Toyota Pallet Truck Service Manual-USB迷|专注于互联网分享

2024年10月29日发(作者：揭爵)

SERVICE MANUAL

Pallet Trucks

6HBW30

6HBE40

6HBC40

27,000 and up

6HBE30

6HBC30

6TB50

27,000 and up

00700-CL390-04 Issued: 2 February 2004

Toyota Pallet Truck Service ManualHow To Use This Manual

Table of Contents

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

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

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Fork Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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

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

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Systems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

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

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

Programmable Maintenance Tool . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Lift/Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Directional/Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Strip Curtain Bypass

(Models 6HBE30/40 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Manual Coast Mode

(Standard on 6HBE30/40, Optional on 6HBW30) . . . . . . . . . . . . 3-8

Motor Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General Truck Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Perform Daily or Every Eight (8) Operating Hours . . . . . . . . . . . . 4-3

Perform Every Two Months or 250 Operating Hours . . . . . . . . . . 4-4

Perform Annually or Every 1500 Operating Hours. . . . . . . . . . . . 4-5

Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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

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

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

Checking for Shorts from Battery to Truck Frame. . . . . . . . . . . . 5-3

Checking for Shorts from Components to Truck Frame. . . . . . . . 5-4

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

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

Acceleration Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Brake Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Current Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Emergency Reverse

00700-CL390-04, Issued: 2 February 2004iii

How To Use This ManualToyota Pallet Truck Service Manual

(6HBW30 and 6HBE30/40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

High Pedal Disable (HPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Overtemperature (Motor Controller) . . . . . . . . . . . . . . . . . . . . . . . 5-7

Overvoltage Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Plugging (Plug Braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Pulse Width Modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Ramp Shape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Sequencing Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Short Circuit or “Short” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Speed Limiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Static Return To Off (SRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Throttle Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Undertemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Undervoltage Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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

Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Monitor Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Faults Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Functions Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Information Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Programmer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

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

Symptom Tables: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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

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

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

Symptom Tables: Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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

Trucks Equipped with Battery Gates and Rollers (optional). . . . . . 6-8

Trucks Without Battery Gates and Rollers . . . . . . . . . . . . . . . . . . 6-9

Battery Exterior Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Battery/Charger/Truck Connectors . . . . . . . . . . . . . . . . . . . . . . . . 6-13

00700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service ManualHow To Use This Manual

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Test/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Test/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Lift Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Grab Rail Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Hydraulic Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Manual Coast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

Hour Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Combination Hour/Battery Discharge Meter. . . . . . . . . . . . . . . 6-24

Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

Return Spring Adjustment

6HBW30, 6HBE30 and 6HBE40. . . . . . . . . . . . . . . . . . . . . . . . 6-26

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

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

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

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

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

Travel Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

Tip Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Main Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Models 6HBW30, 6HBE30, and 6HBE40. . . . . . . . . . . . . . . . . . 6-35

Models 6HBC30, 6HBC40, and 6TB50 . . . . . . . . . . . . . . . . . . . 6-36

Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Motor Brush Spring Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

Commutator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

00700-CL390-04, Issued: 2 February 2004v

How To Use This ManualToyota Pallet Truck Service Manual

Terminal Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

Tooth Pattern of Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

Drive Unit Vent Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Drive Housing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Drive Housing Steering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

Load Wheels

Model 6TB50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Pallet Entry Sliders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

6000 Lb. Models (Single Pallet). . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

Long-John Models (Double Pallet). . . . . . . . . . . . . . . . . . . . . . . . 6-66

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69

General Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

Changing Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . . 6-72

Relief Valve Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72

Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73

Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

Hydraulic Cylinder Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81

Filter Screen and Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 6-81

Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86

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

Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

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

00700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service ManualHow To Use This Manual

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

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

00700-CL390-04, Issued: 2 February 2004vii

Toyota Pallet Truck Service ManualHow to Use This Manual

Section to Use This Manual

00700-CL390-04, Issued: 2 February 20041-1

How to Use This ManualToyota Pallet Truck Service Manual

Map of the Manual

How to Use This

Manual

Table of Contents

Safety

Map of the Manual

Manual Design

Systems

Overview

Vehicle

Specifications

Start Page

General System

Data

Planned

Maintenance

Theory of

Operations

Trouble-

shooting

Component

Procedures

Alphabetical List

of Component

Procedures

Component

Location Photos

Appendix

Index

1-200700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service Manual

Manual Design

The Toyota Pallet Truck Service Manual is

designed with the following objectives in mind:

•Provide technical coverage for expected

levels of user expertise

•Anticipate your needs and reduce your

decisions regarding maintenance

•Reduce page flipping through a “one-stop

shopping” approach

The two-line running page header at the top of

each page tells you:

•Name of the manual

(Toyota Pallet Truck Service Manual)

•Current Chapter Title

(for example, this page How to Use This

Manual)

•Current topic

(for example, this page Manual Design)

It is recommended that you go to the START

page for guidance to the correct chapter.

•How to Use This Manual explains the

manual format and design and contains

the Table of Contents and START page.

•Safety explains warning and caution

notes, general safety rules and safety rules

for batteries, static, jacking, and welding.

•Systems Overview includes truck

specifications and theory of operation

information.

