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Service and Parts Manual
TOYOTA
Model Serial No.
6HBW20 10011 and Up
Date: 10/01/95
Service and Parts Manual TOYOTA
Introduction
PREFACE
This manual indudesinformationrequired for maintenance, troubleshooting, and
repair of the Model 6HBW20. The objectis to insuresafe maintenance and repair
practices and procedures for this Toyota product.
MANUAL OVERVIEW
This manual consists of both a ServiceManual and a PartsManual for the specific
equipment listed on the cover.
The Table of Contentsprovides easy location of all subject matter within the
manual.
The followingsymbols are used throughout this manual to represent a condi-
tion or hazard of which the operator should be aware.
DENOTES A SERIOUSHAZARDTHAT COULD CAUSE INJURYO
R DEATH TO THE
OPERATOROR OTHER PERSONNEL FROMA PARTICULARACTION O
R
CONDITION.
DENOTES A LESSSERIOUS HAZARD FROMAN ACTION O
R CONDITION THAT
ACAUTlON COULD CAUSEMINORINJURY TO THE OPERATORO
RMAINTENANCE
PERSONNEL, O
R CAUSE DAMAGE TO THE EQUIPMENT ITSELF.
Denotes a particular statement pertaining to a particular procedureor explanation.
Revised text and illustrationsare indicated by a black vertical line along the
left-handmargin of the page, oppositerevised, added or deleted material. Revision
linesindicate only current revisions with changes and additionsto or deletions of
existing text and illustrations. Changes in capitalization, spelling, punctuation,
indexing, the physical location of the material or complete page additions are not
identified by revision lines.
Copyright @ 1995 by Toyota lndustrial Equipment, a Division of Toyota Motor Sales,
U.SA., Inc.
All rights reserved. No portion of the manual may be reproducedmechanically,
electronically or by any other means, induding photocopying, electronic retreival or
transfer, or recording without the written permissionof the publisher.
Toyota lndustrial Equipment believesthe informationin this manual is accurate and
current as of the publication date; such information is subject to change without
notice. Toyota lndustrial Equipment is not responsiblefor any errors that may
appear in this manual.
Service and Parts Manual
Table of Contents TOYOTA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1
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General Maintenance Instructions 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Practices 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2
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Hydraulic 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Data For Bolts 6
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Conversion Table 7
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Decals 8
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Decimal Equivalent Chart 10
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Planned Maintenance (PM) 11
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Inspection Form 11
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P
M Schedule and Procedure 11
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Daily Inspection 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly P
M Service (or 100 Hrs.) 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Semiannual Service (or 500 Hrs.) 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual P
M Service (or 1000 Hrs.) 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 13
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Fill Points 14
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PM Chart 15
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Lubrication Equivalency Chart 16
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Scheduled Maintenance 17
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Batteries 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cleaning 17
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Electrolyte Process 17
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Battery Cleaning Procedure 17
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Battery Electrical Leakage To Frame Test 18
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Battery Charging 18
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Charging Process 18
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Hydrometer Use 19
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Procedure 19
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Voltage Check 19
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Adding Water To Battery 20
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Guidelines 20
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Battery History Record 20
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Motors 21
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Motor Cleaning 21
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Brush Care 22
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Maintenance Schedule 22
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Maintenance Inspection Chart 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush Replacement 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Overheating 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Test for Open Circuit 26
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Open Circuit Test Procedure 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Circuit Test .Motors 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Circuit Test 27
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Armature Shorts 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Grounds Test 28
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Grounds.General 28
Service and Parts Manual
Table of Contents TOYOTA
. enQn
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Hydraulic 29
Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing Reservoir Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flush Grease Fitting Adapter 30
Battery-Pak Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bearing Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Head Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Storage Requirements 31
Control Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Travel Control Switches 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn. Lift/Lower Switches 33
Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . .
Pull Rod Bushings Removal and Replacement 35
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrier Frame Linkage and Bushings 35
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 37
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 39
Axle Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drive Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Throttle Potentiometer Setting . . . . . . . . . . . . . . . . . . . . . . . . . 47
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Wiring Hookup 49
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Brake Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Brake Linkage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Brake Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Brake Shoe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service and Parts Manual
Table of Contents TOYOTA
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Lift/Lower 53
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Description 53
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Theory of Operation 53
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 54
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Control Circuits 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wring 54
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Hydraulic and Electrical 55
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Equipment Recommended for Normal Servicing 56
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Pump and Motor 57
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Removal and Installation 57
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Pump Motor Brush Removal 57
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Relief Valve 59
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Removing Solenoid Valve 59
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Installing Solenoid Valve 59
. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Pump and Motor Assembly 59
Removing Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Removing the Pump 59
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installingthe Pump 60
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Reservoir 60
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Check Valve 60
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Cylinder Assembly Removal Installation 60
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Cylinder Removal 60
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Hydraulic Cylinder 69
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Cylinder Disassembly 61
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Inspection 61
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Cylinder Assembly 62
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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Lift Limit Switch 63
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Troubleshooting 64
NoLift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Forks Do Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Forks Will Not Hold Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Transistor Control (Motor Controller) 67
Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Low Voltage Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Runaway Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Static Return to Neutral Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Controller Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Controller Thumbwheel Throttle Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 69
"Emergency Reverse" Plug Breaking Inhibit . . . . . . . . . . . . . . . . . . . . . . . 69
Traction System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Preparing to Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Service and Parts Manual
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Diredionalfipeed Control Forward 72
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Directionalfipeed Control Reverse 73
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Emergency Reverse 74
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Contador Tip/Bar Replacement 75
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Troubleshooting 76
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Vehicle is dead.nothing operates 76
. . . . . . . . . . . . . . . . . . . . . . .
No travel.horn and lift/lower operates OK 76
. . . . . . . . . . . . . . . . .
No forward travel.forward contador does not energize 77
. . . . . . . . . . . . . . . . . . . . . .
No forward travel.forward contador closed 78
No reverse travel.reverse contactor does not energize, forward travel operates . . . . . . 79
. . . . . . . . . . . . . . . . . . . . . . .
No reverse travel.reverse contador closed 80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Emergency Reverse 81
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Troubleshooting 82
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring InspectionProcedure 84
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Miscellaneous Troubleshooting 85
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Battery Charger 86
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Electrical Testing 86
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Equipment Required 86
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lnstrudions 86
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Acceptable Charge Values 86
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Open Circuit Voltage Test 87
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Short Circuit Amperage Test 87
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Testing Components 88
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Diodes 88
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Capacitor 88
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overcharging Problems 89
. . . . . . . . . . . . . . . . . . . . . . . .
Charger and Battery not Properly Matched 89
. . . . . . . . . . . . . . . . . . . . . . . .
Defective Battery or Poor DC Connection 89
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charts 90
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller 91
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 91
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Current 93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Current 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment Panel 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manually Adjustable Potentiometers 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmer Connector 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
StatusLED 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wiring 95
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring 95
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-5kR Throttle ("Type 3") 96
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug Current in Over-Temperature 96.1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Speed Parameter 96.1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp Shap Parameter 96.1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Check 97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming and Adjustment 99
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming 99
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Adjustments 100
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Limit Setting 100
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug Current Adjustment 101
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acceleration Adjustment 101
Service and Parts Manual
Table of Contents TOYOTA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 102
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 102
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic History 102
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics and Troubleshooting 103
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Diagnostics 103
Programmer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Programmer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes 108
Peace-of-mind Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1
Programmer Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programmer Menus 112
. . . . . . . . . . . . . . . . . . . . .
Diagnostics and Special Diagnostics 'Menu" . 113
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix 114
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Motor Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Service and Parts Manual
List of illustrations TOYOTA
. . . . . . . . . . . . . . . . . . . . . . .
Component Identification
. . . . . . . . . . . . . . . . . . .
Component ldentification (Cont'd.)
. . . . . . . . . . . . . . . . . . .
Component ldentification (Cont'd.)
. . . . . . . . . . . . . . . . . . . .
Standard Torque Data for Bolts
. . . . . . . . . . . . . . . . . . . . . . .
Standard Decal Placement
. . . . . . . . . . . . . . . . . . . . . . .
Bilingual Decal Placement
. . . . . . . . . . . . . . . . . . . . . . .
Decimal Equivalent Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points
. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fill Points
. . . . . . . . . . . . . . . . . . . . . .
Example of Cleaning Motor
. . . . . . . . . . . . . . . . . . . .
Measuring Brush Spring Tension
. . . . . . . . . . . . . . . . . . . . . . . .
