Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Service Manual SN 20011 and up - PDF

Service Manual

Models 6HBW30,6HBE30,6HBE40, 6HBC30,6HBC40,6TBSO Serial No.: 2001 1 and Up

00700-CL380

Issued: 8/29/97

Copyright 8 1997 by Toyota lndustrial Equipment, a division of Toyota Motor Sales, 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 retreival or transfer, or recording without the written permission of the publisher.

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

Toyota Walkie Service Manual

How to Use This Manual

How to Use This Manual

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

How To Use This Manual Map of the Manual

Map of the Manual

1

How To Use This Manual

Map of the Manual

I

I Manual Design

I Systems Ovexview I

1

i

Scheduled Maintenance

I

Vehicle Spedication

v I General System Data

Theory of Operations

Troubleshooting

L d Page Revision Record

Component Procedures

Alphabetical List of Component

Appendix

Component Location Photos

Table of Contents

Start Page

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

How To Use This Manual Manual Design

Manual Design The Toyota Walkie Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise.

Anticipate your needs and reduce your decisions regarding maintenance.

Reduce page flipping through a "one-stop shopping" approach.

The two-line running page header at the top of each page tells you: the name of the manual (Toyota Walkie Service Manual) the current Chapter Title (e.g., this page How to Use This Manual) the current topic (e.g., this page Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual.

00700-CL380 Issued: August 29, 1997

How To Use This Manual

Toyota Walkie Service Manual

Manual Design

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

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

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

Systems Overview includes truck specifications and theory of operation information.

Scheduled 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.

The START TROUBLESHOOTING chart (on page 5-20) will guide you to the individual troubleshooting symptom chart you need.

Once you're familiar with the symptoms listed, you may instead simply find the symptom chart from the List of Troubleshooting Charts (page 5- 19).

When you complete a troubleshooting procedure, be sure to follow the steps in End of Troubleshooting Chart END- 1 (page 5-23).

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 (e.g., brake must be removed before drive motor) Functional relation (e.g., carriage and mast components are grouped together)

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

How To Use This Manual Manual Design

To find a component procedure, you may use one of three methods: Look up the component name in the Alphabetical List of Components (page 6-2).

Find the component in the Component Locators (page 6-4).

Look up the component name in the 1). maintenance manual Index (8Appendix contains reference information such as torque values and lubricants.

Index lists subjects alphabetically.

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

How To Use This Manual Page Revision Record

Page Revision Record This page is a record of the latest revised pages in this manual. Whenever a page is revised. we update this section and include it in the revision. This lets you keep track of the latest revised pages for this manual.

If no date appears in the 'Revised" column, it means that the page has never been revised since the manual was first issued.

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00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

How To Use This Manual Page Revision Record

00700-CL380 Issued: August 29, 1997

How To Use This Manual

Toyota Walkie Service Manual

Table of Contents

Table of Contents How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ManualDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 STAEiTPage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Generalsafety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Staticsafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 JackingSafety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Systems O v e ~ e .w. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Truck Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 General System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . .5.3 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . .5.6 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Electrical Comector Locator Chart . . . . . . . . . . . . . . . . . . . . . 5-10 List of Troubleshooting Charts. . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

00700-CL380 Issued: August 29. 1 997

Toyota Walkie Service Manual

How To Use This Manual Table of Contents

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Torque Chart . Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Torque Chart . Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Decimal Equivalent Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Standard/Metric Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1 1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

00700-CL380Issued: August 29. 1997

Toyota Walkie Service Manual

How To Use This Manual Table of Contents

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00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

How To Use This Manual

START Page

START Page

(

START:

/

Why an you here?

1

GOto Chapter 2 "safety"

Yes

,

Go to Chapter 3

Yes

,

\

To review safetv precautions?

1

"Systems Ovendew"

No

Go to Chapter 4 "Scheduled Maintenance"

Go to Chapter 5 'Troubleshooting"

c Q List of Troubleshooting Charts

Go to Chart

00700-CL380Issued: August 29, 1997

+

S T m Troubleshooting

Toyota Walkie Service Manual

How To Use This Manual -

START Page

inspect. adjust.

Yes

Go to Chapter 6 "Component Procedures"

1

w h

1

Alphabetical Idst of Component Procedures

1

Component Locator

general reference information?

4J-J Go to the Index

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

00700-CL380 Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

Safety Definitions

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

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

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

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

Safety General Safety

General Safety

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

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.

00700-CL380 Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

General Safety

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

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

Follow the scheduled lubrication, maintenance and inspection steps.

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

00700-CL380 Issued: August 29, 1997

Toyota Walkie 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.

00700-CL380 Issued: August 29,1997

Safety

Toyota Walkie Service Manual

General Safety

Do NOT wash this truck with a hose.

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

00700-CL380Issued: August 29, 1 997

Toyota Walkie Service Manual

Safety Battery Safety

Battery Safety

As a battery is being charged, an ex losive gas mixture forms within and arounc reach 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 here are no open flames or sparks in the chargin area. An o flame or spark can ignite 1s gas, resu hng In serious damage or injury.

+to

pen

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns.

Should any electrolyte come in contact with your clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in your eyes, flush the area with cold water and get medical help immediately.

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

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

00700-CL380 Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

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 a t the battery terminals. A spark often occurs a t 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.

1 00700CL380 Issued: August 29, 1997

Toyota Walkie 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.

I

Keep filler plugs h l y 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 allow the gas to escape from the cells.

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

00700-CL380 Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

Battery Safety

Make sure you install the correct size battery. A smaller or lighter weight battery could seriously affect truck stability. See the truck's data 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.

00700-CL380Issued: August 29,1997

Toyota Walkie Service Manual

Safety Static Safety

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

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

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.

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

1. Place a static discharge wrist strap around

your wrist. Connect the ground lead to the wrist strap connector.

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 should 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, part number 0059004849-71. The kit includes a wrist strap, ground cord and static-dissipative work surface (mat). Follow the instructions packaged with this kit.

Wrist straps are available in quantities of 25, as part number 00590-04848-7 1.

00700-CL380 Issued: August 29, 1997

Figure 2- 1:

Anti-Static Wrist Strap (without mad

Safety

Toyota Walkie Service Manual

Static Safety

Figure 2-2:

Anti-Static Kit with Wrist Strap and Mat

A wrist strap tester is available as part number

00590-04850-71.

Contact your local Dealer for information.

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Safety Jacking Safety

Jacking Safety Sometimes you may need to jack up the truck off the floor to perform maintenance procedures. When doing so, observe the proper safety precautions: 1. Lower the forks completely. Remove m y

load.

2. Place all controls in neutral.

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

4. Disconnect battery connector.

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

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

Fork Section 1. Using lift button. raise forks to maximum

height.

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

3. Lower forks onto blocks.

4. Disconnect the battery.

Figure 2-3:

00700-CL380 Issued: August 29, 1997

Blocking the Fork Section

Toyota Walkie Service Manual

Safety Jacking Safeiy

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" (2-1/2 cm).

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.

No=: After working on a vehicle, test all controls and functions to assure proper operation.

Figure 2-4:

Jacking Tractor Section

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Safeiy Tiedown for Transport

Tie-down for Transport To transport your Toyota walkie in a n over-theroad 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 Safety" on page 2-7.

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

4. Position a n additional adjustable chain over

and through the battery compartment.

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

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

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

00700-CL380 Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

Towing

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

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

3. Using a suitable towing vehicle, lift the

tractor end of the walkie truck until the drive tire is no more than 1" off the floor.

4. Tow the truck slowly in the tractor-first

direction.

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

Safety Welding Safety

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

R

Coaiin removal may be by mechanical meth s, chemical methods or a combination of methods. Flame cutting and/or welding operations should be carried out only in well ventilated areas using local exhaust if necessary.

J

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

Check for shorts to frame as described on See "Checking for Shorts from Battery to Truck Frame" 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 weldrng operations near the electrical components.

00700-CL380Issued: August 29, 1997

Safety

Toyota Walkie Service Manual

Welding Safety

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.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Systems Overview

Systems Overview

00700-CL380 Issued: August 29, 1 997

Systems Overview

Toyota Walkie Service Manual

Truck Model Identification

Truck Model Identification

6-0

Low-Lift Walk-Behind

6HBC30 and 6HBC40 Center Rider

6HBE30 and 6HBE40 End Rider

6TB50 Tow Tractor

00700-CL3 80 Issued: August 29, 1 997

Systems Overview

Toyota Walkie Service Manual

Vehicle Specifications

Vehicle Specifications 6HBE30

6HBC30

6TB50

Maximum Load Capacity

6,000 lb.

(2.724 kg.)

6,000 lb.

(2.724 kg.)*

6.000 lb.

(2,724 kg.)**

Upright Height

60.1 in.

(152.7 cm.)

60.1 in.

(152.7 cm.)

54.1 in.

(137.4 cm.)

10.000 lb.

(4540 kg.)

54.1 in.

(137.4 cm.)

Overall Length

upto91.7in.

(232.9 cm.)

upto102.4in.

(260.1 cm.)?

upto114.3in.

(290.3 cm.#

53.11in.

(134.9 cm.)

Overall Width

32.5 in.

(82.6 cm.)

36 in.

(91 cm.)

32.5 in.

(82.6 cm.)

32.5 in.

(82.6 cm.)

9 in. (22.9 cm)

9 in. (22.9 cm)

N/A 3.5 mph (4 kph)

Category

I

Maximum Lift Height -

6 0

9 in. (22.9 cm) -

Coast Travel Speed, Maximum

- --

3.5 mph (4 kph) 5.5 mph (9 kph) NA

Stopping Distance

6 ft. (1.83 m.)

3.5 mph (4 kph) 5.5 mph (9 kph) 7.5 mph (12 kph) 6 ft. (1.83 m.)

Battery Compartment Width

9.19 in.

(23 cm)

13.44 in.

(34.1 cm)

13.44 in.

(34.1 cm)

13.44 in.

(34.1 cm)

Battery Voltage

24 volts

24 volts

24 volts

24 volts

Minimum Battery Weight

575 lb.

(261 kg.)

625 lb.

(284 kg.)

1058 lb.

(480 kg.)

965 lb.

(438 kg.)

1500 lb.

(681 kg.)

1234 lb.

(560 kg.)

965 lb.

(438 kg.)

1500 lb.

(681 kg.)

1320 lb.

(599 kg.)

965 lb.

(438 kg.)

1500 lb.

(681 kg.)

1190 lb.

540 kg.

Regular Speed, Maximum Rabbit Speed. Maximum

Maximum Battery Weight Truck Weight Without Battery

3.5 mph (4 kph) 5.5 mph (9 kph) 7.5 mph (12 kph) 6 ft. (1.83 m.)

5.5 mph 19 kph) 7.5 mph (12 kph) 6 ft. (1.83 m.)

* Model 6HBE40 has 80001b. (3632kg.)capacity. ** Model 6HBC40 has 80001b. (3632 kg.) capacity.

t with 8000 lb. (3632 kg.)trucks, overall length is up to 146 in. (370.9 cm.) # with 8000 lb. (3632 kg.) trucks, overall length is 156.3 in. (397 cm.)

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

Ed

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Toyota Walkie Service Manual

Systems Overview General System Data

General System Data

Gauge Console

Gmb Bar

con-tml Handle

/

Tractor

Fork Section

Figure 3- 1:

load Wheels

Model 6HBE30

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Toyota Walkie Service Manual

Systems Overview General System Data

Handle

Figure 3-2: Model 6HBC30

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Toyota Walkie Service Manual

Systems Overview

--

Programmable Maintenance Tool

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

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

Figure 3-3:

Programmable Maintenance Tool

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Toyota Walkie 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.

00700-CL380 Issued: August 29, 1997

Systems Overview

Toyota Walkie Service Manual

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

Lowering solenoid opens.

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

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Toyota Walkie Service Manual

Scheduled Maintenance

Scheduled Maintenance

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scheduled Maintenance

Toyota Walkie Service Manual

Maintenance Guidelines

Maintenance Guidelines Following a regularly scheduled maintenance program: promotes maximum truck performance prolongs truck life reduces costly down time avoids unnecessary repairs: Scheduled maintenance includes: lubrication cleaning inspection 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 s e ~ c e more s often as required to keep the unit in good operating condition.

See page 7-2 in the Appendix for lubrication equivalents. Refer to the manufacturer's supplements for components not listed on the following pages.

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Scheduled Maintenance

Toyota Walkie Service Manual

Daily

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

Item

Daily or Eight Hour Checklist

Battery

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

Check the electrolyte level. See "Adding Waterw on page 6-12.

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

Check the battery gates for bending or cracks if so w equipped. Replace if necessary. Check the "free play of the battery. Make sure it has no more than 1 /2" of movement.

peration General O

Check that the horn operates when you press the horn button. (Battery must be connected.)

Check the speed and directional controls.

Check the steering operation. check the lifting and lowering functions.

Check the operation of the emergency reverse switch.

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

Brake

Verify the drive motor does not run while the brake is applied.

Check that the control handle returns to the vertical position when released. Models 6HBW30, 6HBE30 and 6HBE40 only.

g

Hydraulic System

Check for oil leaks.

Casters

Check the condition of the casters. Remove any steel chips and foreign material to prevent damage to casters. If they are badly worn or have an excessive number of breaks, report the damage to your supervisor or maintenance personnel.

Wheels

Check the condition of the drive wheel, load wheels and pallet entry wheels. Remove any steel chips and foreign material to prevent damage to the wheels.

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

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Toyota Walkie Service Manual

scheduled Maintenance Every Two Months or 250 Operating Hours

Every Two Months or 250 Operating Hours Perform daily checks plus the following: 1

Item Grease Fittings

Forks

Lubrication Points Lift Cylinders

Hydraulic System

General

System

Every Two Months or Every 250 Hours Lubricate all grease fittings. See "Grease Fittings" on page 4-7.

Check the fork height adjustment. See "Fork Height Adjustment" beginning on page 6-87.

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

Lubricate all levers, shafts and leakage points.

Check the Mt cylinders for leaks. Replace components if necessary. See "Hydraulic Ram" on page 6-96.

Check for proper fluid level-1/4" (6.35mm)below fill hole.

Add fluid if necessary. See "Lubrication Equivalency Chart" on page 7-2.

Check hydraulic connections and mountings.

Check the tightness of the pump and motor hardware.

Check hoses, tubes and fittings for leaks. Replace hoses or seals. See "Hydraulic Cylinder Seals" on page 6- 101. Clean the fill/vent plug. See "Hydraulic Unit" on page 6-105.

Check for loose hardware. Tighten if necessary.

Check the tightness of the drive unit mounting bolts.

Tighten if necessary.

Visually inspect all cables for damage. Replace if necessary.

See "Power Cables" on page 6-15.

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

Drive Wheel

Check the tightness of the capscrews on the drive wheel mounting. Tighten to 80 ft. lbs. (112Nm).

Drive Unit

Check for oil leaks. If leaks are found, check the oil level. If the oil level is low, determine the cause. See "Drive Unit" on page 6-63.

Check and lubricate the drive housing support bearing.

Check and clean the drive unit vent plug. See "Drive Unit Vent Plug" on page 6-71.

Contactors

Clean and inspect contactors. Replace worn or burnt tips.

See "Contactors" on page 6-40.

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Toyota Walkie Service Manual

Scheduled Maintenance Every Two Months or 250 Operating Hours

Every Two Months or Every 250 Hours

Item

/

Brushes

/I

Check the condition of brushes, springs and holders.

Check that the brush length exceeds the minimum length.

Drive motor-9/ 16'' (14 mm) Hydraulic pump motor-1/2" (13 mm)

I

Deadman Switch

1 Check adjustment. See .Deadman Switch" on page 6-22.

Load Wheel

Check and lubricate the load wheel bearings and linkage.

Check and replace damaged wheels as necessary.

Pallet Entry Wheels Brake

1 Check the brake shoes for wear. Replace if necessary. See /

"Brake" on page 6-50.

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Toyota Walkie Service Manual

Scheduled Maintenance Annually or Every 2000 Operating Hours

Annually or Every 2000 Operating Hours Perform the every two months checks plus the following: I

I I/ Hydraulic System I Change the hydraulic fluid. See .Hydraulic Fluidnon page 6-92. I/ Item

Annually or Every 2000 Hours

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Toyota Walkie Service Manual

Scheduled Maintenance Grease Fittings

Grease Fittings

Figure 4- 1 :

Caster Grease Fittings and Bell Crank Grease I'ittings [Between Tractor and Fork Section)

Figure 4-2:

Load Wheel Grease Fittings and Fork Grease F'ittings (Lop View)

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Scheduled Maintenance

Toyota Walkie Service Manual

Grease Fittings

Figure 4-3:

Drive Unit Grease Fiffings(2), 18Q Aport (location shown)

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Troubleshooting

Troubleshooting

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Troubleshooting

Toyota Walkie Service Manual

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 START TROUBLESHOOTING Chart TS-1 on page 5-20 to guide you to the individual symptom chart you need.

Once you're familiar with the symptoms listed, you may instead simply look up the symptom chart from the List of Troubleshooting Charts on page 5-19.

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 End of Troubleshooting Chart END1 on page 5-23.

If the troubleshooting symptom charts do not isolate the problem, or if the symptoms are not consistent or repeatable, go to the General Troubleshooting Chart GENl on page 5-21.

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

Each chaft begins with a lozenge-shaped symbol containing the title and symptom.

Charts are identified a s H for Hydraulic and T for Travel. The logic generally flows top to bottom and left to right. A symbol shaped like a baseball home plate means the chart is continued on another page, either a continuation of the current chart, or a different chart. Continuation charts have a suffix number added. A continuation chart begins with a circle-shaped symbol containing the chart number, including suffix.

