.

Tighten the nut to a maximum of 5 ft. lb.

(7 Nm).

5. Reconnect the wires to the terminals on the coil.

Check Valve Removal and Installation 1. Remove the check valve from the adapter.

2. Remove the 1/2-20 hex plug from the valve body.

3. Inspect the ball for pitting or scoring.

Inspect the valve seat for scoring.

4. Reassemble and bleed the pressure line of all air.

To bleed the line, loosen (do not remove or loosen too much) the outlet pressure port fitting and turn the lift motor ON until oil seeps out through the fitting.

5. Turn the lift motor OFF and retighten the outlet pressure port fitting.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Ram

Hydraulic Ram Inspection Slight fluid leakage at the seals indicates the hydraulic cylinder seal and/or O-rings are becoming worn. When leakage becomes excessive, disassemble and inspect the complete assembly. Replace any worn or broken components.

Remova1 NOTE: Removal of the hydraulic ram(s) requires disconnecting the fork section from the truck. Be sure to follow the correct jacking and blocking procedures when separating the truck section and fork section.

Use extreme care when the truck is 'acked up. Kee hands and feet clear Irom vehicle w ile jacking the truck.

After the truck is jacked, place solid blocks beneath it to su port it. DO NOT rely on the jack a one to support the truck.

R

Figure 6-99:

Removing Battery With Hoist

I'

1. Lower the forks completely.

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

3. Using a suitable device, remove battery. See Figure 6-99.

4. Remove the tractor cover.

5. Jack up and block the truck at the drive wheel end to gain access to the bottom of the truck.

6. Place a jack between the forks under the battery compartment. Jack up and block the fork section to gain access to the lower bell cranks. See Figure 6-100.

7. Lift the fork section to maximum height and

block the fork section under the battery compartment.

Figure 6- 100: Blocking Fork Section For Ram Removal

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Ram

8. Remove the lower bell crank pin covers, then remove the two bell crank pins. Insert a 1/4 in. fine-thread bolt into the pin and connect to a slide hammer to remove stubborn pins if necessary.

See Figure 6- 101.

In the next steps, the tractor and frame will separate. Use the jack to stabilize the truck.

Figure 6- 10 1: Removing lower Bell Crank Pins

9. Remove the four hex head cap screws located at the top of the battery compartment housing to disconnect the hydraulic ram clevis from the fork section.

See Figure 6-102.

10. At this time the two sections are disconnected. Move the fork section to gain access to the hydraulic rams.

See Figure 6-103.

11. Remove the hydraulic line from the bottom of the selected hydraulic cylinder. See Figure 6- 104.

NOTE: Be prepared to catch hydraulic fluid under each hydraulic cylinder in a suitable container.

Figure 6- 1 0 2 : Disconnecting Upper Clevis Brackets

12. Remove the vent line from the top of the cylinder. Remove the vent hose fitting from the lift ram housing. See Figure 6-105.

13. Remove the lower hydraulic ram pin cover then remove the pin and spacer. See Figure 6- 106.

14. Remove the upper hydraulic ram pin that secures the ram to the clevis. The pins are held in place by the channel on the battery compartment and will remove easily with the fork section disconnected from the truck section. See Figure 6- 106.

15. Push the piston completely into the cylinder.

Figure 6- 103: H y draulic Ram Area, Forks Removed

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Ram

Lift the ram up and out of the tractor frame.

Inspect the clevis, pin and associated parts fro wear and/or damage. Replace as necessary. If they are in good condition, retain them for later installation.

Figure 6- 104: H y draulic Line Connection

Ins 1. Position the hydraulic ram into the tractor frame and install the upper hydraulic ram pin to secure the ram to the clevis.

Install the lower hydraulic ram pin, placing the ram spacer on the pin before the hydraulic ram then complete installation and secure with the pin cover.

Put sealant on the threads of the hose fitting. (Do not use ~eflon@ tape.)

Install the hose fitting (if removed) in the bottom of the hydraulic ram.

See Figure 6-107.