Minimum Brush Lengths
. . . . . . . . . . . . . . . . . . . . . .
Motor Terminals and Circuits
. . . . . . . . . . . . . . . . . . . . . .
Flush Grease Fitting Adaptor
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery-Pack Lifter
. . . . . . . . . . . . . . . . .
Bearing/Sealing Ring Installation Tool
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Head Unit
. . . . . . . . . . . . . . . . . . . . . . . .
Control Handle Removal
. . . . . . . . . . . . . . . . . . . . .
.
Control Head Exploded View
Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Lower Link
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Tire Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Hub Removal
. . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Hub Installation
. . . . . . . . . . . . . . . . . . . . . . . . .
Drive Tire Installation
. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Drive Unit
. . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Installation
. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Axle Seal
. . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Removed
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Removal
. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Placement
Battery Replacement Showing One Top Battery Swiveled Toward Forks
. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Wiring Hookup
. . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Interlock Switch
. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . Lift
. . . . . . . . . . . . . . . . . . . .
Electrical Schematic . Lift Mode
. . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . Lower
. . . . . . . . . . . . . . . . . . .
Electrical Schematic . Lower Mode
. . . . . . . . . . . . . . . . .
Hydraulic Motor, Pump. and Reservoir
. . . . . . . . . . . . . . . . . . . . .
Lift Cylinder . Exploded View
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Limit Switch
. . . . . . . . . . . . . . . . . . . . . . .
Control System (Simplified)
. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Current Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment Panel
. . . . . . . . . . . . . . . . . . . . . . .
Travel Direction Reference
. . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . Forward
. . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . Reverse
Electrical Schematic . Emergency Reverse . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Contactor . Exploded View
. . . . . . . . . . . . . . . . . . .
Programmer and Motor Controller
Motor Controller Connector . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Controller
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment Panel
Service and Parts Manual
List of Illustrations TOYOTA
16 Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
SK Throttle (Type 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1
Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2
Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2
Manual Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 100
LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 115
vii
Service and Parts Manual
S~ecial
Service Tools TOYOTA
viii
Tool List
00590-04661-71
00590-04667-71
00590-04668-71
00590-04669-71
00590-04670-71
00590-04671-71
00590-04672-71
00590-04673-71
00590-04674-71
00590-04675-71
00590-04676-71
00590-04677-71
Description
Diagnostic Service Tool (Programmer)
Pin Extractor
Pin Extractor
Pin Extractor
Pin Extractor
Crimping Tool
Extraction Tool
Model 1141 FasTest Accessory
Model 1142 Tester
Curtis Battery Book One
Bearing/Sealing Ring Installation Tool
Battery Pack Lifter
Service and Parts Manual
General Information TOYOTA
General Mainte- Industrial vehicles may become hazardous if adequatemaintenance is neglected.
nance Instructions Only trained technicians, using approved procedures, in adequate maintenance
facilities should work on this or any other industrial vehicle.
Maintenance Prac- 1.Follow a scheduled lubrication, maintenance, and inspection schedule.
tices
2. Only qualified, authorized technicians are permittedto inspect, maintain, adiust,
and repair this vehicle.
ACAUTlON REMOVE RINGS, WATCHES, AND ALL JEWELRY BEFORE DOING ANY WORK ON
VEHICLE.
3. Before working on vehicle:
a. Lower load handling mechanism completely to the floor.
b. All controls must be in neutral.
c. Release any trapped pressurein hydraulic systems.
d. Block the wheels to prevent movement of the vehicle.
e. Disconnect battery connector
f. Elevate drive tire off floor.
USE EXTREME CARE WHENEVER THE VEHICLE IS JACKED UP F
O
R ANY REASON.
KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE
JACK STANDS O
R SOLID BLOCKS TO SUPPORT VEHICLE - DO NOT RELY ON
JACKS.
g. Before working on load handler, support to prevent movement.
4. After working on vehicle, test all controls and functionsto assure proper
operation.
5. Work in a clean, dry, well ventilated area.
6. Avoid fire hazards. Have adequate fire fighting equipment in the maintenance
area.
7. DO NOT use open flame or sparking devices around the battery. The gasses
given off by the battery are highly explosive.