For example, look a t Chart H-3 on page 5-31.

One logic path is continued on Chart H-3-2, which is the next page. Another logic path from Chart T-12 goes to the End of Troubleshooting Chart END 1, which is on page 5-23.

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Toyota Walkie 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 Safety" on page 2-7. Be sure to block the truck whenever 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 6-16.

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Troubleshooting

Toyota Walkie Service Manual

Checking for Shorts from Battery to Truck Frame

Checking for Shorts from Battery to Truck Frame 1. Turn the key switch OFF and ~ ~ S C O M ~ C ~ the battery connector.

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

3. Attach the voltmeter leads as follows:

Negative (-) lead to the truck frame Positive (+) lead to the positive battery terminal.

4. The voltmeter should show no more than 3 volts.

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

7. If you get more than a 3 volt reading in Step 4 or 6: a. Remove the battery from the truck. See 'Battery" on page 6-7. b. Thoroughly clean the battery and battery rollers. See "Battery Exterior Cleaning" on page 6-9. c. Reinstall the battery. d. Repeat steps 2 through 6 to see if this has eliminated the problem. e. If excessive voltage is still found. have the battery checked for internal leakage.

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Toyota Walkie Service Manual

Troubleshooting Checking for Shorts from Components to Truck

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

2. Use an ohmmeter and measure the

resistance to frame at 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 continue until this condition is corrected.

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

4. Connect the battery lead to the truck.

5. Use an ohmmeter to measure the leakage current to frame at B+, B-, all fuses and all motors. If the current is less than .001 ampere ( IrnA),the truck system passes. If the current exceeds lrnA, go to step 6.

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

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Troubleshooting

Toyota Walkie Service Manual

Hydraulic Troubleshooting Guide1ines

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

Whenever possible, keep the key switch OFF and the battery connector disconnected.

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Toyota Walkie 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 is activated when a direction is first selected. It is the speed at the minimum throffle setting (minimum 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 switch in the truck that must be closed to allow truck operation. It is activated by the control handle position on the 6HBW30 and 6HBE30 or 6HBE40, and the brake levers on the 6HBC30 or 6HBC40 and 6TB50. The deadman 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, allowing 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 throffle is applied. The motor controller is programmed to have HPD based on the deadman switch input See "Deadman Switch" on page 5-7.

Open Circuit 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 the drive current limit is linearly decreased from full set current down to zero. Plug current is

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual ---

----

Definitions

not reduced 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 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 vary throttle sensitivity a t low speeds.

Eleven preprogramrned ramp shapes are available between 20% and 70%. in 5% steps, e.g.-20%, 25%. 30%, etc.

The ramp shape number refers to the PWM output at half throttle, a s a percentage of its full range. See "Pulse Width Modulation" on page 5-8. Changing either 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 "Short" A short circuit is an unspecified path in a circuit that provides unwanted fuli 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.

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Toyota Walkie Service Manual

Troubleshooting Definitions

Static Return To Off The Static Return to Off (SRO)feature prevents the truck from being started a t 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 walkie is Type " 1" in the programming mode.

Sequencing Delay Sequencing delay allows the deadman switch to be momentarily opened within a set time (sequency delay), thus preventing inadvertent activation of high pedal disable (HPD) or static return to off (SRO).-See "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 with the programmable maintenance tool 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 proper 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 a t less than 25'C (- 13'F), the current limit is cut back resulting in reduced travel speed.

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Troubleshooting

Toyota Walkie Service Manual

Electrical Connector Locator Chart

Electrical Connector Locator Chart Refer also to the electrical connector locator photos which follow the table below:

Function or Routing

Connector

Location

PMC 1

Connector on motor controller

Motor controller

JP2

Handle functions

By motor

JP4

Rail functions

By key switch

JP6

Travel

By motor

JP9

Meters

By key switch

JPlO

Travel and function

In control handle

JPS4

Splice for forward travel

By controller

Figure 5- 1:

Electrical Connector locator Chart

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Troubleshooting

Toyota Walkie Service Manual

Fault Codes

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

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

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

Correct faults by following the Troubleshooting Flowcharts beginning on page 5-20.

Fault Code LED off Solid on Single flash

. ..

.. . ...

1, 3 ....

1, 4 ...

2, 1 .. ..

2, 2 .. ...

2,3 .. ....

2, 4 ....

3, 1 ... ..

3, 2 1, 2

3,4

4, 1 4, 2

4, 3

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

Explanation No power or defective controller Defective motor controller Controller operational, no faults Hardware fail-safe error, defective motor controller (M-) terminal fault or motor output short Static return to off (SRO)fault Throttle wiper input fault Emergency reverse circuit check fault (BB wiring) High-pedal-disable fault (HPD) Throttle pot low open or shorted to B+ or BContactor driver overcurrent (shorted) Welded direction contactor

Low battery voltage (c 16 V) High battery voltage (> 45 V) Thermal cutback (overtemperature/undertemperature)

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Troubleshooting

Toyota Walkie Service Manual

Programmable Maintenance Tool

Pro rammable Maintenance Too

P

The optional Programmable Maintenance Tool (P/N 00590-01943-71)allows you to test and diagnose the motor controller in this w&e truck.

Ir

The Programmable Maintenance Tool ( P Wis 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. Following this initial display, the PMT displays a prompt for further instruction.

NOTE: Follow the prompt at top of the PMT

C

Flgure 5-2

Programmable Maintenance Tool

screen, not blinking icon to choose the correct setting.

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.

No=: Each fault is listed only once, regardless of the number of times it occurred.

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

2. Remove the tractor cover.

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Toyota Walkie Service Manual

Troubleshooting Diagnostic History

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 diagnostics key.

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

1. Hold the more info key, and press the

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

2. Scroll through the mode using the scroll display keys until "CLEAR DUG HIST" is

the top line in the display.

3. Press the more info key again. The Ph4T 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.

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Troubleshooting

Toyota Walkie Service Manual

Test Mode

Test Mode This section shows you different modes you can use on the PMT to troubleshoot this w&e 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 and turn the key

switch on.

5. Press the test key on the PMT. 6. Scroll through the line items using either scroll display key. When the item you want is the top line on the display, press the more info key for a full screen display.

-

Test Mode Explanation

Display THRO?TLE%

Throttle reading, in percent of full

BA'IT VOLTAGE

Battery voltage

HEAT SINK "C

Heat sink temperature

MAX TEMP "C

Maximum temperature seen*

MIN TEMP "C

Minimum temperature seen*

BRAKE INPUT

Deadman switch: on/off

SPEED INPUTt

Speed switch: on/off

EMR REV INPUT

Emergency reverse switch: on/off

FORWARD INPUT

Forward switch: on/off

REVERSE INPUT

Reverse switch: on/off

FWD CONTACTOR

Forward contactor: on/off

REV CONTACTOR

Reverse contactor: on/off

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

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

5-1 4

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Troubleshooting Test Mode

The chart below lists possible messages you may see displayed when the PMT is operain either the Diagnostic History or the Test mode.

The messages are listed in alphabetical order for easy reference.

Diagnostics and Special Diagnostics List Display

/ BB WIRING CHECK I CONT DRVR OC I DIR CONT WELDED

1 Explanation 1 BB wiring check failed (Emergency Reverse) 1 Contactor driver shorted

/ Direction contactor welded High-pedal-disable activated (HPD) Hardware failsafe activated (defective micro controller)

LOW BA'ITERY VOLTAGE

Battery voltage too low*

M FAULT

(M-) terminal output fault

1) MISSING CONTACTOR / NO KNOWN FAULTS I OVERVOLTAGE

/ Open contactor circuit / No known faults

SRO

Static-return-to-off activated (SRO)

THERMAL CUTBACK

Thermal cutback due to temperature

THROTTLE FAULT 1

Throttle input fault

THRC?lTLEFAULT 2

Throttle low input fault

-

--

I Battery voltage too highf

* <16 volts (24-36V models)

t >45 volts (24-36V models)

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Toyota Walkie Service Manual

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

7. Press either change value key until you reach the value you want.

Special Program Mode Display

Explanation

/I RESET ALL SGITlNGS / CONT SETTINGS- PROG 1 PROG SETTINGS* CONT / CLEAR DlAG HISTORY

I Revert to factory settings. See page 5-18. / Save controller settings in PMT / Load programming settings in controller / Clear diagnostic history memory

CONTRAST ADJUSTMENT

Adjust display contrast

LANGUAGE SELECTION

Select displayed language

PROGRAMMER INFO

Display PMT information

CONTROLLER INFO

Display controller info

1 I1

I/

I/

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Toyota Walkie Service Manual

Troubleshooting -

Programming

Programming You can change certain parameters using the PMT (P/N 00590-01943-71).See Table 5-1 on page 5-18.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 either scroll display key until the parameter you want is the top line of the display. See Table 5- 1 on page 5- 18.

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

8. If the display stops changing and you want

to go further, press the more info key. If the display shows "Min Limit" or "Max Limit", you have reached the factory set limit for that parameter.

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

See "Definitions" on page 5-7.

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Troubleshooting

Toyota Walkie Service Manual

Programming

Recommended

Parameter

Description

Ramp Shape

20-70%

50%

Adjust desired PWM output at 50% throttle to vary throttle sensitivity a t low speeds.

Creep Speed/ Min. Duty Cycle

0-25%

10%

Speed (Min. PWM) at minimum throttle setting.

See Caution Below

0.0-0.3 seconds

Sequencing Delay

0-3 seconds

Variable Plug

On/Off

On

Quick Start

0-6

1.4

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

0-3 seconds

1 second

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

M1 Max Speed

40-100%

100%t

Maximum speed (PWM duty factor) in M1 (high speed) mode.

M2 Accel Rate

0-3 seconds

1 second

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

Caution Below

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

Plug current dependent on throttle position or fixed valueSIX Caution B ~ O W

p p p p

Field Weaken Enable

On/Off

On

Enable operation of the field weakening contactor driver (rabbit speed).

t Any percentage less than 100 will disable field weakening contactor driver (rabbit speed). bble 5- 1: Motor Controller Parameters

A CAUTION While adjustment of these parameters is possible, settings at values other than those listed below will produce improper and unauthorized operaiional characteristics. DO NOT adjust these parameters to values other than those listed below: Creep SpeedIMin. Duty Cycle must be set to 10% Sequencing Delay may only be adjusted between 0.0 seconds and 0.3 seconds.

Variable Plug must be set to On.

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Toyota Walkie Service Manual

Troubleshooting List of Troubleshooting Charts

List of Troubleshooting Charts TS1: START TROUBLESHOOTINGTS1: Start. . . . . . . . . . . . . . 5-20 GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 5-21 MISC: Miscellaneous Problems . . . . . . . . . . . . . . . . . . . . . . . . 5-22 END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . 5-23

Hydraulic Charts H- 1: No Lift. Lift Motor Does Not Run. Travel is OK . . . . . . . . . 5-24 H-2: No Lift or Slow Lift. Lift Motor Does Not Run . . . . . . . . . . 5-29 H-3: No Lower. Lift and Travel OK. . . . . . . . . . . . . . . . . . . . . . 5-31

Travel Charts T- 1: No Travel. Lift/Lower OK . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 T-2: No Travel in Either Direction . . . . . . . . . . . . . . . . . . . . . . 5-38 T-3: No Travel in Either Direction. LifX/Lower OK . . . . . . . . . . 5-39 T-4: No Travel. LSt/Lower OK. Fault Code 1.2. . . . . . . . . . . . . 5-40 T-5: No Travel. Fault Code 3.4 . . . . . . . . . . . . . . . . . . . . . . . . 5-41 T-6: Travel in One Direction Only. Fault Code 3.1 . . . . . . . . . . 5-42 T-7: No Travel. Fault Codes 2.1 or 2. 4 (or both) . . . . . . . . . . . . 5-43 T-8: Slow Travel. LifX/Lower OK. No Fault Codes . . . . . . . . . . . 5-45 T-9: No Emergency Release. Travel/Lift/Lower OK . . . . . . . . . 5-50 T-10: Slow Travel. Lift/Lower OK. Fault Codes 2.2 . . . . . . . . . 5-52 T- 11: No Rabbit Speed. Travel/Lift/Lower OK . . . . . . . . . . . . . 5-53 T-12: No Travel. Fault Codes 4.2 . . . . . . . . . . . . . . . . . . . . . . . 5-57 T-13: Slow or No Travel. Fault Codes 4. 1 . . . . . . . . . . . . . . . .5-58 T-14: Slow or No Travel. Fault Codes 4.3 . . . . . . . . . . . . . . . . 5-60 T-15: No Travel. Fault Codes 1.4. . . . . . . . . . . . . . . . . . . . . . . 5-63 T-16: No Travel. Fault Codes 2.3 . . . . . . . . . . . . . . . . . . . . . . .5-66 T-17: No Travel. Fault Code 3.2 . . . . . . . . . . . . . . . . . . . . . . .5-68 T-18: Plugging Does Not Operate Properly . . . . . . . . . . . . . . . . 5-69 T-19: Truck Does Not Accelerate Properly . . . . . . . . . . . . . . . . 5-70

Wiring Charts W- 1: Truck Functions Partially. . . . . . . . . . . . . . . . . . . . . . . . 5-72

00700-CL380 Issued: August 29. 1 997

Troubleshooting

Toyota Walkie Service Manual

Troubleshooting Flowcharts

Troubleshooting Flowcharts /TS1:

START TROUBLESHOOTING

Yes

I

l-7 Go to Chart

Yes

u Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

GEN 1 : General Troubleshooting

GEN1: General Troubleshooting

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

1

Eliminate unlikely causes.

{Whatis the problem?

I

I

Where did it happen?

When did it happen?

What functions are affected?

1

I Select and prioritize the most likely causes.

What conditions trigger the problem?

Talk directly to the operator or foreman.

Operate the truck yourself.

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

00700-CL380 Issued: August 29,1997

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

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

/

I

i

Troubleshooting

Toyota Walkie Service Manual

MISC: Miscellaneous Problems -

~ S CMiscellaneous : Roblems Not Covered B$ 0 t h a Charts

Is a wiring problem

Yes

I

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

END1: End of Troubleshooting Procedure

( E m 1: End of Troubleshooting Procedure

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

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

Verify the problem does not recur.

Make sure all panels are properly reinstalled.

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

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

Fffl out anv required forms.

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

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

f End of Troubleshooting

00700-CL380 Issued: August 29, 1 997

important if the solution you found is not in the troubleshooting chart.

Troubleshooting

Toyota Walkie Service Manual

H-1: N o Lift, Lift Motor Does Not Run, Travel is OK

{H-1: No Lift. Lift Motor Does Not Run,

\

Travel is OK.

A With key switch on and lift switch depressed, measure voltage between pump contactor coil X and Y t e d s .

With key switch off and battery disconnected. check for continuity and wiring shorts between: Pump contactor coil Y to BPump contactor X to lift cut-out switch Lift cut-out switch to P4-2* Lift cut-out switch to P2-4 P4-2 to hand-rail lif't switch* JP2-4 to JP10-9 JP10-9 to control handle lift switch Hand rail lift switch to P4-1 Control handle lift switch JP10- 1 JP10-1 to JP2-2 P4-1 to keyswitch* P2-2 to keyswitch

Is B+ voltage present?

I *End rider models, with grab bar switches /

With battery plugged in. measure voltage between B- and FU1-2.

1 Go to Chart (

l-7

Go to Chart

v Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

H- 1 -2

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

With key switch off and battery disconnected, check for continuity and wiring shorts between FU1-2 to pump contactor; pump contactor to pump motor.

I

I Yes I

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

Are brushes OK?

No+

Replace brushes.

Replace pump contactor.

-

L r A

* Go to Chart H-1-3

00700-CL380 issued: August 29, 1 997

Go to Chart

Troubleshooting

Toyota Walkie Service Manual

.6 Test pump motor.

See Component Procedures.

I

With key switch off and battery disconnected, remove

motor from pump.See Component Procedures. Turn pump shaft with hand.

Go to Chart

Yes

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

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

H-1-4

( Is wiring OK?

>NO-4

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).

Repair or replace.

/

0 Go to Chart

Yes

A With forks lowered, key switch off. battery disconnected and lift cut-out switch closed (manuallypressed). check for continuity in lift cut-out switch.

l-

00700CL3 80 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

Is switch OK?

i

battery disconnected and wires removed, 1 measure resistance of / / pump contactor coil.

Go to Chart

d

<

>No4

1s it approximately l6obs?

Yes

1 Verify the problem still / exists. Repeat H-1. If

you return here, go to General Troubleshooting.

Replace contactor.

6 Go to Chart

v Go to Chart

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

Troubleshooting

H-2:No Lift or Slow Lift, Lift Motor Does Not Run H-2:No Lift or Slow Lift, Lift Motor Does Run

Check the battery.

See Component Procedures.

Yes

Check for any mechanical binding in lift linkage.

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

Yes

Yes

I

and battery disconnected, check the lift motor and brushes. See Component Procedures.

/ Go to Chart /

r-7 Repair.

0

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

If you return here, go to General Troubleshooting.

Yes

Go to Chart

Go to Chart

I

Yes

I Go to Chart 1

00700-CL380 Issued: August 29, 1997

I

Troubleshooting

I Adjust lift pressure.

See Component I Procedures.

I

Toyota Walkie Service Manual

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

correct pressure?

Yes

1

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

1

u Replace pump.

caused by

Replace valve.

Yes

I

Flush system.

Replace hydraulic fluid. See Component Procedures.

u Go to Chart

I

Yes

Flush system.

Replace hydraulic fluid. See Component procedures.