Figure 6 - 1 0 5 : Vent Hose Connection

5. Connect and secure the hydraulic line at the bottom of the hydraulic cylinder.

6. Install the vent hose fitting if removed. See Figure 6-108.

7. Connect and secure the vent line at the top of the cylinder.

8. Slide the fork section back into position

until the clevis makes contact with the mounting plate on the fork frame. Secure each clevis with the four hex head cap screws (two for each ram).

9. Insert the two bell crank pins into the lower bell cranks and fork section then secure with the pin covers.

Figure 6 - 1 0 6 : Hydraulic Ram Removal/lnstallation

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Ram

Jack the fork frame between the forks and remove the block(s)under the battery compartment.

Lower the fork frame.

Jack the tractor end to remove the blocks then lower the tractor end.

Using a suitable lifting device, install the battery.

ITE:

Do not connect the battery connector a t this time.

Check the hydraulic reservoir fluid level. If necessary, add fluid; fill to the bottom of the breather cap elbow. See Lubrication Equivalency Chart on page A-2.

Figure 6- 107: H y draulic Line Connection (Installed)

Connect the battery connector and turn the key switch ON. Lift and lower the forks several times.

Re-check the hydraulic reservoir fluid level.

If necessary, add fluid; fill to the bottom of the breather cap elbow.

Lower the forks completely.

Turn the key switch OFF and disconnect the battery connector.

Install the tractor cover.

Figure 6- 108: Hydraulic Vent Hose Connection (Installed)

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Cylinder Seals

Hydraulic Cylinder Seals Disassembly 1. Remove the lift ram from the truck. See "Hydraulic Ram" on page 6-99.

2. Extend the piston fully from the cylinder.

See Figure 6-109.

3. Remove the outer lock ring.

See Figure 6-109.

4. Push the piston back inside the tube a t

least 0.75 in. (19 mm).

Figure 6- 109: Removing Outer Spiral Lock Ring

Remove the spacer. See Figure 6- 110.

Figure 6- 1 10: Removing the Spacer

6. Remove the head lock ring from inside the cylinder. To make removal easier, push the head assembly into the tube. See Figure 6- 111.

7. Remove the sharp ridge from the back

corner of the head lock ring groove if necessary.

Figure 6-1 1 1 : Removing Lock Ring from Cylinder

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Cylinder Seals

Carefully pull the rod and head assembly from the cylinder. See Figure 6-112.

Figure 6- 1 12: Rod and Head Assembly Out of Cylinder

Remove the piston jam nut and spin off the piston. See Figure 6-113.

Slide the head assembly off the rod a t the piston end of the rod.

Figure 6- 1 13: Remove the Piston Jam Nut

Remove the old seals and clean the metallic parts thoroughly. See Figure 6-114.

(...ounr ~~~kRing ......,~ A

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

Head Assembly

I Pis

~mmsmsmsmssmmmmmmA

Figure 6- 1 14: Piston Rod Components

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Cylinder Seals

Assembly 1. Lubricate new seals with applicable hydraulic fluid and slide the lock ring, spacer and head lock ring on the rod at the piston end of the rod.

2. Slide the head assembly and sleeve on the rod at the piston end of the rod.

3. Install the piston and the piston jam nut on the rod. See Figure 6- 115.

Figure 6- 1 15: Securing Piston Jam Nut

4. Carefully push the rod and head assembly into the tube. Make sure that the head assembly is installed past the head lock ring groove.

5. Install the head lock ring, then pull the rod out to properly seat the head assembly into the head lock ring. See Figure 6- 116.

Figure 6- 1 16: lnstalling the Head Lock Ring

6. Install the spacer and outer lock ring. See Figure 6- 117.

Figure 6- 1 17: lnstalling the Outer Lock Ring

Component Procedures

Toyota Pallet Truck Service Manual

Hydraulic Unit

Hydraulic Unit Draining and cleaning the hydraulic reservoir is important to control the accumulation of condensation and contamination, which damage the hydraulic system.

Condensation is caused by the repeated heating and cooling of hydraulic fluid during normal operation. Contaminants include dirt, rust, scaling, and products of fluid deterioration.

Remova1 1. Lower the forks completely.

2. Disconnect the battery. Remove and tag all wires and cables connected to the pump motor. See Figure 6-118.

3. Remove and tag the hydraulic lines from

the hydraulic unit.