8. Use extreme caution when using flammable cleaning solutions.
More information pertaining to operating and maintenance procedures may be
, obtained from:
American National Standards Institute
1430 Broadway
New York, NY 10018
Ask for ANSI B56.1 - 1988
Service and PartsManual
General Information TOYOTA
Specifications
Model: 6HBW20
Battery Voltage: 24 .
Wheel:
Drive: 10.5 x 5"Rubber
Load: 3.25 x 5" Polyurethane 121
Install load wheels with at least 1 shim on each side
and a maximum of V
1
6
' (1.58mm) end play. -
-~
Transmission
Fluid: Standard Use 80W-90W
Cold Storage "DEXTRONIIVTF
.FluidCapacity: 0.8 Quart (0.75 liter)
Torque Requirement: Torque drive tire retaining
nut to 250 FT./LBS,
(350Nm) (Whilerotating
drive tire)
Torque pivot bearing retaining nut to Zero (0)end play
on pivot bearings while pivoting transmission. -
Hydraulic
Lift/Lower System
Fluid: Standard Use
Cold Storage
Reservoir Capacity:
Relief Valve Setting:
1OW-40W
"Dextron IIVTF
1 Quart (0.9 liters)
2600 psi f50 psi (177 Barf 3.4 bar)
Service and Parts Manual
General Information TOYOTA
Component Identifi-
cation
Battery
Discharge/Hour
Meter
Key Su
Lift Butt01
Lower Button
, Directional/Speed
Control
Horn Button
Belly Button
~evbrse
Switch
Figure 63 Component Identification
Service and Parts Manual
General Information TOYOTA
Component Identifi-
cation (Cont'd.)
' Battery Charger
Timer
Ban
in C
Battery
Charger
Figure 64 Component Identification (Cont'd.)
4
'
1
120 VAC Power Cord
(for the vehicle's battery
charger)
Service and Parts Manual
General Information TOYOTA
Forward Reverse 15 Amp Lift
Contactor Fuse Cylinder
Battery Discharge/Hour Meter
Contactor
Battery
Connector
Motor -
Controller
Circuit 4
Breaker [CBl
Horn
/
Drive
Unit
Key
, Switch
Hydraulic
Pump
Hydraulic
Reservoir
Lift Limit
Cutoff Switch
Figure 65 Component Identification (Cont'd.)
Service and Parts Manual
General Information TOYOTA
Standard Torque
Data For Bolts
Figure 66 Standard Torque Data for Bolts
6
Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
Service and Parts Manual
General Information TOYOTA
Conversion Table
Service and Parts Manual
General Information TOYOTA
Decals The followingpages show proper mounting and location of decals.
NOTE: See the Parts Manual for decal description and ordering information.
a
" 1
:
VlEW A
a
2
.
5
0
' (6.35 cm) 1.2SD(3.17 cm)
4
VlEW A
Decals:
1. Emergency Disconnect
2. Caution-Bilingual
3. No Riding
4. Spec Plate U.S.
5. PocketManual
6. Warning
7. Cold Storage (located next to lift pump.)
Figure 61 Standard Decal Placement

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Toyota 6 hbw20 electric pallet jack walkie walk service repair manual

  • 1. Service and Parts Manual TOYOTA Model Serial No. 6HBW20 10011 and Up Date: 10/01/95
  • 2. Service and Parts Manual TOYOTA Introduction PREFACE This manual indudesinformationrequired for maintenance, troubleshooting, and repair of the Model 6HBW20. The objectis to insuresafe maintenance and repair practices and procedures for this Toyota product. MANUAL OVERVIEW This manual consists of both a ServiceManual and a PartsManual for the specific equipment listed on the cover. The Table of Contentsprovides easy location of all subject matter within the manual. The followingsymbols are used throughout this manual to represent a condi- tion or hazard of which the operator should be aware. DENOTES A SERIOUSHAZARDTHAT COULD CAUSE INJURYO R DEATH TO THE OPERATOROR OTHER PERSONNEL FROMA PARTICULARACTION O R CONDITION. DENOTES A LESSSERIOUS HAZARD FROMAN ACTION O R CONDITION THAT ACAUTlON COULD CAUSEMINORINJURY TO THE OPERATORO RMAINTENANCE PERSONNEL, O R CAUSE DAMAGE TO THE EQUIPMENT ITSELF. Denotes a particular statement pertaining to a particular procedureor explanation. Revised text and illustrationsare indicated by a black vertical line along the left-handmargin of the page, oppositerevised, added or deleted material. Revision linesindicate only current revisions with changes and additionsto or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, the physical location of the material or complete page additions are not identified by revision lines. Copyright @ 1995 by Toyota lndustrial Equipment, a Division of Toyota Motor Sales, U.SA., Inc. All rights reserved. No portion of the manual may be reproducedmechanically, electronically or by any other means, induding photocopying, electronic retreival or transfer, or recording without the written permissionof the publisher. Toyota lndustrial Equipment believesthe informationin this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota lndustrial Equipment is not responsiblefor any errors that may appear in this manual.