Q Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

H-3: N o Lower, Lift and Travel OK

H-3: No Lower,

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

With key switch off and battery disconnected, check for continuity and wiring shorts between: I SOL1-Y to BSOLX to JP2-5 JP2-5 to JP10-8 J P10-8 to LOWER S m H - N O LOWER SWITCH-C to J P 10- 1 JPIO- 1 to JP2-2 JP2-2 to KEY SWITCH-NO SOL1-X to JP4-4* JP4-4 to HANDRAIL LOWER SWITCH-NO* HANDRAIL LOWER SWITCH-C to JP4- 1 JP4-1 to KEY SWITCH-NO* (* end rider models with grab bar switches]

.

Yes

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

.6

i Repair mechanical Do forks lowef?

Yes

cylinders or fork mechanism. See Component

I

00700-CL380 Issued: August 29, 1 997

Yes

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.)

I

Go to Chart

Troubleshooting

Toyota Walkie Service Manual

t Allow forks to completely lower.

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

I

Yes

1

Replace or repair

I

pump.

I

Yes

A Clean Solenoid 1.

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

7 Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

<switches>No{

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

Troubleshooting

Replace switches.

0 Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-1: N o Travel, Lift/Lower OK

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.

Is the battery

Charge or replace the

I

Yes I

Check the battery terminals and quick disconnect plug.

Yes

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 hen.

See PMT acction in mublt~hooting.

I

I

'Programmable Maintenance Tool

Go to Chart T- 1-2

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

Repair, replace, or adjust deadman continuity?

or mechanical actuator.

Y

With key off and battery disconnected. check for continuity and wiring shorts between: SWl-BAT on key switch (switch closed/on) to SW2-NO SW2-NO to M1 -RContactor X M1 -RContactor X to M1 -I? Contactor X MI-F Contactor X to PMC-2

0~

Yes

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

Go to Chart

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

'Programmable Maintenance Tool I s there B+ at

No

Yes

Go to Chart T-1-3

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

G o to Chart

.j 00700-CL380 Issued: August 29, 1997

N

Repair or replace a s

o

Troubleshooting

Toyota Walkie Service Manual

T-1-3

+

With truck jacked and I blocked. battery plugged m.key switch on and 1 handle in travel position: 1 measure voltage a t PMC10(with reference to B-1 while rotattng throttle in forward direction.

I PMT1can be used here.

I

1

' I

1 Programmable Maintenance Tool

section in Troubleehooting.

See

Is B+ present?

II

/

With key switch off and battery disconnected, check for continuity and wiring shorts between: SW2-NO to JP6- 1 (Deadman Switch) JP6-1 to JP10-13 JP10-13 to FWD SW (SW3)-C FWD SW (SW3)-Cto REV SW (SW4)-C FWD SW (SW3)-NOto JP10-2 JP10-2 to JP6-2 JP6-2 to JPS-4 JPS-4 to PMC-10 REV SW (SW4)-NOto JP10-3 JP10-3 to JP6-3 J P ~ -to 3 PMC- 11

I

1

Yes I

Replace motor controller.

<

Is wiring OK?

I

Yes

Go to Chart

Go to Chart T-1-4

)--NO+

Repair or replace.

I

0 I

Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

With key switch off, battery disconnected and FWD and REV switches closed. check for continuity and wiring shorts between: FWD sw-C to

FWD SW NO (SW3) REV sw-Cto REV SW NO (SW4)

Yes

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

1

0 I

Go to Chart

(J

Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-2: No Travel in Either Direction

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

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

Measresistance. and / check for shorts. in wiring 1 harness between: PMC-2 to PMC-18 PMC-2 to PMC-19

1

,

1

'

With key switch off and battery disconnected, remove connector PMC and check for continuity and wiring shorts between: PMC-2 to FWD Contactor-X PMC-2 to REV Contactor-X PMC-19 to REV Contactor-Y PMC-18 to FWD Contactor-Y

Yes

Yes

Disconnect and measure resistance o FWD and REV contactor coils.

I

1 Go to Chart

Programmable Ilbaintenance Tool can be used hen. See PMT section in

1 Replace motor controller.

0 Go to Chart

approx. 30 ohms?

Yes

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

Replace coils.

0 Go to Chart

I Go to Chart 1

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-3: N o Travel in Either Direction, Lift/Lower OK

-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.

Is

Test motor. See

Yes

Replace motor controller.

0 Go to Chart

Yes

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

Go to Chart

00700-CL380 Issued: August 29, 1997

0 I

Go to Chart

Troubleshooting ~ 4 No :

Toyota Walkie Service Manual

ravel, Lift/Lower OK, Fault Code 1.2

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

Replace motor controller.

/ Go to Chart /

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

T-5: N o Travel, Fault Code 3,4

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

Motor Controller Fault Code 3,4.

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

Measure resistance in wiring harness between:

1

Measure resistance o FWD and REV contactor coils.

PMC-2 to PMC-18 With key switch off and battery disconnected, check for continuity and wiring shorts between: No,

PMC-2 to FWD Contactor-X PMC-2 to REV Contactor-X .O N' .=- . . : ' PMC-19 to REV Contactor-Y PMC-19 to FWD Contactor-Y

/

Are

\

PMT section in Troubleshooting.

I

I

Replace motor controller.

I Replace coil(s).

PIKT1 can be used here. See Yes

I

Yes

Verify the problem still exists. Repeat T-5. If the problem still exists, go to General Troubleshoothg.

0 I

Go to Chart

+T6 Repair or replace.

Go to Chart 1 Programmable

Mmtenance Tool

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

Td: Travel in One Direction Only. Fault Code 3,l -

6: Travel in One Direction Only.

Motor Controller Fault Code 3.1.

A / With key switch off and

battery disconnected. remove connector PMC 1 from motor controller.

Measure resistance I between: 1 PMC-2 to PMC-18 PMC-2 to PMC-19. i Check for wiring shorts to frame.

I

'Programmable Maintenance Tool

<

Is wiring OK?

) - - N O - - * / Repair or replace.

'

Yes

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

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 PMC-19 to REV Contactor-Y PMC-18 to FWD Contactor-Y PB¶T1can be used here.

See PMT section in Troubleshooting.

Yes

Measure resistance of forward and reverse contactor coils.

0 I

Go to Chart

l-Are there approx.

30 ohms?

Yes

1

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

Replace coil(s).

.;: I

Go to Chart

i

Replace motor controller.

I Go to Chart /

I Go to Chart /

1 Go to Chart /

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-7: No Travel. Fault Codes 2,l or 2,4(or both)

Close. /T-7: No Travel, Directional Contactors Motor Controller Fault Codes 2,lor 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 aection in Tmubluhooting.

1 Programmable Ma.intenance Tool

)m 0-6K ohms in each \direction?

F!G

Yes

,

j

disconnected. check for contlnuitv and wiring shorts between: PMC-16 to JP6-4 JP6-4 to VR-2 VR-4 to JP10-6 JP10-6 to JP6-5

-

1

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

Go to Chart T-7-2

I

Yes

Replace motor controller.

00700-CL380 Issued: August 29, 1 997

I Go to Chart I

Toyota Walkie Service Manual

Troubleshooting

With key switch off and battery cfisconnected.

I remove connector PMC from motor controller and measure resistance I of throttle 1 potentiometer between I VR-4 to VR-2.

I

I

I

GOm >..-I / Does \ resistance increase 0h ;:ms in

1

I zfiioZ:e

Yes

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

( Go to Chart (

00700-CL380 issued: August 29,1997

Toyota Walkie Service Manual

.

Troubleshooting

T-8: Slow Travel, Lift/Lower OK, N o Fault Codes

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

(-

Has

Verify battery is charged.

changed?

Yes

( Is battery OK?

\)--NO--*(

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

c;narg' L

6 Go to Chart

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

75Go to Chart

With battery disconnected and key switch on. measure voltage at PMC-3 IWfiT B-)to veriFy tmck is operating in high speed mode.

Propmanunable Maintenance Tool can be used here.

L' Go to Chart

00700-CL380 Issued: August 29, 1997

With battery disconnected and 1 key switch on. measure voltage at PMC-3 rnB-)to verify tmck is operating in high speed mode.

Progxaxnmable Maintenance Tool ccm be used here.

I Go to Chart I

Troubleshooting

Toyota Walkie Service Manual

4

No

With key swltch 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.

i With key switch off and

,

remove connector PMC from motor controller.

Measure resistance between PMC-14 to PMC16 while slowly rotating throttle in both direcUons.

PMT1can be used here.

Does from 0-6K ohms in each

i

Yes

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

0

6 Go to Chart

---l-With key swltch off and battery discomected, 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.

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

I

Yes

Go to Chart

0 I

Go to Chart

1 Programmable ~ a i n t e n a n cTool e

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

T-8-3

B+ in each

Replace motor controller.

direction?

Yes

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

I 1 Go to Chart 1

< Are brushes OK? ) - - N O - + Replace the brushes. I Yes

I

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

1 Go to Chart 1

Go to Chart T-8-4

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

i drive motor.

Yes i

1

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

With key switch off, remove brake drum.

See Component Procedures.

ri

Remove drive motor from drive unit. See Component Procedures.

Does the will the drum

Does the armature shaft

hand?

!

Yes

Yes

8. If you return here,

Repair, adjust. or replace the brake.

Repair or replace the drive unit.

1 Go to Chart I

Q

Yes

I Verify the problem still exists. Repeat T-

Repair or replace drive motor.

Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

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

Measure resistance of throttle potentiometer between: VR-4 to VR-2.

from 0-6K ohms in

I

No

Yes

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

Replace potentiometer.

6 Go to Chart

1

Q Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting -

T-9: N o Emergency Release. Travel/Lift/Lower OK

No Emergency Reverse, Travel/Lift/Lower OK. No Motor Controller Fault Codes.

+

1 With truck jacked and blocked. battery connected, key switch on ' and handle m travel position: measure voltage a t PMC-6 (with reference to B-)while pushing I emergency reverse switch.

/

'

PMT1can be rued hen.

See PMT section in j Troubleshooting.

I

With key switch off and battery disconnected. check for continuity and wiring shorts between: DM-NO to P4-11 P4-1 1 to Horn Switch (SW13)-1 Horn Switch (SW13)-l2 to Horn Switch (SW13)-22 Horn Switch (SW13)-22to JP4-122 P4-12 to JP6-6 JP6-6 to JP10-11 JP10- 11 to ER SW7-C (Emergency Reverse Switch)

rl I

I

I

Replace motor conmoller.

Yes

Go to Chart T-9-2

1 Programmable Maintenance Tool

2 These wires are only present if truck is equipped with grab bar switches (end rider models). If not, there is a jumper wire between JP411 and JP4- 12.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

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

Yes

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

0 I

Go to Chart

00700-CL380 Issued: August 29,1997

Troubleshooting

Toyota Walkie Service Manual

T-10: Slow Travel, Lift/Lower OK. Fault Codes 2,2

T-10: Slow Travel, =/Lower OK. Speed Limited to 1 5 O h . Motor Controller Fault Code 2,2 (Emergency Reverse Circuit Fault).

With key switch off and

I

battery &sconnected. remove connector PMC 1 from motor controller.

1 Measure resistance between PMC-24 to PMC-6.

I PMT1can be used hem.

See PBfT eection in 1 TToubl~hooting.

continuity?

Yes

6 Go to Chart

1 Prog~-ammable Maintenance Tool

With key switch off. battery disconnected and PMC disconnected. check for continuity and wiring shorts between: PMC-24 to JP6-8 JP6-8 to JP10-12 JP10- 1 2 to (ER)SW7-NO JPlO-7 to (ER] SW7-NO JPlO-7 to JP6-7 JP6-7 to PMC-6.

I

Yes

i Verify the problem still exists. Repeat T- 10. If you return here, go to General

u Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

T-1 1 : N o Rabbit Speed. Travel/Lift/Lower OK

T-11: No Rabbit Speed (Field Weakening), Travel/I,ift/Lower OK. No Fault Codes.

.---------------L---------------------------------------, NOTES:

/ 1) Rabbit speed only operates in the tractor /

ifirst [forward) direction.

!

/ 2) End Rider models are equipped with 1 "latched" rabbit speed buttons. h e s s and

1 release the button to enable rabbit speed.

/

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

/ /

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

I

j

Yes

I

No Reverse direction and

r-

Yes Field weakening will be engaged if: 1) Max speed is set a t 1 W h 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.

Troubleshooting.

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

I Go to Chart 1

00700-CL3 80 Issued: August 29, 1 997

Go to Chart

Troubleshooting

Toyota Walkie Service Manual

Have the above conditions been

I

0 -:-Yes

1

Using clamp on Ampmeter, verify armature current draw.

Go to Chart

current within limits of conditio #4 above?

See Component Procedures for motors.

v l With key switch off, battery disconnected, and PMC

I disconnected, check for continuity and wiring shorts I between: PMC-22 M2-X

to to

M2-Y J P 4- 6

'J Go to Chart

r-l

GO to chart

Grab bar switch on end rider models Foot bar switch on center rider models

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

?

T-ll-

Is wiring OK?

Yes With key switch off and battery disconnected, disconnect field weakening contactor coil at M2-X and M2-Y and measure resistance of field weakening contactor coil between: M2-X to M2-Y.

,

Troubleshooting

'..:"TI,1 NO+

Repair or replace.

Yes

Go to Chart

Yes

i.

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-NW

I Grab bar switch on end rider models.

Foot switch on center rider models.

00700-CL3 80 Issued: August 29, 1 997

I

/ Go to Chart I

r-l

Go to Chart

Troubleshooting

Toyota Walkie Service Manual

/With key switch off i and battery disconnected. check the field weakening I contactor tips. See l Component 1 Procedures.

.

Yes

With key switch off and battery disconnected, check for continuity and wiring shorts .infield weakening resistor R1, bus bars, and cables between R1 and weakening contactor.

Repair or replace.

Yes

Replace motor controller.

/ Go to Chart I

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting T-12: N o Travel. Fault Codes 4,2

/T-12: No Travel. Motor Controller Fault Code 4.2 - \ Excessive Battery Voltage (>45 Volts)

I Verify the correct

battery is installed in truck.

PMT1 can be used here. &e PMT

1 Programmable Maintenance Tool

aection in

+ Yes

Never plug charger into truck.

Disconnect charger immediately to prevent further damage. Only plug specified battery into 1 truck.

1 Go to Chart

with correct / ., / Replacebattery.

I ,

Replace motor controller.

Go to Chart

00700CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-13: Slow or No Travel. Fault Codes 4,l

-13: Slow or No Travel Motor Controller Fault Code 4.1 - Low Battery Voltage (< 16 Volts

Check the battery.

See Component Procedures.

Yes

I

Check the battery terminals and quick disconnect plug.

+Nojyi connectors

Yes

I

6 Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

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+

1 Programmable Maintenance Tool

PMT1can be used hue. See PlKT section in

Yes

I Replace motor conWoller.

.

I Go to Chart

00700-CL380Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-14: Slow or N o Travel. Fault Codes 4,3

T-14: Slow or No Travel.

Motor Controller Fault Code 4.3 - Thermal Cutback.

Check the battery.

See Component Procedures.

Yes

Check for free movement or mechanical binding of load wheels.

u Go to Chart

Yes

Go to Chart

T-14-2

00700-CL380Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

and blocked, key switch off and battery disconnected, release the brake by pulling the handle down into the operating po~ition.~m&e brake drum by hand.

I

I

1 jor.T''

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

Does the armature shaft turn hely?

I

Yes

Go to Chart

T- 14-3

Remove the drive motor from the drive Procedures.

Yes

Repair or replace the drive motor.

Repair. adjust. or replace the brake.

I Go to Chart I

Repair or replace the drive unit.

I Go to Chart /

00700-CL380 Issued: August 29, 1997

Troubleshooting

overloaded or operated under

Toyota Walkie Service Manual

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

Yes

within specifications.

Go to Chart END 1

correctly?

Replace motor controller.

/ Go to Chart I

6 Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

T-15: N o Travel. Fault Codes 1,4.

{T-15:

No Travel. Motor Controller Fault Code 1.4 Static Return To Off (SRO).

-\

I

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

followed?

Yes

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

PMT1 cpn be used hen.

See PMT section in Troubleshooting.

Is B+ present?

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

Lower handle, then apply throttle.

6 Go to Chart

Replace motor coneoller.

Yes

00700-CL380 Issued: August 29, 1997

1 Programmable Maintenance Tool

Troubleshooting

Toyota Walkie Service Manual

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 disconnectel from motor controller, check for continuity and wiring shorts between: PMC-11 to J P 6 - 3 J P 6 - 3 to J P 1 0 - 3 J P 1 0 - 3 to REVERSE SW(SW4)-NO PMC-10 to JPS-4 J P S - 4 to J P 6- 2 J P 6 - 2 to J P 1 0 - 2 JP10-2 to FORWARD SW(SW3)-NO

Is wiring OK?

Repair or replace.

Yes

Go to Chart T- 1 5 - 3

Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

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

Troubleshooting

I

QNoj71 (open)?

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

6 Go to Chart

Go to Chart

00700-CL380 Issued: August 29, 1997

Troubleshooting

Toyota Walkie Service Manual

T-16: No Travel, Fault Codes 2,3

-16: No Travel,

Motor Controller Fault Code 2.3 - High Pedal Disable.

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

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

-----*--.*.--.---.-----*----..--.-

.

Yes

Test and adjust throttle potentiometer.

See Component Procedures.

Prog~mmrsble Maintenance Tool can be used hue. See PMT section in Troubleshootin&

I Go to Chart I

Adjust or replace potentiometer

potentiometer.

See Component Procedures.