4. Using a suitable lifting device, remove the battery to gain access to the hydraulic unit mounting bolts. See "Battery" on page 6-7.

5. Remove the bolts that secure the hydraulic unit to the tractor frame.

6. Remove the hydraulic unit from the truck.

Installation 1. Install the hydraulic unit on the tractor frame and secure with previously removed cap screws.

2. Install the hydraulic lines on the hydraulic unit.

3. Fill the reservoir with the specified hydraulic fluid. See "Lubrication Equivalency Chart" on page A-2.Use a funnel with a flexible neck. Fill the reservoir only until the fluid is visible at the bottom of the vent plug elbow. See Figure 6-118.

Use up to 1.5 quarts (1.4 liters).

4. Install the vent plug.

5. Using a suitable lifting device, install the battery. See "Battery" on page 6-7.

6. Connect all wires and cables to the pump motor. The lift motor stud terminal securing nut (top nut) must be torqued to 60 to 84 in. lb. (6.8to 9.5 Nm) and the motor cable

Figure 6- 1 18: Hy draulic Unit

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Reservoir

securing nut (bottom nut) to 84 to 108 in. lb. (9.5 to 12.2 Nm). The solenoid stud terminal securing nut (top nut) must be torqued to 35 in. lb. (3.9 Nm).

7. Connect the battery.

8. Raise and lower the forks, and check all hoses and fittings for leaks.

9. Lower the forks.

10. Check the hydraulic fluid level in the reservoir.

Hydraulic Reservoir NOTE: If your truck is supplied with a Haldex ~arnes@ hydraulic unit, the hydraulic reservoir may be constructed of metal or plastic. Refer to the replacement parts manual for the correct part if a replacement is needed.

Remova1 1. Remove the hydraulic unit from truck. see "Removal" on page 6-106 2. Remove the four cap screws that connect the hydraulic reservoir to the adapter housing. See Figure 6- 119.

Figure 6- 1 19: Adapter Cap Screws

3. Remove the reservoir and properly dispose of the old hydraulic fluid. See Figure 6- 120.

4. After the fluid has drained, flush the inside of the reservoir with a suitable cleaning solvent.

5. Dry the inside of the reservoir with clean, dry compressed air.

Installation 1. Inspect the reservoir O-ring for defects and replace if necessary.

2. Lubricate the O-ring (with applicable hydraulic fluid) and install the O-ring.

See Figure 6-120.

3. Carefully install the reservoir on the adapter housing and secure with four cap screws. Torque the cap screws to 20 to 25 in. lb. (2.2 to 2.8 Nm).

4. Install the hydraulic unit in the truck. See "Installation" on page 6-106.

Figure 6- 120: Removed Reservoir

Component Procedures

Toyota Pallet Truck Service Manual

Filter Screen and Suction Tube

Filter Screen and Suction Tube 1. Remove the reservoir. See "Hydraulic Reservoir" on page 6- 107.

2. With pump assembly inverted, push the spring clip toward the pump housing. See Figure 6-121.

3. Grasp the suction tube with the filter screen and pull out of pump housing.

4. Clean the filter screen at the bottom of the suction tube with suitable solvent. See Figure 6-122.

5. From the pump side, blow dry with clean, dry compressed air.

Suction Tube

Figure 6- 12 1 : Pump Housing Components

Installation 1. Inspect the filter screen and tube for defects and replace if necessary.

2. Lubricate the pump end of the suction tube with hydraulic fluid.

3. Push the spring clip toward the pump housing. Insert the suction tube through the spring clip and into the pump housing until it stops. See Figure 6-122.

4. If necessary, rotate the suction tube so that the filter screen is toward the center line of the pump.

5. Install the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-107.

Figure 6- 122: Cleaning Filter Screen

Toyota Pallet Truck Service Manual

Component Procedures Hydraulic Pump

Hydraulic Pump Remova1 1. Remove the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-107.

2. With the pump assembly inverted, push spring clip toward the pump housing. See Figure 6-121.

3. Grasp the suction tube with the filter screen and pull out of the pump housing.

See Figure 6-121.

4. Remove the eight screws that secure the pump to the adapter body.

Figure 6- 123: Pump and Adapter Body

5. Separate the pump from the adapter body.

See Figure 6-123.