  • 3. Service and Parts Manual Table of Contents TOYOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Maintenance Instructions 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Practices 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Identification 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Torque Data For Bolts 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion Table 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decals 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal Equivalent Chart 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planned Maintenance (PM) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection Form 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P M Schedule and Procedure 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Inspection 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monthly P M Service (or 100 Hrs.) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semiannual Service (or 500 Hrs.) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annual P M Service (or 1000 Hrs.) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Points 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fill Points 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM Chart 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Equivalency Chart 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scheduled Maintenance 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Cleaning 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Process 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Cleaning Procedure 17 . . . . . . . . . . . . . . . . . . . . . . . . Battery Electrical Leakage To Frame Test 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Process 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrometer Use 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Check 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Water To Battery 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidelines 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery History Record 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motors 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Cleaning 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Care 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Maintenance Inspection Chart 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Replacement 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Overheating 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Test for Open Circuit 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Open Circuit Test Procedure 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Circuit Test .Motors 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Circuit Test 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Armature Shorts 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Grounds Test 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounds.General 28
  • 4. Service and Parts Manual Table of Contents TOYOTA . enQn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic 29 Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Changing Reservoir Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush Grease Fitting Adapter 30 Battery-Pak Lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Bearing Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Control Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Head Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Storage Requirements 31 Control Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Control Switches 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn. Lift/Lower Switches 33 Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . . . . . . . Pull Rod Bushings Removal and Replacement 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . Carrier Frame Linkage and Bushings 35 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 37 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 39 Axle Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Throttle Potentiometer Setting . . . . . . . . . . . . . . . . . . . . . . . . . 47 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Wiring Hookup 49 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Brake Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Linkage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Shoe Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
  • 5. Service and Parts Manual Table of Contents TOYOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift/Lower 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation 53 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Circuits 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wring 54 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic and Electrical 55 . . . . . . . . . . . . . . . . . . . . . . Equipment Recommended for Normal Servicing 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump and Motor 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor Brush Removal 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Solenoid Valve 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Solenoid Valve 59 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Pump and Motor Assembly 59 Removing Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pump 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installingthe Pump 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Reservoir 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Valve 60 . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Assembly Removal Installation 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Removal 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinder 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Disassembly 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Assembly 62 Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Limit Switch 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 64 NoLift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Forks Do Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Forks Will Not Hold Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistor Control (Motor Controller) 67 Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Low Voltage Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Runaway Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Static Return to Neutral Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Controller Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Controller Thumbwheel Throttle Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 69 "Emergency Reverse" Plug Breaking Inhibit . . . . . . . . . . . . . . . . . . . . . . . 69 Traction System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Preparing to Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