Go to Chart

I Go to Chart I

T-16-2

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

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 J P 6- 4 to J P 1 0 - 5 J P 1 0 - 5 to VR-2 VR-4 to J P 1 0 - 6 JP10-6 to JP6-5 JP6-5 to PMC-14.

Yes

Replace motor controller.

I Go to Chart I

00700-CL380 Issued: August 29, 1997

0 I

Go to Chart

Troubleshooting

Toyota Walkie Service Manual

T-17: N o Travel, Fault Code 3,2

T-17: No Travel, Motor Controller Fault Code 3.2 (Directional Contactor Stuck in Closed Position).

With key switch off and battery disconnected, check for continuily and wiring shorts of drive motor cables between: drive motor and directional

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

h\'

tips

contactor. tips

\

Are cables OK? > N o 4

I

Yes

Yes

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

I 1

I

Replace motor controller.

Repair or replace.

1

I

0 Go to Chart

u Go to Chart

Yes

A

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting -

- -

T-18: Plugging Does Not Operate Properly.

(618:

Plugging Does Not Operate Properly.

Truck Travels OK in Forward and Reverse.

A With key switch off,

check brushes and motor.

See Component Procedures.

motor OK?

Repair or replace as necessary.

Yes

I

( Go to Chart /

Replace the motor controller.

00700-CL380 Issued: August 29, 1 997

Troubleshooting

Toyota Walkie Service Manual

T-19:Truck Does Not Accelerate Properly.

T-19: Truck Does Not Accelerate Properly.

Check to see the battery is charged.

Charge or replace QNO ~*_.

With key switch off

and battery disconnected. check throttle potentiometer adjustment. See Component Procedures.

Is it adjusted

Yes

Go to Chart T-19-2

6 Go to Chart

Adjust throttle potentiometer.

6 Go to Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Troubleshooting

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

See Component

With key switch off and battery disconnected. check for mechanical reason for slow acceleration.

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

Connect battery, turn key switch on and connect PhTP to motor controller.

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

Drive truck and note results.

No

Is motor OK?

No

v

Yes Yes

Repair or replace motor. See Component Procedures.

Repair as required.

v Yes

Replace motor controller.

1 Return to service.

v Go to Chart

v Go to Chart

Go to Chart Programmable maintenance tool

00700-CL3 80 Issued: August 29, 1 997

Troubleshooting

Toyota Walkie Service Manual

W-1: Truck Functions Partially.

- 1 : ~ n r c k unctions P M ~ . Some ~ u n c t i i n s \ Do Not Work When Commanded.

I

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

Look for damage to the wiring.

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

I

Yes

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

continuity

Repair or replace wires a s required.

Yes

measurements

Visually check the

Repair or replace wires a s required.

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

;i Go to Chart

connectors in the area of the motor controller.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures

Component Procedures

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

Component Procedures List of Component Procedures

List of Component Procedures

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Adding Water . . . . . . . . . . . . . . . . . . 6-12 Charging . . . . . . . . . . . . . . . . . . . . . . 6-10 Exterior Cleaning . . . . . . . . . . . . . . . . 6-9 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Gates and Rollers . . . . . . . . . . . . . . . . 6-7 Maintenance Free . . . . . . . . . . . . . . . 6-14 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Specific Gravity . . . . . . . . . . . . . . . . . 6-13 Storage . . . . . . . . . . . . . . . . . . . . . . . 6-14 Voltage Check . . . . . . . . . . . . . . . . . . 6-13 Without Gates and Rollers . . . . . . . . . . 6-8 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Emergency Reverse Check . . . . . . . . . . . .6.37

Filter Screen . . . . . . . . . . . . . . . . . . . . . 6.107 Fork Height Adjustment 6000 Lb. . . . . . . . . . . . . . . . . . . . . . . .6.87 8000 Lb. . . . . . . . . . . . . . . . . . . . . . . .6.88 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25 Casters . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Cold Storage . . . . . . . . . . . . . . . . . . . . . .6.112 Commutator . . . . . . . . . . . . . . . . . . . . . . 6-55 Contactors . . . . . . . . . . . . . . . . . . . . . . . 6-40 Forward/Reverse Travel . . . . . . . . . . 6-45 Rabbit Speed . . . . . . . . . . . . . . . . . . . 6-41 Control Handle . . . . . . . . . . . . . . . . . . . . 6-30 Covers Tractor . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Deadman Switch . . . . . . . . . . . . . . . . . . . 6-22 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Drive Housing Lubrication . . . . . . . . . . . 6-72 Drive Housing Steering Beaning . . . . . . . 6-73 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Drive Unit Vent Plug . . . . . . . . . . . . . . . . 6-71 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . 6-75

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32 Hydraulic Components General . . . . . . . . . . . . . . . . . . . . . . .6-91 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 6.92 Hydraulic Pump . . . . . . . . . . . . . . . . . . .6.108 Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . 6.96 Hydraulic Reservoir . . . . . . . . . . . . . . . . 6.106 Hydraulic Solenoids . . . . . . . . . . . . . . . . . 6.24 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . 6.105

Key Switch . .

Lift Limit Switch . . . . . . . . . . . . . . . . . . . . 6.89

00700-CL380Issued: August 29.1997

Toyota Walkie Service Manual .

.

Component Procedures

-

List of Component Procedures

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 6-109

Load Wheels . . . . . . . . . . . . . . . . . . . . . . 6-84

Maintenance Free Batteries . . . . . . . . . . . 6-14 Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 Motor Controller . . . . . . . . . . . . . . . . . . . 6-33 Motors Brush Spring Tension . . . . . . . . . . . . 6-54 Brushes . . . . . . . . . . . . . . . . . . . . . . . 6-52 Commutator . . . . . . . . . . . . . . . . . . . 6-55 Drive . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 General . . . . . . . . . . . . . . . . . . . . . . . 6-52 Lift . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Tests . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

P

Seals Hydraulic Cylinder . . . . . . . . . . . . . . 6.101 Solenoids Hydraulic . . . . . . . . . . . . . . . . . . . . . .6.24 SuctionTube . . . . . . . . . . . . . . . . . . . . .6-107 Switches Deadrnan . . . . . . . . . . . . . . . . . . . . . .6.22 General . . . . . . . . . . . . . . . . . . . . . . . .6-20 Key . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 Lift Limit . . . . . . . . . . . . . . . . . . . . . . .6.89

Terminal Nuts . . . . . . . . . . . . . . . . . . . . .6.56 Throttle Potentiometer . . . . . . . . . . . . . . . 6.37 Tractor Cover . . . . . . . . . . . . . . . . . . . . . . .6.6

Pallet Entry Wheels . . . . . . . . . . . . . . . . . 6-86 Power Cables . . . . . . . . . . . . . . . . . . . . . . 6-15 Wheels Load . . . . . . . . . . . . . . . . . . . . . . . . . .6-84 Pallet Entry . . . . . . . . . . . . . . . . . . . . .6.86 Wiring Harness . . . . . . . . . . . . . . . . . . . . .6.16 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 6-94 Return Spring Adjustment . . . . . . . . . . . . 6-31

00700-CL380 Issued: August 29. 1997

Toyota Walkie Service Manual

Component Procedures Component Locators

Component Locators

Contoctors

Power Cables

Page 6-40

Page 6- 15

\

Page 6-63

I I

II

II I

Figure 6-1:

Drive Unit

t

I

Drive Wheel Page 6-73

Inside Tractor, Model 6HBE30/6HBE40 Shown

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Component Locators

lift Limit Switch Page 6-89

Page 6- 106

Figure 6-2:

Hydraulic Components

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Tractor Cover

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

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

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Battery

Battery

A CAUTION Before working on the battery, review Battery Safety, beginning on page 2-7 Batteries may weigh more than 1,000 pounds. Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

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

With Battery Gates And Rollers Removal 1. After the truck is stopped and the handle is

returned to the full up position, turn the key switch OFF. 2. Disconnect the battery connector located at the top of the tractor cover.

3. Position the battery replacement device in

accordance with the manufacturer's recommendations.

4. Remove the battery gate by lifting straight

UP5. Remove the battery with the lifting device.

Installation 1. With a fully charged and tested battery on

the lifting device, position the lifting device at the Toyota walkie in accordance with the manufacturer's recommendations.

2. Position the battery in the compartment. Be sure the battery has no more than 0.50" (1.27 cm) of "free play" movement in the battery compartment.

00700-CL3 8 0 Issued: August 29, 1 997

Component Procedures

Toyota Walkie Service Manual

Battery Gates (Optional) 3. Install the side-gate. See "Battery Gates (Optional)"on page 6-8. Move the llfhng device from the area.

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

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

Replace if necessary.

Baitery Rollers (Optional) Inspection Inspect the battery rollers to ensure they can turn freely. Clean off electrolyte using a solution of 1 lb. (.45 kg) of baking soda added to 1/2 gal. (3.7 liters) of hot water.

Replacement Lift damaged roller from its slot and replace with a new one.

Without Battery Gates And Rollers Removal 1. After the truck is stopped, apply the

parking brake. For 6HBW30 and 6HBE30 or 6HBE40 models, move the handle to the full up position; for 6HBC30/6HBC40 and 6TB50 models, squeeze the brake levers and turn the knob under the handle counterclockwise.

2. Turn the key switch OFF. 3. Disconnect the battery connector located at the top of tractor cover.

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

5. Remove the battery by lifting straight up.

6. Place the discharged battery on the charging stand.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Battery Exterior Cleaning

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

2. Lower the battery and position it in compartment. Be sure the battery has no more than 0.50" (1.27 cm) 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 operation of the

Toyota walkie.

Baitery Exterior Cleaning 1. lnspect 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 clean the top of the battery with the soda solution while it is installed in the truck.

Water would seep into the electrical compartments and cause serious damage. a. Disconnect the battery connector, and remove the battery from the truck before you clean it. b. Tighten the battery filler plugs. c. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 Ib. (.45 kg) of baking soda added to 1/2 gal. (3.7 liters) of hot water. d. Use a brush with flexible bristles to clean the entire top of the battery with

00700-CL380Issued: August 29, 1997

Figure 6-3:

Batiery Filler Plugs and Vent Holes

Component Procedures

Toyota Walkie Service Manual

Charging

the soda solution. Wait until all foaming stops, indicatmg that the battery exterior is neutralized. e. Rinse the battery with clean water. f. Dry the battery completely before reinstalling it.

g. Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

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

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

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

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

1. Familiarize yourself with the following:

charging rate, starting rate, and finish rate time available for charge overheating, excessive gassing, or overcharging variations between cell voltage

00700-CL3 80 Issued: August 29, 1 997

Toyota Walkie Service Manual

Component Procedures Charging

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.

6. Inspect the battery.

7. Check the electrolyte level in each cell.

Electrolyte should cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. See "Adding Water" on page 6-12. Do not fill to level yet.

Electrolyte level will rise during charging.

8. Using a hydrometer, measure and record the specific gravity of each cell. See "Specific Gravity" on page 6-13.

9. Check and record the voltage of each cell.

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

11. Ensure 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 eleckical system. Plug the charger ONLY into the connector from the battery.

00700-CL380 Issued: August 29,1997

Component Procedures

Toyota Walkie Service Manual

Adding Water

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

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

14. If, after charging, the electrolyte level is

below the fill port, add water to bring it to the fill level. See "Adding Water" on page 6-12. Do not o v e m the cells or allow electrolyte to spill onto 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 (43" C).

Temperatures of 120" F (49" C)are allowed 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 plates.

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

Keep the outside of the battery case clean and dry.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Specific Gravity

Specific Gravity Specific gravity readings for lead acid batteries with electrolyte temperatures at 80" F (27' C) vary with the state-of-charge as follows:

/I Charge / SpecificGnvity /

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.

Voltage Check Take a voltage check on each cell after performing the specific gravity check on page 6- 13. Connect the leads of a voltmeter to the positive and negative terminals of each cell.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Maintenance Free Batteries

Voltage readings will vary with the state of charge:

Charge

Voltage Reading

1000/0

2.14

75%

2.07

50%

1.95

25%

1.80

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

Maintenance Free Batteries The Toyota walkie may be equipped with a maintenance free battery, in which 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 should be kept clean and dry and may be washed to remove any accumulated foreign matter. See "Battery Exterior Cleaning" on page 6-9.

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

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

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

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Power Cables

Power Cables Power cables should be checked for damage, including: evidence of overheating burned spots in the cable nicks in the insulation damaged or overheated terminal lugs damaged mounting hardware or brackets Repair or replace damaged cables or mounting hardware as necessary.

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

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

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Wiring Harness

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

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

When you disconnect a mated J P connector, you will have two connector halves. The individual connector halves are designated by "Jx" and "Px." For example, connector JP2 is the mated connector in the control handle. 52 represents the jack connections. P2 represents the pin connections.

Use the chart below to locate electrical connectors on the truck.

Connector PMC 1 JP2 JP4 JP6 JP9 JPlO JPS4

Function or Routing

Connector on motor controller Handle functions Rail functions Travel Meters 'Travel and function ' Splice for forward travel

Location

Motor controller ,In control handle By key switch In control handle By key switch In control handle By motor controller

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Toyota Walkie Service Manual

Component Procedures Wiring Harness

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

Do not pull on wires.

Carefully mate and unmate all connectors.

Do not pry apart connectors with unspecified tools.

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

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

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

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

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

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

NOTE:

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

00700-CL3 80 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Diodes

Diodes

A CAUTION Use the proper precautions against electrostatic discharge. See "Static Safety ' on page 2-11. f

Test Check diodes with a digital multimeter. Use the diode testing feature.

Replace the entire assembly if defective diodes are found.

00700-CL380 Issued: August 29,1997

Component Procedures

Toyota Walkie 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 Rxl scale and measure the resistance across the fuse. The resistance should be less than 1 ohm.

Figure 64:

00700-CL380 Issued: August 29, 1 997

Fuse location

Component Procedures

Toyota Walkie Service Manual

Switches (General)

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

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

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

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

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Key Switch

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

Inspection With the battery plugged in and key switch ON, battery voltage B+ should be present on both terminals of the switch. Test the key switch with an ohmmeter after removing the wires from the switch terminals. In the OFF position, the ohmmeter should read greater than 1 megaohm, and in the ON position, the ohmmeter should read less than 1 ohm. If not, replace the switch.

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

2. Remove the tractor cover.

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

4. Remove the key switch.

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

Installation 1. Connect the wires to the terminals.

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

3. Reconnect the battery connector and check operation.

4. Turn the key switch OFF and disconnect

the battery connector.

5. Install tractor cover.

6. Reconnect the battery connector.

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Toyota Walkie 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 6-5.

1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

II

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

II

Deadman

Switch

4. Using the nuts on the barrel of the

deadrnan 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 6-5.

Figure 6-5:

Deadman Switch, 6HBW30 and 6HBE30 or

6HBE40

For 6HBC30/6HBC40 and 6TB50 models, the parking brake is on. See Figure 6-6.

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.

Removal

Figure 6-6:

Deadman Switch, 6HBC30/6HBC40 and

6TB50

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 n u t holding the deadman switch on the mounting bracket.

6. Remove the deadman switch.

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Toyota Walkie Service Manual

Component Procedures Deadrnan Switch

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 6-22.

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

7. Install the tractor cover.

8. Reconnect the battery connector.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Hydraulic Solenoids

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

2. Turn the key switch to OFF. Disconnect the

battery connector.

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

4. Remove the nut holding the solenoid coil to

the solenoid valve.

5. Lift the solenoid coil off the solenoid valve.

6. Remove the solenoid valve from the manifold.

Installation 1. Inspect the seat where the solenoid seals

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

2. Inspect the O-ring for any damage. If the 0ring is damaged or deformed in any way, replace it.

3. Thread the solenoid valve into the manifold.

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

Figure 6-7: Hydraulic Solenoids

4. Install the solenoid coil onto the solenoid

valve and tighten the nut.

5. Connect the wires to the terminals.

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

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

8. Install any covers that were removed.

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Toyota Walkie Service Manual

Cornponent Procedures Gauges

Gauges Toyota walkie 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. 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 back of the gauge (with respect to pin 2, B-). If voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery).

If the meter does not log hours, verify that B+ is present on pin 3 when the 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, the hour meter gauge is faulty.

00700-CL380 Issued: August 29,1997

Component Procedures

Toyota Walkie Service Manual

-

Battery Discharge Meter

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

2. Remove the tractor cover.

3. Remove the wires from the back of the

gauge and make careful note of their orientation.

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

the mounting bracket.

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

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

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

3. Connect the wires to the proper terminals.

4. Reconnect the battery connector and test

operation.

5. Install the tractor cover.

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 begin flashing when the battery is almost fully discharged.

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

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

00700-CL380 Issued: August 29,1997

Toyota Walkie Service Manual

Component Procedures Combination Hour/Battery Discharge Meter (2)

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

2. Remove the tractor cover.

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

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

the mounting bracket.

5. Remove the gauge by lifting throu g h the top of the tractor frame.

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

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

3. Connect the wires to the proper terminals.

4. Reconnect the battery c o ~ e c t o and r test

operation.

5. Install the tractor cover.

Combination Hour/Batkry Discharge Meter (2) Low Battery Lift Cut-Out (Optional) The Toyota walkie may be equipped with a low battery lift cut-out feature a s 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.

Adjustrnent With the optional Lift cut-out feature, two adjustments are present on the back of the gauge. One setting, labeled "discharge," programs the battery discharge level at which the forks will be prevented from raising and is adjustable from "K" to "P." The other setting, labeled "reset," programs the battery level at

00700-CL380 Issued: August 29, 1997

Component Procedures -

Toyota Walkie Service Manual

-

Combination Hour/Battery Discharge Meter (2)

which the gauge 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 counter increases. The meter logs hours when the deadman switch is closed Batkry 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. A s the battery loses its charge, a green or yellow bar moves closer to 0.Two red bars begin flashing when the battery is almost fully discharged.