6. Set aside the pump drive coupling to be reused.

Installation 1. Stand the motor assembly on end, with the adapter body facing up.

2. Lubricate the three O-rings and place them between the pump and adapter body.

3. Insert the pump shaft coupling on the end of the motor armature shaft. Fill the coupling cavity with lubricant (P/N 0059004836-71).See Figure 6-124.

Figure 6-124: Pump Drive Coupling

4. Place the pump on the adapter body while lining up the shaft with the coupling. See Figure 6-125. Rotate if necessary.

5. Secure the pump with the eight screws and torque to 10 to 12 ft. lb. (13.6 to 16.3 Nm).

6. Install the reservoir. See "Hydraulic Reservoir" on page 6- 107.

Figure 6- 125: Installing Pump in Adapter

Component Procedures

Toyota Pallet Truck Service Manual

Lift Motor

Lift Motor General Data Lubrication

None required. Sealed bearings are used at the two ends of the motor.

Armature Test

These armatures have standard winding connections and can be tested on a growler using a metal strip or hacksaw blade to locate shorted windings.

Commutator

Replace the armature when commutator has worn to the minimum diameter of 1.5 inches (38.1 mm).

Brush Replacement

Replace brushes when they have worn to the minimum length of 0.5 inch (12.7 mm).

Spring Tension

Check that spring tension of new brushes is 32 to 40 oz. (908.8 to 1136 grams).

Brush Inspection See "Motors, General" on page 6-53.

Remova1 1. Remove the hydraulic unit from the truck.

See "Hydraulic Unit" on page 6-106.

2. Remove the two bolts from the end plate that attach the motor to the adapter housing. See Figure 6-126.

Figure 6- 126: Bolts Securing Motor To Adapter

3. Separate the motor from the adapter housing. See Figure 6- 127.

4. Remove the solenoid from the side of the motor housing to be reused.

Figure 6- 127: Separated Reservoir and Motor

Toyota Pallet Truck Service Manual

Component Procedures General Data

Installation 1. Stand the pump assembly on end, with the adapter body facing upwards.

2. Set aside the pump drive coupling to be reused. See Figure 6- 127.

NOTE: The coupling is the mechanical connection between the pump shaft and the electric motor armature shaft. It may have been removed with the motor.

3. Insert the pump drive coupling on the end of the pump shaft. Fill the coupling cavity with lubricant (P/N 00590-04836-7 1). See Figure 6- 128.

4. Rotate the pump or motor shaft to make sure the motor shaft fits correctly into the coupling.

Figure 6- 128: Coupling Cavi?/

5. Install the new motor on the adapter housing. Rotate further if necessary until the motor contacts the adapter body.

NOTE: An indexing pin on the end of the motor housing fits into a hole in the adapter body. This ensures the motor mounting screws align with the threaded holes in the adapter body. See Figure 6- 129.

Figure 6- 129: Indexing Pin

6. Insert the screws into the motor end plate, through the motor and into the adapter body. See Figure 6-130.

7. Make sure the motor is mating flush with the adapter body and torque screws to 6.3 to 7.4 ft. lb. (8.5 to 10 Nm).

8. Install the solenoid. Torque the mounting screws to 60 to 69 in. lb. (6.8 to 7.9 Nm).

9. Install the hydraulic unit. See "Hydraulic Unit" on page 6-106.

Figure 6- 130: Securing the Motor and Adapter Body

Component Procedures Cold Storage Conditioning

Cold Storage Conditioning New Toyota pallet trucks to be used in a cold storage environment are equipped at the factory with cold storage components for cooler and freezer applications except for fluids in the hydraulic reservoir.

A CAUTION When a truck is to be installed in a cold storage environment, change the fluid in the hydraulic reservoir according to the following items.

Classes of Cold Storage Toyota pallet trucks can be conditioned for two classes of cold storage:

Cooler Environment where temperatures fluctuate from 20°F to 70°F (-7°Cto 21°C) in a continuous duty cycle.

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

Freezer Environment where temperatures fluctuate from -20°F to 40°F (-29°C to 4°C).