  • 6. Service and Parts Manual Table of Contents TOYOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diredionalfipeed Control Forward 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Directionalfipeed Control Reverse 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Reverse 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contador Tip/Bar Replacement 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle is dead.nothing operates 76 . . . . . . . . . . . . . . . . . . . . . . . No travel.horn and lift/lower operates OK 76 . . . . . . . . . . . . . . . . . No forward travel.forward contador does not energize 77 . . . . . . . . . . . . . . . . . . . . . . No forward travel.forward contador closed 78 No reverse travel.reverse contactor does not energize, forward travel operates . . . . . . 79 . . . . . . . . . . . . . . . . . . . . . . . No reverse travel.reverse contador closed 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Emergency Reverse 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring InspectionProcedure 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Troubleshooting 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Testing 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Required 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lnstrudions 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acceptable Charge Values 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Circuit Voltage Test 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Circuit Amperage Test 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Components 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diodes 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor 88 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overcharging Problems 89 . . . . . . . . . . . . . . . . . . . . . . . . Charger and Battery not Properly Matched 89 . . . . . . . . . . . . . . . . . . . . . . . . Defective Battery or Poor DC Connection 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charts 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Current 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Current 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment Panel 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually Adjustable Potentiometers 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmer Connector 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StatusLED 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5kR Throttle ("Type 3") 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug Current in Over-Temperature 96.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Speed Parameter 96.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ramp Shap Parameter 96.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Check 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming and Adjustment 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Adjustments 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Limit Setting 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug Current Adjustment 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acceleration Adjustment 101
  • 7. Service and Parts Manual Table of Contents TOYOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 102 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic History 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics and Troubleshooting 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Diagnostics 103 Programmer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Programmer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Modes 108 Peace-of-mind Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 Programmer Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmer Menus 112 . . . . . . . . . . . . . . . . . . . . . Diagnostics and Special Diagnostics 'Menu" . 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix 114 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Motor Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
  • 8. Service and Parts Manual List of illustrations TOYOTA . . . . . . . . . . . . . . . . . . . . . . . Component Identification . . . . . . . . . . . . . . . . . . . Component ldentification (Cont'd.) . . . . . . . . . . . . . . . . . . . Component ldentification (Cont'd.) . . . . . . . . . . . . . . . . . . . . Standard Torque Data for Bolts . . . . . . . . . . . . . . . . . . . . . . . Standard Decal Placement . . . . . . . . . . . . . . . . . . . . . . . Bilingual Decal Placement . . . . . . . . . . . . . . . . . . . . . . . Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fill Points . . . . . . . . . . . . . . . . . . . . . . Example of Cleaning Motor . . . . . . . . . . . . . . . . . . . . Measuring Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . Minimum Brush Lengths . . . . . . . . . . . . . . . . . . . . . . Motor Terminals and Circuits . . . . . . . . . . . . . . . . . . . . . . Flush Grease Fitting Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery-Pack Lifter . . . . . . . . . . . . . . . . . Bearing/Sealing Ring Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Head Unit . . . . . . . . . . . . . . . . . . . . . . . . Control Handle Removal . . . . . . . . . . . . . . . . . . . . . . Control Head Exploded View Load Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly of Lower Link . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Tire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . Drive Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lever Placement Battery Replacement Showing One Top Battery Swiveled Toward Forks . . . . . . . . . . . . . . . . . . . . . . . . . Battery Wiring Hookup . . . . . . . . . . . . . . . . . . . . . . . . Brake Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Brake Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematic . Lift . . . . . . . . . . . . . . . . . . . . Electrical Schematic . Lift Mode . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematic . Lower . . . . . . . . . . . . . . . . . . . Electrical Schematic . Lower Mode . . . . . . . . . . . . . . . . . Hydraulic Motor, Pump. and Reservoir . . . . . . . . . . . . . . . . . . . . . Lift Cylinder . Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Limit Switch . . . . . . . . . . . . . . . . . . . . . . . Control System (Simplified) . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Current Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . Travel Direction Reference . . . . . . . . . . . . . . . . . . . . . Electrical Schematic . Forward . . . . . . . . . . . . . . . . . . . . . Electrical Schematic . Reverse Electrical Schematic . Emergency Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contactor . Exploded View . . . . . . . . . . . . . . . . . . . Programmer and Motor Controller Motor Controller Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment Panel
  • 9. Service and Parts Manual List of Illustrations TOYOTA 16 Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 SK Throttle (Type 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2 Active Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2 Manual Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 100 LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 115 vii
  • 10. Service and Parts Manual S~ecial Service Tools TOYOTA viii Tool List 00590-04661-71 00590-04667-71 00590-04668-71 00590-04669-71 00590-04670-71 00590-04671-71 00590-04672-71 00590-04673-71 00590-04674-71 00590-04675-71 00590-04676-71 00590-04677-71 Description Diagnostic Service Tool (Programmer) Pin Extractor Pin Extractor Pin Extractor Pin Extractor Crimping Tool Extraction Tool Model 1141 FasTest Accessory Model 1142 Tester Curtis Battery Book One Bearing/Sealing Ring Installation Tool Battery Pack Lifter
  • 11. Service and Parts Manual General Information TOYOTA General Mainte- Industrial vehicles may become hazardous if adequatemaintenance is neglected. nance Instructions Only trained technicians, using approved procedures, in adequate maintenance facilities should work on this or any other industrial vehicle. Maintenance Prac- 1.Follow a scheduled lubrication, maintenance, and inspection schedule. tices 2. Only qualified, authorized technicians are permittedto inspect, maintain, adiust, and repair this vehicle. ACAUTlON REMOVE RINGS, WATCHES, AND ALL JEWELRY BEFORE DOING ANY WORK ON VEHICLE. 3. Before working on vehicle: a. Lower load handling mechanism completely to the floor. b. All controls must be in neutral. c. Release any trapped pressurein hydraulic systems. d. Block the wheels to prevent movement of the vehicle. e. Disconnect battery connector f. Elevate drive tire off floor. USE EXTREME CARE WHENEVER THE VEHICLE IS JACKED UP F O R ANY REASON. KEEP HANDS AND FEET CLEAR FROM BENEATH VEHICLE WHILE JACKING. USE JACK STANDS O R SOLID BLOCKS TO SUPPORT VEHICLE - DO NOT RELY ON JACKS. g. Before working on load handler, support to prevent movement. 4. After working on vehicle, test all controls and functionsto assure proper operation. 5. Work in a clean, dry, well ventilated area. 6. Avoid fire hazards. Have adequate fire fighting equipment in the maintenance area. 7. DO NOT use open flame or sparking devices around the battery. The gasses given off by the battery are highly explosive. 8. Use extreme caution when using flammable cleaning solutions. More information pertaining to operating and maintenance procedures may be , obtained from: American National Standards Institute 1430 Broadway New York, NY 10018 Ask for ANSI B56.1 - 1988
  • 12. Service and PartsManual General Information TOYOTA Specifications Model: 6HBW20 Battery Voltage: 24 . Wheel: Drive: 10.5 x 5"Rubber Load: 3.25 x 5" Polyurethane 121 Install load wheels with at least 1 shim on each side and a maximum of V 1 6 ' (1.58mm) end play. - -~ Transmission Fluid: Standard Use 80W-90W Cold Storage "DEXTRONIIVTF .FluidCapacity: 0.8 Quart (0.75 liter) Torque Requirement: Torque drive tire retaining nut to 250 FT./LBS, (350Nm) (Whilerotating drive tire) Torque pivot bearing retaining nut to Zero (0)end play on pivot bearings while pivoting transmission. - Hydraulic Lift/Lower System Fluid: Standard Use Cold Storage Reservoir Capacity: Relief Valve Setting: 1OW-40W "Dextron IIVTF 1 Quart (0.9 liters) 2600 psi f50 psi (177 Barf 3.4 bar)
  • 13. Service and Parts Manual General Information TOYOTA Component Identifi- cation Battery Discharge/Hour Meter Key Su Lift Butt01 Lower Button , Directional/Speed Control Horn Button Belly Button ~evbrse Switch Figure 63 Component Identification
  • 14. Service and Parts Manual General Information TOYOTA Component Identifi- cation (Cont'd.) ' Battery Charger Timer Ban in C Battery Charger Figure 64 Component Identification (Cont'd.) 4 ' 1 120 VAC Power Cord (for the vehicle's battery charger)
  • 15. Service and Parts Manual General Information TOYOTA Forward Reverse 15 Amp Lift Contactor Fuse Cylinder Battery Discharge/Hour Meter Contactor Battery Connector Motor - Controller Circuit 4 Breaker [CBl Horn / Drive Unit Key , Switch Hydraulic Pump Hydraulic Reservoir Lift Limit Cutoff Switch Figure 65 Component Identification (Cont'd.)
  • 16. Service and Parts Manual General Information TOYOTA Standard Torque Data For Bolts Figure 66 Standard Torque Data for Bolts 6
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  • 18. Service and Parts Manual General Information TOYOTA Conversion Table
  • 19. Service and Parts Manual General Information TOYOTA Decals The followingpages show proper mounting and location of decals. NOTE: See the Parts Manual for decal description and ordering information. a " 1 : VlEW A a 2 . 5 0 ' (6.35 cm) 1.2SD(3.17 cm) 4 VlEW A Decals: 1. Emergency Disconnect 2. Caution-Bilingual 3. No Riding 4. Spec Plate U.S. 5. PocketManual 6. Warning 7. Cold Storage (located next to lift pump.) Figure 61 Standard Decal Placement