Inspection If the displays do not illuminate when the key switch is on, use the voltmeter to check for B+ at pin 6 on the connector P9 (with respect to pin 1, B-). If the voltage is not present, use the schematic in the Appendix and trace B+ and Bto the source (battery via key switch).

If the meter does not log hours, verify that B+ is present on P9-2 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 gauge is faulty.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Combination Hour/Battery Discharge Meter (2)

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

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

2. Remove the tractor cover.

3. Remove the connector from the back of the gauge.

4. Remove the mounting nuts and slide off the

mounting bracket.

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

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

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

3. Plug connector in gauge.

4. Reconnect the battery connector and test operation.

5. Install the tractor cover.

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Toyota Walkie Service Manual

Component Procedures Control Handle

Control Handle

Figure 6-9: Control Handle Assembly, Models 6HBW30 and 6HBE30 or 6HBE40

Figure 6- 10: Control Handle Assembly, Models 6HBC30/6HBC40 and 6TB50

00700-CL380 Issued: August 29, 1 997

Toyota Walkie Service Manual

Component Procedures Return Spring Adjustment 6HBW30 and 6HBE30

Return Sprin Adjustment bHBW30 an bHBE30 or bHBE40

!

Trucks Without Coast Adjust the preload so that the handle will return to full vertical position when released from any position

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

00700-CL380 Issued: August 29, 1 997

Handle Return

Figure 6- 1 1: Return Spring Adjustment

Component Procedures

Toyota Walkie Service Manual

Horn

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

Removal 1. Turn the key switch OFF and disconnect

the battery connector.

2. Remove the tractor cover.

3. Disconnect the two wires from the horn.

4. Remove the horn mounting bolt. See Figure 6- 13.

Installation 1. Attach the horn to the tractor frame and tighten the mounting bolt. See Figure 6- 13.

2. Attach the two wires.

3. Reconnect the battery connector and test operation.

4. Turn key switch OFF and disconnect the

battery connector.

Figure 6- 12: Horn Location

5. Install the tractor cover.

6 . Reconnect the battery connector.

Figure 6 13: Removing Horn

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Toyota Walkie Service Manual

Component Procedures 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 6-14: Motor Controller Connections

3. Remove any dirt or corrosion from the bus bar area. Wipe the controller with a moist rag. Allow 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.

Removal 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 6-14.

5. Disconnect the three (3)bus bars (terminals B+, B-and A2) on the motor controller. Use two wrenches to avoid stressing the bus bars. See Figure 6-14.

6. Remove the four (4) hex head cap screws

securing the motor controller to the truck frame, and pull the controller out. See Figure 6-15.

00700-CL380 Issued: August 29, 1 997

Figure 6-15: Removing h e Motor Controller

Component Procedures

Toyota Walkie Service Manual

--

Motor Controller

Installation 1. Secure the motor controller to the truck frame with the four (4) previously removed hex head cap screws. See Figure 6- 14.

2. Connect the three (3)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- 14.

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.

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

9. Connect the battery connector.

Cloning With the Programmable Maintenance Tool (P/N 00590-01943-71),you are able to 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.

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

2. Remove the tractor cover.

3. Connect the battery and turn on the key switch.

4. Connect the PMT to the motor controller you want to clone. See Figure 6-16.

5. Press the program key to enter the special program menu.

Figure 6- 16: Connecting the PMT to the Motor Controller

6. Press the appropriate change value key (either up or down) until you reach the desired setting.

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Toyota Walkie Service Manual

Component Procedures Motor Controller

Programming You can change certain parameters using the PMT (P/N 00590-01943-71). Table 6- 1 on page 6-36.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 either scroll display key until the parameter you want is the top line of the display. Table 6-1 on page 6-36.

7. Press either change value key until the setting you want is displayed. The parameter is now set a t 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 allow you to change the setting further.

To find definitions of each parameter, see "Definitions" on page 5-7.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Motor Controller

Parameter

Range

Recommended

Description

Value

Ramp Shape

20-70%

500/6

Adjust desired PWM output a t 50% throttle to vary throttle sensitivity a t low speeds.

Creep Speed/ Min. Duty Cycle

0-25%

10%

Speed (Min. PWM) at minimum throttle setting.

I

See Caution elo ow

Sequencing Delay

0-3 seconds

Variable Plug

On/Off

0.0-0.3 seconds See Caution &low

On See Caution m o w

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

Plug current dependent on throttle position or fixed value.

Quick Start

0-6

1.4

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

M1 Accel Rate

0-3 seconds

1 second

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

M1 Max Speed

40- 100%

1OO%t

Maximum speed (PWM duty factor) in M1 (high speed) mode.

M2 Accel Rate

0-3 seconds

1 second

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

Field Weaken Enable

On/Off

On

Enable operation of the field weakening contactor driver (rabbit speed).

t Any percentage less than 100 will disable field weakening contactor driver (rabbit speed).

Table 6- 1: Motor Controller Parameters

A CAUTION While adiustment of these parameters is possible, settings at values other than hose listed below will produce improper and unauthorized operational characteristics. DO NOT adiust these parameters to values other than hose listed below: Creep SpeedlMin. Duty Cycle must be set to 10% Sequencing Delay may only be adjusted between 0.0 seconds and 0.3 seconds.

Variable Plug must be set to On.

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Toyota Walkie Service Manual

Component Procedures Emergency Reverse Check

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 6-16.

Throttle Potentiometer The throffle is a two wire resistive throttle that connects between the 5kQ-0/0-5kQ pin (PMC16) and the Pot Low pin (PMC-14). Zero speed corresponds to 0Q and full speed corresponds to 5kQ.

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

4. Remove 4 screws from the underside of the

switch cover assembly. Lay the cover back to access the throttle potentiometer.

5. To electrically center the potentiometer, the throffle must be in the neutral position.

Loosen nut on the potentiometer shaft.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Throttle Potentiometer

6. Connect the ohmmeter to pins VR-2 and VR-4.Measure the potentiometer resistance while rotating the potentiometer body until the ohmmeter reads as close to '0'ohms as possible.

7. With the ohmmeter still connected to pins VR-2 and VR-4, verify that the forward and reverse throttle positions are equal by rotating the Directional/Speed Control Handle fully in both directions. Record the maximum resistance value in both directions. In either direction the resistance value should be 5,000 + 500 ohms. In addition, the difference between the two readings must be 200 ohms or less.

Maximum Variation Example Handle Position Fully clockwise

/I

I Resistance (Ohms) 1 1

5,200

I/

Fully counterclockwise 8. To determine the ideal maximum potentiometer position, add the previously . recorded readings in Step 5 and divide that result in half. (See example below.) Loosen the potentiometer nut (1/ 2 turn) so that the potentiometer will move in the bracket when you apply force with your finger.

Example: 5,000 ohms CW + 5.200 ohms CCW = 10,200 ohms 10.200 +2 = 5,100 ohms (ideal resistance setting) 9. Rotate the throttle control fully in one direction. Move the potentiometer body until the ideal maximum resistance value is obtained. Once the potentiometer is electrically centered, tighten the potentiometer nut securely to prevent the pot from moving in the bracket.

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Toyota Walkie Service Manual

Component Procedures Throttle Potentiometer

10. Reattach the switch cover assembly to the control handle with 4 screws previously removed.

1 1. Reconnect the battery connector.

12. Test the truck's operation.

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

14. Install the tractor cover.

15. Reconnect the battery connector.

00700-CL380 Issued: August 29, 1 997

Component Procedures

Toyota Walkie Service Manual

Contactors

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

Burning indicates a loss of contact point material.

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

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

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

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.

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Toyota Walkie Service Manual

Component Procedures Rabbit Speed (Field Weakening) Contactor Models

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

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Toyota Walkie Service Manual

Component Procedures

Rabbit Speed (Field Weakening) Contactor Models 6HBE30/6HBE4O1 6HBC30/6HBC40 and 6TB50

Removal Remove the contactor assembly. See "Assembly Removal" on page 6-41.

Remove the two (2)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 6-24.

Figure 6-20: Disassembling Contactor Assembly

4. Remove the brass locknut on each main terminal. See Figure 6-21.

Figure 6-2 1 : Removing Brass locknuts

Fixed Contrrct

5. Remove the lock washer.

6. Extract the fixed contact from inside the top cover molding.

Fixed Contact

I

Figure 622: Removing Fixed Contacts

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Rabbit Speed (Field Weakening) Contactor Models

Tip Installation 1. Install the fixed contacts through the holes in the top cover molding. Make sure the hexagons are properly seated. See Figure 623.

2. install the lock washer and M8 brass locknut and torque to 70-84 in. lbs. (8-9.5 Nm.)

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

Figure 6-23: Installing he 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 onto the moving contact insulator, Make sure the spring is seated.

5. Arrange you, andthe fit the coiltop with cover the assembly terminals over toward the

moving contact assembly and tighten the top cover screws to 19-24 in. lbs. (2.1-2.7 Nm).

6. Test coil resistance. See the following procedure.

Coil Resistance

Nom 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

lead from the contactor. Connect the other lead to the Y lead from the contactor.

5. The reading should be 28.5-30.5 ohms.

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Return Spring

Screws

Magnet Fmme Assembly

!#l$ ~

%

Ii

-

fhltke

7s

t

Top Cover Molding

t

Moving Contact Assembly

Figure 6-24: Rabbit Speed Contactor Components

Component Procedures

Toyota Walkie Service Manual

Rabbit Speed (Field Weakening) Contactor Models 6HBE30/6HBE40,6HBC30/6HBC40 and 6TB50

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.

Figure 6-26: Securing Bus Bar to Contactor

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

4. Install the tractor cover.

5. Connect the battery connector, and turn the key switch on.

6. Test the operation of the truck.

Figure 6-27: Connecting Wires to Contactor

00700-CL3 80 Issued: August 29, 1 997

Toyota Walkie Service Manual

Component Procedures 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 later' See Figure 6-28'

Figure 6-28: Disconnecting FWD/REV Travel Contach

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 6-45.

Figure 6-29: Removing Contactor Assembly

Loosen and remove the three (3)top cover screws. See Figure 6-30.

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 fixed contacts.

Figure 6-30: Removing Top Cover

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Forward/Reverse Travel Contactor

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

Top Cover

Assembly

Magnet Fmme

Assembly

Figure 6-31: Separated Contactor Assembly

Insulator

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 allow the moving contacts to lift up on one side and expose the return springs. See Figure 6-32.

Fixed Contact

Figure 632: 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 allows you to remove the moving contact sideways from the top cover assembly.

Figure 633: Accessing the Return Springs

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie 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 (2) 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

No= 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 fixed contact in its correct position in the inverted top cover.

See Figure 6-35.

Elastic Band

Insulator

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

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

NOTE: I t 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. Once the top and bottom assemblies are together, cut and remove the elastic band.

00700-CL380 Issued: August 29, 1997

pegs

Normally Closed Fixed Contactor

Figure 6-35: Assembling Top Cover Assembly

Toyota Walkie 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.

Figure 6-36: Assembling the Contactor

9. Insert the three (3)screws into the top cover and tighten to 16-20 in. lbs. (2 Nm).

A CAUTION Do not over tighten the screws.

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

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

12. Test the coil resistance. See the following procedure.

.

Figure 6-37: Securing Top Cover Assembly

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

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

2. Remove the tractor co\.er.

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

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

Figure 6 3 8 : Testing Coil Resistance

5. The reading should be 28.5-30.5 ohms.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Forward/Reverse Travel Contactor

Assembly Installation 1. Secure the contactor assembly to the frame

with the two screws.

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 M1-2.

A CAUTION Using more toque than 84 in. Ibs. (9.5 Nm) may damage 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.

00700-CL380 Issued: August 29, 1997

Figure 6-39: Installing the F W D / R E V Contuctor

Toyota Walkie Service Manual

Component Procedures Brake

-

Brake

A CAUTION Allow the brake to cool completely before servicing.

Adjustment 1. Move the handle down to a 45" angle on Models 6HBW30.6HBE30 and 6HBE40.

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 both sides of the brake rod.

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

See Figure 6-40.

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

Removal

Cock

Lock

Nut

Nut

Figure 6-40: Broke Adjustment

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 x 16 nut holding the brake drum to the armature shaft.

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

6. Remove brake rod.

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

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Brake

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.

1 1. Remove the five (5)bolts holding the brake

assembly to the drive motor assembly.

Springs

12. Remove the brake.

Installation 1. Install the brake using the five (5)mounting bolts to the drive motor assembly.

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 x 16 nut.

6. Install the control handle.

7. Adjust the brake.

8. Test operate the truck.

00700-CL380 Issued: August 29, 1997

Bolts Figure 6-4 1 : Brake Shoes and Springs

Component Procedures

Toyota Walkie Service Manual

Motors, General

Motors, General Motor Brushes Inspection 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 frequeqtly.

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

Each partial inspection of the motor should include thecfollowing: 1. Inspect the brushes for wear and for proper contact with the commutator. Record the level of wear on the brushes. This history will give you an indication of whether a brush should be changed or if it can wait until the next inspection. Refer to page 6-54 for acceptable brush length and general motor information.

Figure 6-42: Motor Brush, Typical location

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 6-54.

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.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

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

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

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

1. Move the motor brush springs out of your

way.

2. Wrap a piece of 00 sandpaper around the commutator. DO NOT use emery cloth t o seat brushes.

3. Move the brushes back down in their

holders so that the face of the brushes matches the curve of the commutator.

4. Remove the sandpaper.

5. Blow any dust out of the motor with clean, compressed air a t a maximum of 30 p.s.i.

(207 H a ) .

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Motor Brush Spring Tension

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

2. Remove 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 a t the brush, hook the spring scale directly to the spring.

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

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

8. When the paper strip begins to move freely, the s p ~ scale g will read the spring brush tension.

Pull Paper in Direction of Rotation

9. Refer to table below for proper spring tension Figure 6-43: Motor Brush Spring Tension Inspection

Motor

Minimum Brush Length

Drive Motor

9 / 16" (1 4mm)

Lift

1 /2" ( 13mm)

Motor

spring Tension 30 to 3 6 oz.

(842 to 1016 grams)

I

32 to 40 oz.

(909 to 1136 grams)

10. Repeat steps 3 through 9 for the remaining brushes.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Commutator

Commutator Inspection The commutator should 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.

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 should be removed for s e ~ c i n g .

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 should be undercut to a depth equal to the width of the mica (usually 1 /32 inch, but may vary in some motors). See Figure 6-44.

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.

00700-CL380 Issued: August 29, 1997

MI cn

MI cn

SEGMENTS

\

/

GOOD

UNDERCUT

SEGHENTS

MI cn

BhD UNDER CUT

Figure 6-44: Mica Undercufting

SEGMENTS

Toyota Walkie Service Manual

Component Procedures Terminal Nuts

Terminal Nuts Whenever you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing nut to avoid twisting the stud.

Stud Terminal Securing Nuts should be torqued to 140-160 in. lbs. (15.8-18.1 Nm) and Motor Cable Securing Nuts to 100-120 in. lbs.

(11.2-13.6 Nm). Check these torques each time you check motor brushes.

Electric Motor Tests

krmirml

stud

Motor Cable

Flat Washer

Fiber

rL r1e,

Stud brrninal Securing

Nut

I

I

Washer Motor Housing

Figure 6-45: Motor Terminal Nuts

Motor Types See Figure 6-46.

A shunt-wound or series-wound motor, such a s 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.

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

Shunt-Wound or Series-Wound Drive Motor

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 Refer to Figure 6-46 for the following procedure: 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal stud.

Figure 6-46: Motor Circuits

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Electric Motor Tests

2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor.

3. Observe the following measurements:

Acceptable Resistance Readings

Motor I

Traction

Armature

A1 to A2

0.9-1.6 ohms

> 2.0 ohms

Field

S1 to S2

0.9-1.6 ohms

> 2.0 ohms

A to S

0.020-4.030 ohms

> 0.5 ohms

Lift

I

Unacceptable Resistance Readings

Measure all readings at room temperature.

4. If the meter indicates high resistance in the

armature, check the condition of the brushes before replacing the motor.

5. If an open circuit is found in a serieswound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

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

The ground may be caused by: insulation breakdown brush leads touching the motor housing build-up of carbon dust or other materials.

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.

00700-CL380 Issued: August 29, 1997

1 !

Component Procedures

Toyota Walkie Service Manual

Electric Motor Tests

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 a t two or more points. The breakdown creates a low resistance path, allowing current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow. The severity of the short circuit depends on its location.

A shorted motor may be indicated by:

slow or sluggish operation running faster than normal overheating blowing a power fuse severe burning or discoloring on one or two commutator segments every 90"of rotation These symptoms can be caused by problems other than the motor itself: brake too tight or dragging wheel bearings too tight faulty transmission binding in an attached pump Testing a motor for short circuited windings requires special equipment a t a motor rebuilding facility.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Electric Motor Tests

Short Circuited Armature A short circuit in the armature will cause heating, which will probably result in burning

of: the armature coil brush wires commutator segments Visual inspection may reveal this condition.

Positive determination of a short circuited armature requires special equipment at a motor rebuilding facility.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Motor

Drive Motor Removal 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 6-50.

5. Unscrew the deadman switch wires. See "Deadman Switch" on page 6-22.

6. Remove the four (4) hex head nuts and drive motor power cables. Use two wrenches to avoid twisting the motor stud.

7. Remove the hex head bolts securing the mounting plate to the main case of the drive unit. See Figure 6-47. Use a steel jack handle in the control handle frame to rotate the drive unit for access to all bolts. Remove bolts (7).