Application where truck operates continuously in a temperature of -20°F (-29°C).

Refer to: "Lubrication Equivalency Chart" on page A-2.

Select the correct fluid for a particular temperature range.

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Appendix

Appendix

Appendix

Toyota Pallet Truck Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart

(all applications)

0590-04837-71

Exxon Nuto H 4 6 Forsythe AWTH215 IS046 Mobil DTE-1B NOCO NOCOLUBE AW46 Texaco Cygnus 46 or HD 46 Ultramar Ultra Hydraulik AW46

trucks) (+40°Fto -

Mobil Aero HFA Texaco Aircraft Hydraulic Fluid 15

Texaco HD AZ 3 2 1627 Rando or

Mobil423 or 424 NOCO Torque TDH

Gulf Gulfcrown Grease No. 2 Mobil Grease 7 7 Phillips Philube 1B and RB Grease Shell Alvania Grease EP2 Sohio Bearing Guard "LT"

Table A- 1: Lubrication Equivalency Chart

(1 quart/0.9 liter) 0590-04840-71 (5 gal./ 18.9 liter)

0590-04843-71 (5 gal./ 18.9 liter)

(1 ga1./3.785 liter)

0590-04845-71 (5 gal./ 18.9 liter)

Toyota Pallet Truck Service Manual

Appendix Torque Chart - Standard (Ferrous)

Torque Chart

- Standard (Ferrous)

Table A-2: Torque Chart - Standard "Note: Use "oiled" values for bolts with thread-locking compound

Appendix

Toyota Pallet Truck Service Manual

Torque Chart - Metric

Torque Chart

- Metric

Table A-3: Torque Chart - Ferrous Metric "Note: Use "oiled" values for bolts with thread-locking compound

Table A-4: Torque Chart - Non-Ferrous Metric "Note: Use "oiled" values for bolts with thread-locking compound

Toyota Pallet Truck Service Manual

Appendix Decimal Equivalent Chart

Decimal Equivalent Chart

Table A-5: Decimal Equivalent Chart

Appendix Decimal Equivalent Chart

Table A-5: Decimal Equivalent Chart

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Appendix Standard/Metric Conversions

Standard/Metric Conversions

Appendix Standard/Metric Conversions

Toyota Pallet Truck Service Manual

Toyota Pallet Truck Service Manual

Appendix Electrical Schematics

Electrical Schematics

I NOTES: 7

1 . SCHEMATIC SHOWN WITH KEY SWITCH OFF, BRAKE APPLIED AND FORKS FULLY LOWERED.

A Figure A- I:

I

B

I

M o d e l 6HBW30 Electrical Schematic (Sheet 1 of 2)

C

I

D

43

6

E

I

F

M o d e l 6HBW30 Electrical Schematic (Sheet 2 o f 2)

I

NOTES: 1. SCHEMATIC SHOWN WITH KEY SWITCH OFF, BRAKE APPLIED, COAST SYSTEM DISENGAGED AND FORKS FULLY LOWERED. 2. ON TRUCKS WITHOUT COAST INTERLOCK PS-5A AND JS-5BARE CONNECTED TOGETHER. A

Figure A-2:

I

B

I

C

M o d e l 6HBE30/6HBE40 Electrical Schematic (Sheet 1 of 2)

J95

, METER OPTIONS CONNECTOR

+I+

E

I

F

I

M o d e l 6HBE30/6HBE40 Electrical Schematic (Sheet 2 of 2)

G

NOTES: 1 . SCHEMATIC SHOWN WITH KEY SWITCH OFF, BRAKE APPLIED AND FORKS FULLY LOWERED.

A Figure A-3:

I

B

I

C

Model 6HBC30/6HBC40 Electrical Schematic (Sheet 1 of 2)

I

D

+b

+b

E

I

F

I

M o d e l 6HBC30/6HBC40 Electrical Schematic (Sheet 2 of 2)

G

I

H

FU3 15 AMPS

p N 1 SW1 KEYSW

4

I

,

IGN2

N

y

SW2 BRAKE

1 FU2 250A

2

B+ r----1

=; - 2

-

v

1

4

I

- B

I I

-T

I I

- E

I

-

MI-1

I I I

FIELD WEAKEN CIRCUIT

I

IM1-4

u' ,

I ,

MI-2

52

MOTOR FIELD

---

L---------------------------

DlRECTlONAI COMACTORS

HANDLE ASSEMBLY

I

I

L ----------- )- ---------- 1 B-

NOTES: 1 . SCHEMATIC SHOWN WITH KEY SWITCH OFF AND BRAKE APPLIED.