•Planned Maintenance outlines the

recommended schedule of preventive

services to keep your truck working most

efficiently.

•Troubleshooting is a set of “decision-tree”

charts and tables designed to take you

from a symptom to a specific sequence of

tests in order to isolate a failing

component.

•Chart “TS1: START

TROUBLESHOOTING” on page5-22

will guide you to the individual

troubleshooting symptom chart you

need.

00700-CL390-04, Issued: 2 February 2004

How to Use This Manual

•When you’re familiar with the

symptoms listed, you may instead

simply find the symptom chart. See

“List of Troubleshooting Charts” on

page5-19.

•When you complete a troubleshooting

procedure, be sure to follow the steps in

chart “END1: End of Troubleshooting

Procedure” on page5-24.

•Component Procedures gives

step-by-step procedures for testing,

removal, installation, and adjustment of

individual truck components. Components

are listed in an order which considers:

•Frequency of attention

•Physical attachment (for example,

brake must be removed before drive

motor)

•Functional relation (for example, drive

motor and drive unit components are

grouped together)

To find a component procedure, you may

use one of three methods:

•Look up the component name in the

“List of Component Procedures” on

page6-2.

•Find the component in the

“Component Locators” on page6-5.

•Look up the component name in the

maintenance manual Index.

•Appendix contains reference information

such as torque values, lubricants and

schematics.

•Index lists subjects alphabetically.

1-3

Toyota Pallet Truck Service Manual

START Page

00700-CL390-04, Issued: 2 February 2004

How To Use This Manual

START Page

1-5

How To Use This ManualToyota Pallet Truck Service Manual

START Page

START:Why are you here?

To review safety

precautions?

Yes

Go to Chapter 2

"Safety"

To examine

specifications or

theory of

operations?

Yes

Go to Chapter 3

"Systems Overview"

To do scheduled

maintenance?

Yes

Go to Chapter 4

"Planned Maintenance"

To troubleshoot

a problem?

Yes

Go to Chapter 5

"Troubleshooting"

List of Troubleshooting Charts

Go to Chart

START-2

START Troubleshooting

1-600700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service ManualHow To Use This Manual

START Page

START-2

To test,

inspect, adjust,

remove/install a

Yes

Go to Chapter 6

"Component Procedures"

component?

Alphabetical List of

Component Procedures

To find general

reference

Yes

Go to the

Component Locator

information?

"Appendix"

To locate

an object or

Go to the Index

procedure by

Yes

name?

00700-CL390-04, Issued: 2 February 2004

1-7

Toyota Pallet Truck Service Manual

Section

00700-CL390-04, Issued: 2 February 2004

Safety

2-1

Safety

Definitions

Throughout this manual, you will see two kinds

of safety reminders:

Warning means a potentially hazardous

situation exists that, if not avoided,

could result in death or serious injury.

Caution means a potentially hazardous

situation exists that, if not avoided,

could result in minor or moderate injury

or in damage to the truck or nearby

objects.

2-2

Toyota Pallet Truck Service Manual

Definitions

00700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service Manual

General Safety

Do not operate or work on this truck unless you

are trained, qualified and authorized to do so.

223L6S008

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.

2O-6

Operate this truck only from the operator’s

position.

2O-7

00700-CL390-04, Issued: 2 February 2004

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).

2S-1

Do not wear watches, rings, or jewelry when

working on this truck.

Follow the scheduled lubrication, maintenance

and inspection steps.

2-3

Thank you very much

for your reading.

Please click here and go

back to the website.

Then, you can

download the complete

manual instantly.

No waiting.

Safety

Follow exactly the safety and repair instructions

in this manual. Do not take “shortcuts.”

Do not use an open flame near the truck.

223L6S012

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.

2-4

Toyota Pallet Truck Service Manual

General Safety

Always park this truck indoors.

2O-63

Do not wash this truck with a hose.

Do not add to or modify this truck until you

contact your local Toyota Dealer to receive

written manufacturer approval.

00700-CL390-04, Issued: 2 February 2004

Toyota Pallet Truck Service Manual

Battery Safety

As a battery is being charged, an

explosive gas mixture forms within and

around each cell. If the area is not

properly ventilated, this explosive gas

can remain in or around the battery for

several hours after charging. Be sure

there are no open flames or sparks in

the charging area. An open flame or

spark can ignite this gas, resulting in

serious damage or injury.

Battery electrolyte is a solution of

sulfuric acid and water. Battery acid

causes burns. If any electrolyte comes in

contact with your clothing or skin, flush

the area immediately with cold water. If

the solution gets on your face or in your

eyes, flush the area with cold water and

get medical help immediately.

Wear personal protective equipment to protect

eyes, face and skin when checking, handling or

filling batteries. This equipment includes

goggles or face shield, rubber gloves (with or

without arm shields) and a rubber apron.

225L6SO16

00700-CL390-04, Issued: 2 February 2004

Safety

Make sure a shower and eyewash station are

nearby in case there is an accident.

204GS059

A battery gives off explosive gases. Never

smoke, use an open flame, or use anything that

gives off sparks near a battery.

223L6S012

Keep the charging area well-ventilated to avoid

hydrogen gas concentration.

2-5