A CAUTION Due to the weight of the drive motor and the attached components, it is recommended that YOU use a hoist to lift-themotor from the truck.

Figure 6-47: Drive Unit Mounting Plate Bolts

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures 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 seven (7)bolts mounting the motor to the drive unit mounting plate. See Figure 6-48.

Drive Motor Mounting Bohs (7J

10. Remove the bolts mounting the control handle frame to the drive motor. Separate the motor from the handle frame.

Pinion Gear Figure 6-48: Drive Unit, Pinion Gear

Installation 1. Position the control handle frame on brush end of drive motor and attach with hex head cap screws (4).Apply thread locking compound (P/N 00590-01931-7 1) and torque to 25-30 ft. lbs.

When instolling the hex head bolts that secure the mounting plate, torque the hex bolts to the specified 25-30 Ft. Lbs. (35-42 NM). Failure to torque these bolts properly may cause the braking and steering to fail.

See decal to right and on mounting plate on truck.

2. Position the drive uIlit mounting plate on the opposite end of motor and secure with hex head cap screws (7).Torque to 120-150 in.lbs.

3. Install pinion gear and lock nut on armature shaft and torque to 50 ft. lbs.

00700-CL380 Issued: August 29, 1997

Figure 6-49: Decal on Mounting Plate

Toyota Walkie 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 generous coating of gasket compound (P/N 00590-00438-71) to both the drive unit case and the 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. lbs.

7. Attach power cables with four (4) hex bolts.

Torque to 100-120 in. lbs. (11.2-13.6 Nm).

Use a second wrench on the stud terminal securing nut to avoid twisting the motor stud. See "Terminal Nuts" on page 6-56.

8. Re-attach deadman switch and wires.

9. Re-attach brake and brake linkage and adjust as described on page 6-50.

10. Install control handle.

11. Connect wiring harness connectors and install new cable tie straps in exact locations from which they were removed.

12. Before testing operation, move handle from extreme left to right and back several times.

Check for any wire and cable interference.

Repair or adjust as necessary.

13. Reconnect battery connector.

14. Test operation.

15. Disconnect battery and install tractor cover.

Drive Motor Data Lubrication

None required. Sealed ball bearings are used a t both 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 2.9" (7.3 cm).

Brush Replacement

, Replace brushes when they have worn to the minimum length of 9 / 1 6 i (14 mm).

Spring Tension

Adjust the spring tension of new brushes to 30 to 36 oz. (842 to 1016 grams).

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Unit

Drive Unit Removal 1. Lower the forks. Turn the key switch OFF.

Disconnect the battery connector.

2. Remove the drive unit fill plug (Figure 6-50) and drain plug (Figure 6-51). Allow the gear oil to drain.

Figure 6-50: Drive Unit Fill Plug

3. Remove the control handle.

4. Unscrew the deadman switch wires. See "Deadman Switch" on page 6-22.

5. Remove the four (4) hex head nuts holding the drive motor power cables. Use two wrenches to avoid twisting the motor stud.

Drive Unit

Figure 6-5 1 : Drive Unit Drain Plug

Figure 6-52: Jacking Tractor

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Unit

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

For deiuils, see "Jacking Safety" on page

2-13.

6. Jack the truck and block the frame.

7. Remove the socket head cap-screws which secure the drive unit to the frame. See Figure 6-53.

8. Secure hoisting straps through the control handle frame. Remove the drive unit, drive motor, and control handle frame using a hoist with at least 1-ton capacity.

9. To separate the drive unit from the drive motor, you must first separate the drive unit plate from the drive unit main case.

Remove the hex head bolts securing the drive unit plate to the main case. See Figure 6-53.

Figure 6-53: Drive Unit Mounting

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Drive Unit

Drive Motor

Mounting Bobs

m

10. Remove the pinion gear nut and pinion gear from the underside of the drive unit plate.

Remove seven (7)hex head bolts mounting the motor to the drive unit plate. See Figure 6-54.

Figure 654: Drive Unit mounting to Drive Motor

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Drive Unit

LEGEND: 1 . Helical Geor

10. P i p Plug

19. Shim 3.5 OD

28. Vent Plug

2. Spirol Gear and Pin~onShah

1 1. Bear~ngCup/Com

20. Shim 3.5 OD

29. Hsx Heod Cap Screw

3. Main Cox

12. Bearing Cup/Cone

21. Shim 3.5 OD

30. N/A

4. Cover Plak

13. Bear~ngCup/Com

22. Lock Nut

31. Flat Washer

5. Bearing Filler Plug

14. Shim 2.0 OD

23. Ring SecKit

32. N/A

6. Hex Plug

15. Shim 2.0 OD

24. Lock Nut

33. G m x Fitting

7. Boll (34)

16. Shim 2.0 OD

25. Boll (35)

34. Spiml Pin

8. D r ~ wWheel Shah

17. Shim 2.0 OD

26. Lock Washer (6)

35. Mliml Gear ond Pinion Set

9. Ring

18. Shim 3.5 OD

27. SeaCOiI

Figure 6-55: Drive Unit, Cross-Sectional View

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures -

Drive Unit

Assembly 1. To determine the proper shim pack [14-171 follow the procedure below. Refer to Figure 6-55 on page 6-66 for numbers in [brackets]. a. Press the bearing cone [ l11 on the pinion shaft [2]. 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 [14-1 71.

MD - (Length + SD) = shim 2. Place the shim pack [14-171in 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 [l1) 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. Allow approximately 0.005" (. 127mm)end play.

6. Place the helical gear [l]on the spline of the pinion [2].

7. Tighten the nut I221 to adjust the end play of the pinion shaft (0.000" to 0.002") (0.000 rnm to 0.050mm).

8. Press the bearing cone [12] on the spiral gear (21.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Unit

9. Place the shim [18-211 (approximately 0.020" to 0.030") (0.508 mm to 0.762 mm) in the bearing cup bore and position the bearing cup [12] in place. The cup should be a slip fit. Tap it in place with a soft face hammer.

10. Prevent the helical gear [ 11 from turning by inserting a 1 / 8 bolt through the pipe plug hole (281. 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 [12].The required backlash is 0.003" to 0.005" (0.076 mm to 0.127 mm). Add to or subtract from the shim pack [18-211 to achieve the proper backlash. Check the tooth pattern. See Tooth Pattern of Drive Unit" on page 6-74.

12. Press the bearing cup 1131in the case. Place the bearing cone in the cup, and press the seal (271into the case.

13. Insert the wheel drive shaft (81through 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. Use the lock nut [24]to adjust the torque to 55 ft. lbs. (77 Nm) and obtain a setting of 0.000" to 0.001" (0.000 mm to 0.025 rnm) preload.

15. Place the complete drive wheel assembly on the wheel drive shaft.

16. Apply sealant (85gram tube P/N 0059004851-71 or 300 ml cartridge P/N 0059004852-71) in continuous bead around all holes and perimeters of mating parts. Use 6 bolts [29]and lock washers [26].Torque to 18 ft. lbs. (25.2 Nm).

17. Install the pipe plug [6],drain plug [ 101, and vent plug [28]into the unit using antiseize compound.

18. Install the drive motor. See "Drive Motor" on page 6-60.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Unit

Installation

A CAUTION Be sure h e key switch is OFF, and the battery connector disconnected before you begin.

1. Position the drive unit mounting plate on the opposite end of motor and secure with hex head cap screws (7).Torque to 120-150

in. lbs. See Figure 6-56.

2. Instal pinion gear and lock nut on armature shaft and torque to 50 ft. lbs. See Figure 6-55.

3. Using a gasket scraper, remove any gasket material from the mating surfaces of the drive unit mounting plate and the main case.

4. Apply a generous coating of gasket compound (PJN 00590-00438-7 1) to both the drive unit case and the drive unit mounting plate.

Figure

Figure 6-57: Drive Unit Mounting

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Unit

5. With a suitable hoist, position the assembled motor and mountrng plate on the drive unit. Install hex head cap screws and torque to 50 ft. lbs. See Figure 6-57.

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 cap-screws in

the steering bearing and torque them to 80

ft. lbs. (112 Nm). See Figure 6-57.

A CAUTION Do not remove the hoist until the cap screws are in place and torqued to 80 ft. Ibs. (1 12 Nm).

9. Remove the hoist and install the brake. See "Brake" on page 6-50.

10. Mount the control handle.

1 1. Connect the wiring harness.

12. Connect the drive motor cables. Torque to 100-120 in. lbs. (11.2-13.6 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 6-22.

14. Install drain plug. See Figure 6-58.Ensure the drive unit is filled to the proper level with gear oil. Install fill plug. See Figure 659.

15. Reconnect the battery connector and turn the key switch ON. 16. Check the controls for proper operation.

Figure 6-58: Drive Unit Drain Plug

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Toyota Walkie Service Manual

Component Procedures Drive Unit 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 6-59.

Cleaning 1. Remove the vent plug from the top cover of

the drive housing. See Figure 6-59.

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.

00700-CL380 Issued: August 29, 1997

Figure 6-59: Drive Unit Fill Plug and Vent Plug

Toyota Walkie Service Manual

Component Procedures Drive Housing Lubrication

Drive Housing Lubrication Gear Oil Level 1. Remove the level plug. See Figure 6-60.

2. Check oil level. When truck is level, the oil should 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 660: Drive Unit Level Plug

Changing Gear Oil 1. Remove the drain plug from the bottom of the gear housing cover and allow the oil to drain. See Figure 6-61.

2. Remove and clean the vent plug. See "Cleaning" on page 6-71.

3. After the oil has drained completely, flush

the housing with a suitable solvent and allow it to drain.

4. Install the drain plug. See Figure 6-61.

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 2.25 qts. (2.130 liters) of gear oil. Do not overfill.

Figure 661 :

Unit

00700-CL380 Issued: August 29,1997

Toyota Walkie Service Manual

Component Procedures Drive Housing Steering Bearing

Drive Housing Steering Bearing Removal 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the drive unit fill plug and drain

plug and allow gear oil to drain. See Figure 6-59 and Figure 6-61.

3. Remove the drive unit as described on page 6-63.

4. Remove the snap ring [Item [ 191 in Figure 6-55 on page 6-66) which secures the bearing [34] to the drive housing. Remove the bearing.

Installation 1. Install the bearing. Index the inner race to the transmission casting with a roll pin.

2. Replace the snap ring to secure the bearing to the drive housing.

3. Use a hoist to replace the drive unit as described on page 6-63.

A CAUTION Do not remove the hoist until the cap screws are in place and torqued to 80 ft. Ibs. (1 12 Nm)

.

4. Replace the drain plug.

5. Replace the gear oil.

6. Replace the fill plug.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

-

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. Correct improper tooth patterns as shown in the chart below; the degree of change depends on the position of the patterns on the teeth.

ON RING GEAR CONCAVE

CONVEX

FLANK

FLANK

DRI UEN CONCAVE FLANK

CORRECT PATIERN

BY CHANGING THE SHIMS IN THE DIRECTION SHOW BY THE ARROWS

DRI UI NG CONVEX FLfiNK

No Adjustment Needed

I

IDEAL P A T T E R N

PATTERN AT TIP

I

P A T T E R N AT R O O T

T O E PATTERN

I

HEEL PA'ITERN

I

Figure 6-62: Drive Unit'Gear Tooth Pattern

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Drive Wheel

Drive Wheel Removal 1. Turn the key switch OFF and discomect the battery connector.

2. Turn the control handle all the way to the left.

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

Figure 6-63: Jacking Tractor End

For details, see "Jacking Safety" on page

2- 13.

3. Jack and block the truck under the tractor frame. See Figure 6-63.

4. Remove drive wheel mounting bolts. See Figure 6-64.

5. Remove drive wheel.

Figure 6-64: Drive Wheel and Tire

00700-CL380Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Drive Wheel

Cushion Tire Replacement Any misalignment of the tire and hub while the tire is being pressed onto the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire's metal insert. The chamfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

OUTSIDE OF HUB AND TIRE ASSEMBLY

A CAUTION To prevent damage, the hub must be installed on the circular ram with the chamfered side UP* 1. Check the inside surface of the metal insert

on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert and lubricate it with a soap solution.

2. Place a circular ram on the press table. See Figure 6-65. The length of the ram must be

longer than the width of the old tire to allow complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

Figure 6-65: Cushion Tire Replacement

3. If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightly smaller in diameter that the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the proper amount of recession.

4. Position the hub assembly with the old tire

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

00700-CL380 Issued: August 29, 1997

Toyota Waikie Service Manual

Component Procedures Drive Wheel

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

6. Apply a soap solution to the inside of the tire rim.

7. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

8. Begin pressing the new tire onto the hub and the old tire off of the wheel. Run the press slowly for the first few inches of travel because this is the critical stage of the 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.

9. Release the press. Remove the wheel, tire assembly and the old tire from the press table. Wipe off any grease. Inspect the wheel and tire assembly.

10. Install the wheel and tire assembly on the drive axle of the truck. Torque the mounting hub bolts to 100 ft. Ibs. (140 Nm).

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Drive Wheel

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00700-CL380 Issued: August 29, 1 997

Component Procedures

Toyota Walkie Service Manual

Casters

Casters Casters are used on Models 6HBW30, 6HBE30/ 6HBE40 and 6HBC30/6HBC40.

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

2. Jack and block the tractor. See "Jacking

Safety" on page 2-13.

Bolts (4)

The casters are very heavy. Do not place hands under the casters when removing the four bolts in the following step.

Figure 6-63: Removing Caster

3. Remove the four bolts and their washers from the mounting plate. See Figure 6-63.

Wheel Replacement 1. Remove the caster assembly. See "Removal" on page 6-79.

2. With hammer and pin punch, drive the tension pin out of axle shaft.

See Figure 6-64.

Figure 6-64: Removing Tension Pin

Figure 6-65: Removing Axle Shah

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Casters

4. Remove the wheel and shims.

See Figure 6-66.

Figure 6-66: Removed Wheel and Shims

Caster Disassembiy

Bolts and Washers

Do not remove the pivot in until the springs are compressed in the fo lowing step.

P

1. Install two 1 /4-20 x 3" bolts and several

washers through caster frame and into the springs. See Figure 6-67.

NOTE: Use washers a s spacers. Allow the bolt to thread into the spring 4-5 turns before it starts to compress springs.

?

>"

-

- - . - W - . d

-"

Figure 6-67: Compressing Caster Springs

2. Tighten the bolts against the washers compressing the spring until the tension relieved from the pivot. St.->Figure 6-68.

Figure 6-68: Relieving Pivot Tension

00700-CL380Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Casters

3. Remove pivot pin retainer screw. See Figure 6-69.

Figure 6-69: Removing Pivot Pin Retainer Screw

Use hammer and pin punch to drive out the pivot pin and washers. See Figure 6-70.

If necessary, replace the springs. If spring replacement is not necessary, leave springs compressed for reassembly.

Figure 6-70: Removing Pivot Pin

Caster Assembly 1. Lubricate the pivot pin with white lithium grease (P/N 00590-04833-71). See Figure 6-71.

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 6-7 1: Separated Caster

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Casters

Remove the bolts and washers compressing the springs.

Figure 6-72:

Removing Bolts From Springs

Wheel Installation

1 . Turn the caster assembly on its side. See

Figure 6-73. 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 6-74.

Figure 6-73: Installing New Wheel

Figure 6-74: lnstalling Axle Shaft

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Casters

2. Drive the tension pin in the axle shaft.

3. Lubricate via grease fittings.

Figure 6-75: Installing Tension Pin

Caster Installation 1. Secure the shims and caster assembly with

the four bolts and washers. See Figure 6-76 and Figure 6-77.

2. Lubricate via grease fittings.

3. Remove block and jack.

Figure 6-76: Caster, Shims and Mounting Bolts

Figure 6-77: Securing Caster To Tractor

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Load Wheels

Load Wheels Replacement 1. Lilt 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 6-78.

Figure 6 7 8 : Removing Tension Pin

3. Drive the axle out of the load arm casting with a hammer and brass drift pin. See Figure 6-79.

r-"

Figure 6-79: Removing Axle From load Arm Casting

4. Push the tire out. Note the location of the washers and pin. See Figure 6-80.

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.

"-

Washers (2)

0

Figure 680: Removed load Wheel and Components

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Load Wheels

8. Align the tire and washers with the holes in the load arm casting.

9. Drive the axle through the load arm casting, tire and washers. Make sure the pin hole in the axle aligns with the housing.

10. Install tension pin.

1 1. Lubricate the grease fittings.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Pallet Entry Wheels 8000 Lb. Models

Pallet Entry Wheels 8000 Lb. Models Replacement 1. Raise the forks and block them in the

raised position. See "Jacking Safety" on page 2-13.

2. Remove lock nut and bolt from sides of entry roller bracket. See Figure 6-8 1.

3. Replace roller. See Figure 6-8 1 .

4. Insert bolt through the entry roller bracket

and roller and secure with the lock nut. See Figure 6-8 1.

Roller

Bolt

Figure 6-8 7 : Replacing Pallet Entry Wheel

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Fork Height Adjustment 6000 Lb. Models

Fork Height Ad'ustment 6000 Lb. Mode s

I

To adjust the lowered fork height for new load wheels, refer to Figure 6-82.

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 at '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 should be 3-1/4" (83 mm).

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 should be 31 /4" (83 mm).

2. If the fork height is incorrect, jack the forks up a few inches from the floor and block them in place.

3. Loosen the nut [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.

00700-CL380 Issued: August 29, 1997

Figure 6 8 2 : Fork Height Adjustment, 6000 Ib.