A Figure A-4:

I

B

I

M o d e l 6TB50 Electrical Schematic (Sheet 1 of 2)

C

I

D

+b

+b

E

I

F

M o d e l 6TB50 Electrical Schematic (Sheet 2 of 2)

I

FU3-2 B+ BATTERY SW2-NOBRAKE SWITCH

DISCHARGE METER OPTION

HOUR METER OPTION COMMON (0-1

METER OPTIONS TERMINALS

+

COMPONENT LEGEND SWl KEYSWITCH SW2 BRAKE SWITCH SW3 FORWARD SWITCH SW4 REVERSE SWITCH SW7 BELLY BUITON SWITCH (OPT.) SW9 HORN SWITCH (HANDLE) SWlO LIFT CUT-OUT SWITCH (OPT.) SWl 1 LOWER SWITCH (HANDLEOPT.) SW12 LlFT SWITCH (HANDLE OPT.) SW13 HORN SWITCH (RAILOPT.) SW14 LOWER SWITCH (RAILOPT.) SW15 LIFT SWITCH (RAILOPT.) SWl6A,B RABBIT SWITCH (RAIL OPT.) SW17 RABBIT SWITCH (FLOOR OPT.) SW27 HlGH SPEED ENABLE (OPT.) SW28 COAST INTERLOCK (OPT.) PMCl

CONNECTOR ON MOTOR CONTROLLER

FUl FUSE PUMP CIRCUIT 150 AMPS FU2 FUSE MOTOR CIRCUIT 250 AMPS FU3 FUSE CONTROL CIRCUIT 15 AMPS MI-F CONTACTOR FORWARD MI-R CONTACTOR REVERSE M2 CONTACTOR FIELD WEAKEN M3 CONTACTOR PUMP RLYl SPEED MODE RELAY (OPT.) DA2 MOD FOR HORN SUPPRESSION DA3 MOD FOR HORN ALERT FEED (OPT.) SOL1 SOLENOID LOWER MD MOTOR DRIVE MP MOTOR PUMP HTRl HEATER IN HANDLE

JP2 JP4 JP6 JP9 JPlO

Figure A-5:

CONNECTOR BY MOTOR FOR HANDLE FUNCTIONS CONNECTOR BY KEY SWITCH FOR RAIL FUNCTIONS CONNECTOR BY MOTOR FOR TRAVEL TERMINAL CONNECTIONS FOR METERS CONNECTOR IN HANDLE FOR TRAVEL AND FUNCTION CONNECTIONS

JPS2 JPS3 JPS4 JPS5

SPLICE BY CONTROLLER FOR FORWARD TRAVEL SPLICE BY CONTROLLER REVERSE TRAVEL SPLICE BY CONTROLLER FOR FORWARD TRAVEL SPLICE BY CONTROLLER HlGH SPEED INPUT

SPL3

SPLICE IN CONNECTOR JP4

Electrical Schematic - legend (Sheet 1 of 2)

VR

THROTTLE POTENTIOMETER

FU3-2B+ BAnERY 'SWIdGNl KEYSWITCH 'SW2-NO BRAKE SWITCH

SW2-NO BMKE SWITCH

HOUR/DISCHARGE METER OPTION COMMON I51

M3-Y

HOUR/DISCHARGE WITH INTERRUPT METER OPTION

METER OPTIONS TERMINALS

+

CONNECTORS

-- J9d J9-2

I

-J9-5

MTR-I MTR-2 MTR-I 1 MTR-7 MTRd

-J9-3

I

FROM HORN SWITCH

HZIPOSI

BNEG

WIRING FOR ELECTROMECHANICAL HORN

E

WIRING FOR ELECTRONIC HORN

I

F

Electrical Schematic - Legend (Sheet 2 of 2)

Appendix

Toyota Pallet Truck Service Manual

Electrical Schematics

This page intentionally left blank.