Component Procedures

Toyota Walkie Service Manual

8000 Lb. Models

8000 Lb. Models To adjust the lowered fork height for new load wheels, refer to Figure 6-83.

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

2. Remove the cover plate to gain access to the turnbuckle adjustment.

3. Loosen the 1-3/8" - 12 nuts (one is lefthand thread) [l]on the pullrod adjuster [2].

Loosen the additional 1 /4-20 alleri head cap screw on the adjusting nut [3].Turn the adjuster until it reaches 3-1/4" (83mm). Tighten the 1-3/8"-12 nuts.

4. Remove the blocks and lower the forks completely. Check the fork height a t 'B'.

The lowered fork height should be 3-1 /4" (83rnm).

Figure 6-83: Fork Height Adjustment, 8000 Ib.

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. The lowered fork height should be 3-1 /4" (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 1-3/8" -12 nuts (one is lefthand) [ 11 on the pullrod adjuster (21.Turn the adjuster until it reaches 3-1 /4" (83

mm).

4. Remove the blocks and lower the forks completely. Check the fork height a t 'B'.

The lowered fork height should be 3-1 /4" (83 mm).

5. Make sure both wheels are adjusted to share the load equally.

00700-CL380 Issued: August 29, 199'

Component Procedures

Toyota Walkie Service Manual

Lift Limit Switch

Lift Limit Switch When the forks are fully raised, the lift-limit switch turns the hydraulic pump motor off.

This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure 6-84.

Adjustment 1. Raise the forks until they reach their fully raised position.

2. Loosen the bolt, and slide the switch bracket up or down to activate (cut power off)when the lift is 1 /2"to 1" (12.7 mm25.4 mm) before its fully raised position.

3. Tighten the bolt.

Figure 6-84: Lih limit Switch

00700-CL380 Issued: August 2 9 , 1997

Toyota Walkie Service Manual

Component Procedures Lift Limit Switch

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00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Hydraulic Components

Hydraulic Components General Guidelines To prolong the life of your Toyota walkie, adhere to the following guidelines: Keep all fittings and c o ~ e c t i o n tight s 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.

Whenever you remove a fitting with a pipe thread, use a sealing compound on the outside of the threads before you re-install the fitting. (Never use ~ e f l o n @ tape.) Make sure all parts q e 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.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Hydraulic Fluid

Hydraulic Fluid Proper Level To prevent air from entering the lines, the fluid level (with the forks fully lowered) should be filled and visible to the bottom of the fill plug elbow. Add the specified fluid if necessary. See "Lubrication Equivalency Chart" on page 7-2.

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, should 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 6-85: Hydraulic Unit

4. Remove one of the lift cylinder hoses from

the fitting at the hydraulic pump. See Figure 6-86.

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 m or s lash. Point hose away from ho18firm1~ in waste fluid container.

b&ZT Figure 6-86: Hydruolic Connections

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

7. Run the hydraulic pump by pressing the lift button until all the hydraulic fluid is pumped from the system.

00700-CL380 Issued: August 29, 1997

Toyota Walkie 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 7-2. Replace vent plug.

11. Connect the battery and turn the key switch ON. 12. Raise and lower the forks several times to purge air from the system.

13. 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.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures 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 6-87.The relief valve is set by the manufacturer to open at a specified pressure.

0- 3000

PSI GAUGE

FEMALE RUN TEE 7/16-20 JIC X 1/8" NPT X 7/16"-20 JIC

/

RELIEF VALVE ADJUSTING SCREW

Relief Vahre Seth'ngs

0 '

Table 6-2: Truck Pressure Levels

Prtssure Settings T CYLINDERS

Capacity

'

,+

PUY P

,,J RESERVOIR

I

6,000lb.

(2,724kg.)

8.000lb.

(3,632kg.)

Figure 6 8 7 : Checking Relief Valve Pressure

1

2,250

/

15.513

1

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"NIT 0-3.000psi (0-20684kPa) pressure gauge in place of the elbow. See Figure 6-87.

3. Turn the key switch ON. Leave the control handle in the neutral (vertical) position.

4. Press the 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 as follows: a. Remove the lock nut covering the relief valve adjustment screw.

See Figure 6-87. b. As you depress the lift button, turn the adjusting screw inward to increase the

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Relief Valve Settings

pressure setting or outward to decrease the pressure setting. c. Check the indicator on the pressure gauge. After the relief valve is properly set, release the lift button. d. Re-install the locknut. e. Check the relief valve setting. f. Lower the forks completely. Turn the key switch OFF. g. Remove the pressure gauge. Replace the elbow. h. Raise the forks. Inspect all hoses and fittings for leaks. i. Adjust the lift-limit switch to shut down

the pump when the forks reach their upper limit. See "Lift Limit Switch" on page 6-89.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Hydraulic Ram

Removal 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 6-88.

4. Remove the tractor cover.

5. Remove the five (5)hex head nuts that secure gauge mounting console, and remove console. This provides the necessary clearance to remove the hydraulic ram.

6. Jack up and block truck a t drive wheel end to gain access to the bottom of the hydraulic cylinder. See "Jacking Safety" on page 2- 1 3 .

Figure 6-88: RemovingBattery With Hoist

Remove the hydraulic line from the bottom of the selected hydraulic cylinder. See Figure 6-89.

1TE:

Be prepared to catch hydraulic fluid under the hydraulic cylinder in a suitable container.

Figure 6 8 9 : Removing Hydraulic Line From Cylinder

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures Hydraulic Ram

8. Remove hose fitting inserted in the bottom of the hydraulic cylinder to gain clearance for ram removal. See Figure 6-90.

9. Remove the block(s) and lower the tractor end of the truck.

10. Remove the horn to access lift cylinder more easily. See 'Horn" on page 6-32.

Figure 6-90: Removing Hose Fitting From Cylinder

Remove vent line from the top of the cylinder. Remove the vent hose fitting from the lift ram housing. See Figure 6-91.

Place a jack between the forks under the battery compartment.

Figure 6-91: Remove Vent Line From Cylinder

Lift the fork section to maximum height and block the fork section under the battery compartment. The tractor section will remain on the floor.

Figure 6-92: Blocking Fork Section For Ram Removal

00700-CL380 Issued: August 29, 1 997

Component Procedures

Toyota Walkie Service Manual

Hydraulic Ram

Remove the two (2)hex head cap screws securing the retaining plate at the top end of the cylinder and remove the plate. See Figure 6-93.

Figure 6-93: Removing the Retaining Plate

15. Remove the two (2) hex head cap screws securing the piston clevis to the fork frame.

See Figure 6-94.

16. Push piston completely into the cylinder.

17. Support the tractor with a jack.

A CAUTION In the next step, the tractor and frame will separate at top. Use the jack to stabilize the truck.

18. Remove the two bolts from the opposite piston clevis. At this point, the fork frame separates from the tractor.

Figure 6-94: Removing Piston Clevis From Fork Frame

19. Lift the ram up and out of the tractor frame.

20. With the hydraulic ram on a work bench, remove the clevis pin "C" clip and slide out the clevis pin.

21. Inspect the clevis, pin and associated parts for wear and/or damage. Replace a s necessary. If they are in good condition. retain them for later installation.

22. To replace hydraulic cylinder seals, See "Hydraulic Cylinder Seals" on page 6-101.

00700-CL380Issued: August 29,1997

Toyota Walkie Service Manual

Component Procedures Hydraulic Ram

1. If truck was lowered from block, place a jack between the forks under the battery compartment.

2. Lift the fork section to maximum height and block the fork section under the battery compartment. The tractor section will remain on the floor.

3. Install the clevis pin through the clevis and piston end and secure with the clevis pin "C" clip.

4. Position the hydraulic ram in bores of tractor frame.

Figure 6 9 5 : Installing Ram Retuiner Plate

5. Install the ram retainer plate and secure with the two (2) hex head cap screws. See Figure 6-95.

6. Use the jack the raise the tractor end until the tractor frame comes together with the fork frame.

7. Slide the piston up until the clevis makes contact with the mounting plate on the fork frame and secure clevis with the four hex head cap screws (two for each ram). See Figure 6-96.

8. Lower the jack and use it to jack the fork

frame between the forks and remove the block(s) under the battery compartment.

See "Jacking Safety" on page 2-13. Lower the fork frame.

Figure 6-96: Securing Clevis To Fork Frame

Jack up and block a t tractor end to gain access to the bottom of the hydraulic cylinder. See "Jacking Safety" on page 2-13.

Put the sealant on threads of hose fitting.

Install the hose fitting in the bottom of the hydraulic ram. See Figure 6-97.

Connect and secure the hydraulic line at the bottom of the hydraulic cylinder.

Remove the block(s) under the tractor end and lower the truck. See "Jacking Safety" on page 2-13.

Install the vent line fitting.

Figure 6-97: Installing the Hose Fining

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual -----

Hydraulic Ram

Connect and secure the vent line at the top of the cylinder. See Figure 6-98.

Install the gauge console and secure with five (5)hex head nuts.

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

'TE:

Do not connect battery connector a t this time.

Check the hydraulic reservoir fluid level. If necessary, add fluid; fill to the bottom of breather cap elbow. See "Lubrication Equivalency Chart" on page 7-2.

Connect the battery connector and turn the key switch ON.

Figure 6-98:

installing he Vent line On Cylinder

20. Lift and lower the forks several times.

21. Re-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 7-2.

22. Lower the forks completely.

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

24. Install the tractor cover.

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Hydraulic Cylinder Seals

Hydraulic Cylinder Seals Disassembly 1. Remove the lift ram from the truck. See "Hydraulic Ram" on page 6-96.

2. Extend the piston fully from the cylinder.

See Figure 6-99.

3. Remove the outer lock ring.

See Figure 6-99.

4. Push the piston back inside the tube at least 3/4".

Cylinder

Outar Lock Ring

Figure 6-99: Removing Outer Spiral lock Ring

5. Remove the spacer. See Figure 6-100.

Figure 6- 100: Removing the Spacer

6. Remove the lock ring from inside the tube.

See Figure 6-101.

7. Cut the sharp edge from back comer of the head lock ring groove.

Figure 6- 10 1: Removing Lock Ring From Tube

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Hydraulic Cylinder Seals

Carefully pull the rod and head assembly from tube. See Figure 6-102.

I Piston

sleeve

b m b b

Figure 6-102: Rod and Head Assembly Out of Tube

Remove the piston jam nut (Figure 6-103) and spin off piston (Figure 6-104).

#

Figure 6-103: Removing h e Piston Jam Nut

Slide the head assembly off the rod at the piston end of the rod.

Figure 6 104: Removing Piston Assembly

00700-CL380Issued: August 29,1997

Toyota Walkie Service Manual

Component Procedures Hydraulic Cylinder Seals

11. Remove old seals and clean metallic parts thoroughly. See Figure 6-105.

Assembly 1. Lubricate new seals with applicable hydraulic fluid and slide the lock ring, spacer and head lock ring onto the rod a t the piston end of the rod. See Figure 6-106.

1 Head

\

lock Ring

Head Assembly

Cock Ring

Figure 6- 1 0 5 : Piston Rod Components

2. Slide the head assembly and sleeve on the rod at the piston end of the rod. See Figure 6-106.

I

Spacer

Lock Ring

\

Head Assembly

Figure 6- 1 0 6 : Reassembling Piston Rod

3. Install the piston and the piston jam nut on the rod. See Figure 6- 106 and Figure 6-107.

Figure 6- 1 0 7 : Securing Piston Jam N u t

00700-CL380 Issued: August 29, 1997

\

Piston

Component Procedures

Toyota Walkie Service Manual

Hydraulic Cylinder Seals

4. Carefully push the rod and head assembly into the tube. See Figure 6- 108.

5. Install the head lock ring. See Figure 6- 108.

Figure 6- 108: lnstalling the Head Lock Ring

6. Install the spacer and lock ring. See Figure 6- 109 and Figure 6- 1 10.

Figure 6 109: Installing the Spacer

Figure 6 1 10: lnstalling the Lock Ring

00700-CL380 Issued: August 29, 1997

Component Procedures

Toyota Walkie 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.

Removal 1. Lower the forks completely.

2. Disconnect the battery. Remove and tag all wires and cables connected to the pump motor, See Figure 6-111.

3. Remove and tag the hydraulic lines from the hydraulic unit. See Figure 6-111.

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 7-2. Use a funnel with a flexible neck. Fill the reservoir only until the fluid is visible a t the bottom of the vent plug elbow. See Figure 6-111.

Use up to 1.5 quarts (1.41 liters).

4. Install the vent plug. See Figure 6-111.

00700-CL380 Issued: August 29, 1997

Figure 6-71 1 :

Hydraulic Unit

Toyota Walkie Service Manual

Component Procedures Hydraulic Reservoir

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. Connect the battery.

7. Raise and lower the forks, and check all hoses and fittings for leaks.

8. Lower the forks.

9. Check the hydraulic fluid level in the

reservoir.

Hydraulic Reservoir Removal 1. Remove the hydraulic unit from truck. See "Removal" on page 6-105.

2. Remove the four cap screws that connect the hydraulic reservoir to the adapter housing. See Figure 6-112.

3. Remove the reservoir and properly dispose of the old hydraulic fluid. See Figure 6-113.

4. After the fluid has drained, flush the inside of the reservoir with a suitable cleaning solvent.

Figure 6- 1 12:

Adapter Cap Screws

5. Dry the inside of the reservoir with clean, dry compressed air.

Installation 1. Inspect 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 6-113.

3. Carefully install the reservoir on the adapter housing and secure with four (4) cap screws.

4. Install hydraulic unit in truck. See

"Installation" on page 6-105.

Figure 6-1 13: Removed Reservoir

00700-CL380Issued: August 29,1 997

Toyota Walkie Service Manual

Component Procedures Filter Screen and Suction Tube

Filter Screen and Suction Tube 1. Remove the reservoir. See 'Hydraulic Reservoir" on page 6-106.

2. With pump assembly inverted, push the

spring clip toward the pump housing. See Figure 6-114.

3. Grasp the suction tube with the filter screen and pull out of pump housing. See Figure 6-114.

4. Clean the filter screen a t the bottom of the

suction tube with suitable solvent. See Figure 6-115.

5. From the pump side, blow dry with clean, dry compressed air.

'Housing :,

P4 Figure 6- 1 14: Pump Housing Components

Installation 1. Inspect the filter screen and tube for defects and replace if necessary.

2. Lubricate the pump end of the suction tube with hydraulic fluid.

3. Push the spring clip toward the pump housing and insert the suction tube through the spring clip and into the pump housing until it stops. See Figure 6-114.

4. If necessary, rotate the suction tube so that

the filter screen is toward center line of the Pump.

5. Install the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-106.

00700-CL380 Issued: August 29, 1997

Figure 6- 1 15: Cleaning Filter Screen

%

Component Procedures

Toyota Walkie Service Manual

Hydraulic Pump

Hydraulic Pump Removal 1. Remove the hydraulic reservoir. See "Hydraulic Reservoir" on page 6-106.

2. With the pump assembly inverted, push spring clip toward the pump housing. See Figure 6-114.

3. Grasp the suction tube with the filter screen and pull out of the pump housing.

See Figure 6-114.

4. Remove the eight (8)screws that secure the

pump to the adapter body.

Figure 6- 1 16: Pump and Adapter Body

5. Separate the pump from the adapter body.

See Figure 6-116.

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 (3)O-rings and place them between the pump and adapter body.

3. Insert the pump shaft coupling onto the end of the motor armature shaft and fill coupling cavity with lubricant (P/N 0059004836-71). See Figure 6-1 17.

Figure 6- 1 17: Pump Drive Coupling

4. Place the pump on the adapter body while

lining up the shaft with the coupling. See Figure 6-118. Rotate if necessary.

5. Secure the pump with the eight (8)screws and torque to 10- 12 ft. lbs. (13.56816.2816 Nm).

6. Install the reservoir. See "Hydraulic Reservoir" on page 6-106.

Figure 6- 1 1 8: Installing Pump In Adapter

00700-CL380 Issued: August 29,1997

Toyota Walkie Service Manual

Component Procedures

Lift Motor

Lift Motor General Data Lubrication

None required. Sealed bearings are used a t both ends of the motor.

Armature Test

These armatures have standard windmg 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 - 1 /2"(3.81 cm).

I

I

1

Brush Replacement

Replace brushes when they have worn to the minimum length of 1 /2" (12.70mm).

Spring Tension

Adjust the spring tension of new brushes to 32 to 40 oz. (908.8to 1136 grams).

Brush Inspection See "Motors, General" on page 6-52.

Removal 1. Remove the hydraulic unit from the truck.

See "Hydraulic Unit" on page 6-105.

2. Remove the two (2)bolts from the end plate that attach the motor to the adapter housing. See Figure 6-1 19.

Figure 6- I 19: Bolts Securing Motor To Adapter

3. Separate the motor from the adapter housing. See Figure 6-120.

4. Remove the solenoid from the side of the motor housing to be reused.

See Figure 6-120.

Figure 6120: Separated Reservoir and Motor

0 0 7 0 0 - C L 3 80 Issued: August 29, 1 997

Component Procedures

Toyota Walkie Service Manual

General Data

Installation 1. Stand pump assembly on end, with the adapter body facing up.

2. Set aside the pump drive coupling to be reused. See Figure 6-120.

NO=

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 onto the end of the pump shaft and fill coupling cavity with lubricant (P/N 00590-04836-71). See Figure 6-121.

4. Rotate the pump or motor shafts to make sure the motor shaft fits correctly into the coupling.

5. Install the new motor onto the adapter housing. Rotate further if necessaq until the motor contacts the adapter body.

Figure 6- 12 1: Coupling Cavity

There is an indexing pin on the end of the motor housing that fits into a hole in the adapter body to make sure the motor mounting screws align with the threaded holes in the adapter body.