Toyota Pallet Truck Service Manual

Index

Index

Assembly. Casters . . . . . . . . . . . . . . . . . . 6-81

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Adding Water . . . . . . . . . . . . . . . . . . 6-13 Charging . . . . . . . . . . . . . . . . . . . . . . 6-11 Exterior Cleaning . . . . . . . . . . . . . . . 6- 10 Gates . . . . . . . . . . . . . . . . . . . . . . . . .6-8 Gates And Rollers . . . . . . . . . . . . . . . . 6-7 Maintenance Free . . . . . . . . . . . . . . . 6-15 Rollers . . . . . . . . . . . . . . . . . . . . . . . .6-8 Specific Gravity . . . . . . . . . . . . . . . . . 6-14 Storage . . . . . . . . . . . . . . . . . . . . . . . 6-15 Voltage Check . . . . . . . . . . . . . . . . . . 6-15 Without Gates and Rollers . . . . . . . . . . 6-9 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

Cables. Power . . . . . . . . . . . . . . . . . . . . . 6-16 Casters . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Assembly . . . . . . . . . . . . . . . . . . . . . 6-81 Wheel Replacement . . . . . . . . . . . . . . 6-79 . 1 12 Cold Storage . . . . . . . . . . . . . . . . . . . . . 6.

Commutator . . . . . . . . . . . . . . . . . . . . . . 6-56 Component Locators . . . . . . . . . . . . . . . . . 6- 5 Connectors. Battery/Charger/Truck . . . . 6-16 Contactors Fonvard/Reverse Travel . . . . . . . . . . 6-44 Rabbit Speed (Field Weakening) . . . . . 6-40 Tip Inspection . . . . . . . . . . . . . . . . . . 6-39 Control Handle . . . . . . . . . . . . . . . . . . . . 6-31 Return Spring Adjustment . . . . . . . . . 6- 31 Conversions. Standard/Metric . . . . . . . . . A-7 Covers. Tractor . . . . . . . . . . . . . . . . . . . . . 6-7 Cushion Tire . . . . . . . . . . . . . . . . . . . . . . 6-76

Deadman Switch . . . . . . . . . . . . . . . . . . . 6-23 Decimal Equivalent Chart . . . . . . . . . . . . . A-5 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Drive Housing Steering Bearing . . . . . . . 6-74

Toyota Pallet Truck Service Manual

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . .6.65 Housing Lubrication . . . . . . . . . . . . . .6.73 Tooth Pattern . . . . . . . . . . . . . . . . . . .6-70 Vent Plug . . . . . . . . . . . . . . . . . . . . . .6.72 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . .6.75

Electrical Connectors . . . . . . . . . . . . . . . .5-10 Electrical Schematics . . . . . . . . . . . . . . . . .A-9 Emergency Reverse Check . . . . . . . . . . . .6.35 Equivalent Chart. Decimal . . . . . . . . . . . . .A-5

Filter Screen . . . . . . . . . . . . . . . . . . . . .6-108 Fork Height Adjustment . . . . . . . . . .6.88. 6.90 6000 Lb. . . . . . . . . . . . . . . . . . . . . . . .6.88 Long-John Models . . . . . . . . . . . . . . .6.88 .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20

Gauges . . . . . . . . . . . . . . . . . . . . ..6.26. 6.30 Battery Discharge Meter . . . . . . . . . . .6-27 Combination Hour/Battery Discharge Meter (2) . . . . . . . . . . . . . . . . . . . .6.28 Hour Meter . . . . . . . . . . . . . . . . . . . . .6.26 Gear Oil Changing . . . . . . . . . . . . . . . . . . . . . .6.73 Level . . . . . . . . . . . . . . . . . . . . . . . . . .6.73

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31 High Mica . . . . . . . . . . . . . . . . . . . . . . . .6.56 .