See Figure 6-122.

Figure 6- 1 2 2 : Indexing Pin

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Component Procedures General Data

6. Insert the screws into the motor end plate, through the motor and into the adapter body. See Figure 6-123.

7. Make sure the motor is mating flush with the adapter body and torque screws to 1719 ft. Ibs. (23.0656-25.7792 Nm).

8. Install the solenoid.

9. Install the hydraulic unit. See "Hydraulic Unit" on page 6-105.

Figure 6-123: Securing the Motor and Adapter Body

00700-CL380Issued: August 29, 1997

Component Procedures

Toyota Walkie Service Manual

Cold Storage Conditioning

Cold Storage Conditioning New walkie 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 and drive unit.

A CAUTION When a truck is to be installed in a cold storage environment, change the fluid in the hydraulic reservoir and the drive unit according to the following items.

Classes of Cold Storage Toyota walkie trucks can be conditioned for two classes of cold storage:

Cooler Environment where temperatures fluctuate from 20°F(-7°C)to 70°F(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(-29°C)to 40°F(4°C).

Application where truck operates continuously in a temperature of -20°F (-29°C).

Refer to: The Lubricant Equivalent Chart on page 7-2.

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix

Appendix

00700-CL380 Issued: August 29, 1997

Appendix

Toyota Walkie Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart Approved Toyota Lubricants Where Used

TYPe

Drive Unit Gear Case (above 30" F)

Gear Lubricant

Approved Manufacturer Forsythe Ltd.

Toyota Part Number 00590-04834-71 (1 quart/0.9 liter)

Shell Spirax HD 00590-04838-71 (5 gal. / 18.9 liters)

Drive Unit Gear Case (below 30" F) (below - 1" C) Lift Chains

Oil

Chevron Delco 400 15W-40 API Service SE

00590-04835-71 (1 quart/0.9 liter)

Citgo C-6 10W-30 Motor Oil MIL-H46152

00590-04837-71 (5 gal./ 18.9 liters)

Exxon Extra Motor Oil 10W-30 API Service SE Gulflube Motor Oil X.H.D. 10W-30 Mobil Delvac Special 1OW-30 API Service SE Phillips Trop-Arctic All Season Motor Oil 1OW-40 MIL-L46152 Shell Rotella T 15W-40 API Service SE, CC and CD Sohio Multron 10W-30 MILL46152 API Service SE Texaco URSATEX 1OW-30 2 166 Figure 7- 1:

Lubrication Equivalency Chart

0 0 7 0 K L 3 8 0 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Lubrication Equivalency Chart I

11

Approved Toyota Lubricants Where Used

Hydraulic Reservoir (non-cold storage trucks)

Hydraulic Fluid

Toyota Part

Approved Manufacturer

'OF

Number

Chevron AW I S 0 4 6 Citgo 4 6 Exxon Nuto H 4 6

I

005900-04934-71 (2 gal. /7.6 liters) 00590-04840-7 1 (5gal./ 18.9 liters)

Forsythe AWTH215 IS046 Mobil DTE- 1B NOCO NOCOLUBE AW46 Texaco Cygnus 4 6 or I-ID 4 6 Ultramar Ultra Hydraulik AW46 Hydraulic Reservoir (cold storage trucks) (+40° F to -20" F) (4" C to -29" C)

Hydraulic Fluid

Hydraulic Reservoir (cold storage trucks) (20" F to 70" F) (-6"C to 21" C)

Hydraulic Fluid

Hydraulic Reservoir (for extreme heating conditions)

Hydraulic Fluid

Figure 7- 1:

Exxon Univis 513 (similar to MIL-H5606A)

00590-04841-7 1 (1 gal./3.785 liters)

Mobil Aero HFA Texaco Aircraft Hydraulic Fluid 15 NOCO NOC 1866

00590-04842-71 (1 gal./3.785 liters)

Shell Tellus T Oil 3 2 Texaco HD AZ 3 2 1627 Rando or Cygnus 3 2 Chevron AW-MV Mobil423 or 424 NOCO Torque TDH

lubrication Equivalency Chart

00700-CL380 Issued: August 29, 1 997

00590-04843-7 1 (5 gal./18.9 liters) 00590-04842-71 (1 gal./3.785 liters)

1

I

Appendix

Toyota Walkie Service Manual

Lubrication Equivalency Chart

Where Used

Agpnmed Manufacturer

Tppe --

Bearings

-

Chevron Avi-Motive Grease

Grease

Citgo HEP2 (above 30" F only) Exxon RONEX MP or UNIREX N2

1

Toyota Part n-er 00590-04844-71 (10 cartridges per case) 00590-04845-71 (5gal./ 18.9 liters)

Gulf Gulfcrown Grease No. 2

I

Mobil Grease 77 Phillips Philube 1B and RB Grease Shell Alvania Grease EP2 Sohio Bearing Guard "LT" Texaco Regal AFB 2 Grease MILG18709A

Figure 7- 1:

lubrication Equivalency Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Torque Chart - Standard

-

Torque Chart Standard Idenacation

Figure 7-2:

Torque Chart - Standard

00700-CL380 Issued: August 29, 1997

Appendix

Toyota Walkie Service Manual

-

Torque Chart Metric

-

Torque Chart Metric Ferrous Metric Bolts (The grade rating is stamped on the head of the bolt.)

Diameter (in millimeters)

Grade 10.9

Torque (with bolts oiled)

Torque (with bolts oiled)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

8.6 21 42 72 174 340 340

6 15 30 55 130 255 255

12 29 58 101 245 475 475

21 43 75 181 350 350

6 8 10 12 16 20 24 Figure 7-3:

Grade 8.8

-

-

-

-

i I I

,iI

Torque Chart - Ferrous Metric

Non-Fenrous Metric Bolts

Figure 7-4:

Torque (with bolts oiled)

Diameter (in millimeters)

Newton-meters

Foot-pounds

6 8 10 12 16 20

12 .29 58 101 245 475

9 21 !

43 75 181 350

Torque Chart - Non-Ferrous Metric

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Decimal Equivalent Chart

Decimal Equivalent Chart 4ths

8th

16th.

32nds

1 /64 1

1 /32

3/64 1/16 5/64

/

3/32 7/64 1 /8

9/64 5/32 11/64 3/16 13/64

/

7/32 15/64 1 /4

Figure 7-5:

Decimal Eq uivalent Chart

00700-CL380 Issued: August 29, 1997

,1 MM Equivalent.

To 3

64th.

.016 .031 .047 .062 .078 .094 .lo9 .125 .I41 .156 .172 .188 .203 .219 .234 .250

1

1 1

.02 .03 .05 .06 .08 .09 .ll .12 .14 .16 .17 .19 .20 .22 -23 .25

.397 .794 1.191 1.587 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.593 6.350

I

Appendix

Toyota Walkie Service Manual

Decimal Equivalent Chart

Figure 7-5:

Decimal Equivalent Chart

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Standard/Metric Conversions

StandardIMetric Conversions

...

.

Multiply

To Convert..

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

s q uare-yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.1 13

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to grams

Ounces x 28.35

Grams to ounces

Ounces x 0.035

Ounces to kilograms

Ounces x 0.028

-

00700-CL380 Issued: August 29, 1997

7-9

Appendix

Toyota Walkie Service Manual

Standard/Metric Conversions

...

To Convert...

Multiply

Kilograms to ounces

Kilograms x 35.27

Pounds to Kilograms

Pounds x 0.454

Kilograms to pounds

Kilograms x 2.2

Pounds per Square Inch to Kilopascals

Pounds per Square Inch x 6.894

Kilopascals to Pounds per Square Inch

Kilopascals x 0.145

Inch Pounds (in. lbs.) to Newton Meters (Nm)

Inch Pounds x 0.113

Newton Meters (Nm) to Inch Pounds (in.lbs.)

Newton Meters x 8.85

Foot Pounds (fi. lbs.) to Newton Meters (Nm)

Foot Pounds x 1.3568

Newton Meters (Nm) to Foot Pounds (ft. lbs.)

Newton Meters x 0.737

Miles per hour to kilometers per hour

Miles per hour x 0.6214

Kilometers per hour to miles per hour

Kilometers per hour x 1.609

Fahrenheit to Celsius

('F - 32)x 0.555

Celsius to Fahrenheit

('Cx 1.8)+ 32

00700-CL380 issued: August 29, 1 997

I

Toyota Walkie Service Manual

Appendix Electrical Schematic

Electrical Schematic

Figure 7-6: Model 6HBW30 (Sheet 1 of 5)

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Electrical Schematic

Figure 7-7: Models 6HBE30 and 6HBE40 (Sheet 2 of 5)

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Electrical Schematic

Figure 7-8:

Models 6HBC30 and 6HBC40 [Sheet 3 of 5)

00700-CL380 Issued: August 29, 1997

Toyota Walkie Service Manual

Appendix Electrical Schematic

OPT IONS rnNECTOR

---------------------------,--.

I I

I l MOTOR l CONTROLLER

I I I

'----------()---------a

B-

Figure 7-9:

Model 6TB50 (Sheet 4 of 5)

00730-CL380 Issued: August 29, 1997

HANDLE ASSEh13LY~

Toyota Walkie Service Manual

Appendix Electrical Schematic

II

HOUR METER OPTION

DISCHARGE METER O P T I O N

J

METER OPT l ONS MNNECTOR

CONNECTOR OPTIONS METER

KEYSW l TCH BRAKE SWITCH FORWARD SWITCH R E V E R S E SWITCH B E L L Y B U TTO N S WI T C H ( O P T . ) HORN SWITCH (HANDLE) L l F T CUT-OUT SWITCH (OPT. LOWER SW l TCH (HANDLE OPT. L l F T SWITCH HANDLE O P T . ) HORN sw 1 T c H ! R A I L OPT. ) LOWER-sw l TC H ' ( R A ~ L - O P T ) L l F T SWITCH ( R A I L O P T . ) R A B B I T SWITCH ( R A I L O P T . ) RABB l T SW l TCH (FLOOR OPT. )

1

:

PMCl

CONNECTOR ON MOTOR CONTROLLER

JP2 JP4 JP6 JP9 JPlO

CONNECTOR BY MOTOR FOR HANDLE FUNCTIONS CONNECTOR BY KEY SWITCH FOR R A I L FUNCTIONS CONNECTOR BY MOTOR FOR TRAVEL TERMINAL CONNECTIONS FOR METERS CONNECTOR I N HANDLE FOR TRAVEL AND FUNCTION CONNECTIONS

JPS4

S P L I C E BY CONTROLLER FOR FORWARD TRAVEL

SPL3

S P L I C E I N CONNECTOR J P 4

00700-CL380 Issued: August 29, 1997

I

FUSE PUMP C I R C U I T 1 5 0 AMPS FUSE MOTOR C I R C U I T 2 5 0 AMPS FUSE CONTROL C I R C U I T 1 5 AMPS M I -F M I -R M2 M3

CONTACTOR FORWARD CONTACTOR REVERSE CONTACTOR F I E L D WEAKEN CONTACTOR PUMP

SOL 1

SOLENOID LOWER

MD MP

MOTOR D R I V E MOTOR PUMP

HTRl

HEATER I N HANDLE

VR

THROTTLE POTENTIOMETER

NOTES: 1 . FOR HOUR/DISCHARGE METER WITH LlFT INTERRUPT, MAIN HARNESS "M3-Y" LEAD IS DISCONNECTED FROM THE PUMP AND HEATSHRUNK. METER HARNESS "M3-Y" IS INSTALLED O N THE PUMP. Figure 7- 10: Meter Options and legend (Sheet 5 of 5)

-

I

COMPONENT LEGEND

SWlO SWll

HOUR/DISCHARGE METER O P X N

I I

I

S E NOTE ~ 1

HOUR/DISCHARGE, W l TH l NTERRUPJ METER OPTION

Toyota Waikie Service Manual

Index

Index

00700-CL380Issued: August 29, 1997

Toyota Walkie Service Manual

Index

Battery . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Adding Water . . . . . . . . . . . . . . . .6. 12 Charging . . . . . . . . . . . . . . . . . . . . 6. 10 Exterior Cleaning . . . . . . . . . . . . . . 6.9 Gates . . . . . . . . . . . . . . . . . . . . . . .6.8 Gates And Rollers . . . . . . . . . . . . . .6.7 Maintenance Free . . . . . . . . . . . . . 6. 14 Rollers . . . . . . . . . . . . . . . . . . . . . .6.8 Specific Gravity . . . . . . . . . . . . . . .6. 13 Storage . . . . . . . . . . . . . . . . . . . . .6. 14 Voltage Check . . . . . . . . . . . . . . . . 6. 13 Without Gates and Rollers . . . . . . . .6.8 Brake . . . . . . . . . . . . . . . . . . . . . . . . .6.50 Brushes . . . . . . . . . . . . . . . . . . . . . . -6-52

Casters . . . . . . . . . . . . . . . . . . . . . . . .6.79 Wheel Replacement . . . . . . . . . . . .6.79 Cold Storage . . . . . . . . . . . . . . . . . . .6. 112 Commutator . . . . . . . . . . . . . . . . . . . .6.55 Contactors Forward/Reverse Travel . . . . . . . .6.45 Rabbit Speed (Field Weakening) . . . 6.4 1 Tip Inspection . . . . . . . . . . . . . . . .6.40 Control Handle . . . . . . . . . . . . . . . . . .6.30 Return Spring Adjustment . . . . . . .6.30 Conversions Standard/Metric . . . . . . .7.9

.

Deadman Switch . . . . . . . . . . . . . . . . .6.22 Decimal Equivalent Chart . . . . . . . . . . .7.7 Diodes . . . . . . . . . . . . . . . . . . . . . . . .6. 18 Drive Housing Lubrication . . . . . . . . . .6.72 Drive Housing Steering Bearing . . . . .6.73 Drive Unit . . . . . . . . . . . . . . . . . . . . . . 6.63 Drive Unit Vent Plug . . . . . . . . . . . . . .6.71 Drive Wheel . . . . . . . . . . . . . . . . . . . . 6.75

Emergency Reverse Check Equivalent Chart. Decimal

Fork Height Adjustment 6000 Lb. . . . . . . . . . . . . . . . . . . . . 6-87 80OOLb. . . . . . . . . . . . . . . . . . . . . 6-88 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Gauges

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

Handle . . . . . . . . . . . . . . . . . . . . . . . . 6-30

High Mica . . . . . . . . . . . . . . . . . . . . . 6-55 Horn . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Hydraulic Fluid . . . . . . . . . . . . . . . . . 6-92 Hydraulic Pump . . . . . . . . . . . . . . . . 6-108 Hydraulic Ram . . . . . . . . . . . . . . . . . . 6-96 Hydraulic Reservoir . . . . . . . . . . . . . 6-106 Hydraulic Solenoids . . . . . . . . . . . . . . 6-24 Hydraulic Unit . . . . . . . . . . . . . . . . . 6-105

Key Switch . . . . . . . . . . . . . . . . . . . . . 6-21

Lift Limit Switch . . . . . . . . . . . . . . . . . 6-89 Load Wheels . . . . . . . . . . . . . . . . . . . . 6-84 Lubrication Equivalency Chart . . . . . . . 7-2

Map. Navigating the Manual . . . . . . . . . 1-2 Metric Conversions . . . . . . . . . . . . . . . 7-9 Motor Controller . . . . . . . . . . . . . . . . . 6-33 Motors Brush Spr.. Tension . . . . . . . . . . 6-54 Brushes . . . . . . . . . . . . . . . . . . . . 6-52 Drive . . . . . . . . . . . . . . . . . . . . . . 6-60 General . . . . . . . . . . . . . . . . . . . . 6-52 Lift . . . . . . . . . . . . . . . . . . . . . . . 6-109 Tests . . . . . . . . . . . . . . . . . . . . . . 6-56

,.

. . . . . . . . .6.37 . . . . . . . . . .7.7 Pallet Entry Wheels . . . . . . . . . . . . . . 6-86 Power Cables . . . . . . . . . . . . . . . . . . . 6-15

Filter Screen . . . . . . . . . . . . . . . . . . . 6. 107

00700-CL380Issued: August 29. 1997

Twota Walkie Service Manual

Relief Valve . . . . . . . . . . . . . . . . . . . . 6-94 Return Spring Adjustment . . . . . . . . . 6-31

Seals Hydraulic Cylinder . . . . . . . . . . . .6. 101 Solenoids Hydraulic . . . . . . . . . . . . . . . . . . 6-24 SuctionTube . . . . . . . . . . . . . . . . . . .6-107 Switches Deadman . . . . . . . . . . . . . . . . . . . 6-22 General . . . . . . . . . . . . . . . . . . . . 6-20 Key . . . . . . . . . . . . . . . . . . . . . . . 6-21 Lift Limit . . . . . . . . . . . . . . . . . . . 6-89

Terminal Nuts . . . . . . . . . . . . . . . . . . 6-56 Throttle Potentiometer . . . . . . . . . . . . 6-37 Torque Chart Metric . . . . . . . . . . . . . . . . . . . . . . 7-6 Standard . . . . . . . . . . . . . . . . . . . . 7-4 Tractor Cover . . . . . . . . . . . . . . . . . . . 6-6

Voltage . . . . . . . . . . . . . . . . . . . . . . . 6-13

Wheels Caster . . . . . . . . . . . . . . . . . . . . . 6-79 Load . . . . . . . . . . . . . . . . . . . . . . 6-84 PalletEntry . . . . . . . . . . . . . . . . . 6-86 Wiring Harness . . . . . . . . . . . . . . . . . 6-16

00700-CL380 Issued: August 29. 1 997

Index