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . .6-94 Hydraulic Pump . . . . . . . . . . . . . . . . . . .6-109 Hydraulic Ram . . . . . . . . . . . . . . . . . . . . .6-99 Hydraulic Reservoir . . . . . . . . . . . . . . . .6-107 Hydraulic Solenoids . . . . . . . . . . . . . . . . .6-25 Hydraulic Unit . . . . . . . . . . . . . . . . . . . .6-106

Key Switch . . . . . . . . . . . . . . . . . . . . . . . .6.22

Toyota Pallet Truck Service Manual

Lift Limit Switch . . . . . . . . . . . . . . . . . . . 6-91 Load Wheels . . . . . . . . . . . . . . . . . . . . . .6-84 Model 6TB50 . . . . . . . . . . . . . . . . . . .6-85 Lubrication Equivalency Chart . . . . . . . . . A-2

M Map. Navigating the Manual . . . . . . . . . . . 1-2 Metric Conversions . . . . . . . . . . . . . . . . . .A-7 Motor Controller . . . . . . . . . . . . . . . . . . .6-34 Cloning . . . . . . . . . . . . . . . . . . . . . . .5-20 Diagnostic History . . . . . . . . . . . . . . . 5- 12 Programmable Maintenance Tool . . . . 5- 12 Programming . . . . . . . . . . . . . . . . . . . 5- 17 Special Program Mode . . . . . . . . . . . . 5- 16 Test Mode . . . . . . . . . . . . . . . . . . . . . 5-14 Motors Brush Spring Tension . . . . . . . . . . . . 6-55 Brushes . . . . . . . . . . . . . . . . . . . . . . .6-53 Drive . . . . . . . . . . . . . . . . . . . . . . . . .6-61 General . . . . . . . . . . . . . . . . . . . . . . .6-53 Lift . . . . . . . . . . . . . . . . . . . . . . . . .6-110 Tests . . . . . . . . . . . . . . . . . . . . . . . . .6-58

Power Cables . . . . . . . . . . . . . . . . . . . . . .6- 16 Programmable Maintenance Tool . . . .3.6. 5-12 Cloning . . . . . . . . . . . . . . . . . . . . . . .5-20 Diagnostic History . . . . . . . . . . . . . . . 5- 12

Relief Valve . . . . . . . . . . . . . . . . . . . . . . .6-96 Return Spring Adjustment . . . . . . . . . . . . 6-32

Index

Safety .

Battery . . . . . . . . . . . . . . . . . . . . . . . . 2.7 .

Definitions . . . . . . . . . . . . . . . . . . . . . 2.2 General . . . . . . . . . . . . . . . . . . . . . . . . 2-3 .

Jacking . . . . . . . . . . . . . . . . . . . . . . . .2-13

.

Static . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Schematics . .9 Electrical . . . . . . . . . . . . . . . . . . . . . . A Seals Hydraulic Cylinder . . . . . . . . . . . . . .6. 103 Sliders Pallet Entry Pallet Entry Wheels/Sliders . . . . . . 6.87 Solenoids .

Hydraulic . . . . . . . . . . . . . . . . . . . . . 6.25 Static Safety . . . . . . . . . . . . . . . . . . . . . . .2. 11 Suction Tube . . . . . . . . . . . . . . . . . . . . .6. 108 Switches Deadman . . . . . . . . . . . . . . . . . . . . . . 6-23 General . . . . . . . . . . . . . . . . . . . . . . . 6-21 .

Key . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 . .

Lift Limit . . . . . . . . . . . . . . . . . . . . . . 6-91

.

Terminal Nuts . . . . . . . . . . . . . . . . . . . . 6.57 Torque Chart .

Metric . . . . . . . . . . . . . . . . . . . . . . . . . A.4 . .2 Standard . . . . . . . . . . . . . . . . . . . . . . A .

Tractor Cover . . . . . . . . . . . . . . . . . . . . . . 6.7 Travel Potentiometer . . . . . . . . . . . . . . . . .6.36

. 15 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 6.

.

Wheel. Drive . . . . . . . . . . . . . . . . . . . . . . 6.75 Wheels Caster . . . . . . . . . . . . . . . . . . . . . . . . . 6.79 .

Load . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Pallet Entry . . . . . . . . . . . . . . . . . . . . .6.87 Wiring Harness . . . . . . . . . . . . . . . . . . . . .6. 17

Index

Toyota Pallet Truck Service Manual

This page intentionally left blank.