Master Service Manual
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
WARNING
WARNING
Part no: 00700-CL3WS-RP Date: August 01, 2002
Front Cover
6BWC10/15/20 6BWS11/15/20 6BWR15
Electric Walkie High Lifter Trucks
Effective Serial Number 6BWC10-20001 - UP
3
0 45
9
7-0
0
0
3
0
4
5 97
-
0
00
3
0
4
5 97
-
0
00
6BWC
6BWS
6BWR
Standard Codes
F-code Section C-code
Version no T-code
001
Toyota
1
2002-08-01 Master Service Manual
Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code
R-Code = Reason code
SO-Code = Assortment
F-Code List
PS Powered Pallet Stackers
T-Code List
No. Model
6BWC 6BWC10/15/20
6BWS 6BWS11/15/20
6BWR 6BWR15
C-Code List
No Function Group C-Code
0 Chassis 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
001
Version no T-code
F-code Section C-code
Standard Codes
2
2002-08-01 Master Service Manual
8 Peripheral / Installation Equipment 8000
9 Optionals / Attachments 9000
10 Tools 10000
Table of Contents
Toyota
3
2002-08-01 Master Service Manual
Standard Codes ........................................................................................................ 1
Warning Symbols ..................................................................................................... 13
Warning Levels .................................................................................................... 13
Prohibitory Symbols ................................................................................................ 14
Ordinance Symbols .............................................................................................. 14
Safety ........................................................................................................................ 15
General Safety ..................................................................................................... 15
Battery Safety ........................................................................................................... 19
Static Safety ............................................................................................................. 24
Welding Safety ......................................................................................................... 25
Introduction, Service Manual .................................................................................. 27
Contents, Section M ................................................................................................ 29
Machine Information ............................................................................................ 29
General Product Information .................................................................................. 31
Presentation of Walkie Trucks. ............................................................................ 31
Truck Side Views ........................................................................................ 32
Intended Truck Application .......................................................................... 32
Prohibited Truck Application ....................................................................... 32
Truck Data ................................................................................................... 33
6BWC10 Dimensions .................................................................................. 34
6BWC15 Dimensions .................................................................................. 35
6BWC20 Dimensions .................................................................................. 36
6BWS11 Dimensions .................................................................................. 37
6BWS15 Dimensions .................................................................................. 38
6BWS20 Dimensions .................................................................................. 39
6BWR15 Dimensions .................................................................................. 40
Data Plate ................................................................................................... 41
Main Components ................................................................................................ 42
Inch (SAE) and Metric Fasteners ........................................................................... 45
Introduction .......................................................................................................... 45
Nomenclature, Threads ........................................................................................ 46
Strength Identification .......................................................................................... 47
Conversion of Metric and English Units ............................................................... 54
Technical Service Data ............................................................................................ 57
Ordering Spare Parts ............................................................................................... 61
Contents, Section P ................................................................................................. 63
Table of Contents
4
2002-08-01 Master Service Manual
Planned Maintenance .......................................................................................... 63
Introduction, Maintenance ...................................................................................... 65
Jacking Truck Off The Floor ................................................................................. 66
Elevate Rear of Truck ................................................................................. 66
Elevate Either Side of Truck ........................................................................ 66
Lubricants ............................................................................................................ 67
Standard ...................................................................................................... 67
Corrosion ..................................................................................................... 67
Cold Storage ............................................................................................... 68
Service Schedule ..................................................................................................... 71
Planned Maintenance Schedule .......................................................................... 71
Planned Maintenance Procedures ....................................................................... 76
Services Performed Daily or Every 8 Operating Hours ............................... 76
Services Performed Monthly or Every 120 Operating Hours. ..................... 77
Services Performed Every 480 or 960 Operating Hours ............................. 80
Services Performed Annually or Every 1400 Operating Hours ................... 81
Lubrication Chart ..................................................................................................... 83
Oil and Grease Specifications ................................................................................ 84
Approved Oils and Grease ................................................................................... 84
6BWC Grease & Mast Adjustment Points Location ............................................. 85
6BWS Grease & Mast Adjustment Points Location ............................................. 86
6BWR Grease & Mast Adjustment Points Location ............................................. 87
Contents, Section S ................................................................................................. 89
Service Instructions .............................................................................................. 89
Frame/Chassis ......................................................................................................... 91
General ................................................................................................................ 93
Main Components ................................................................................................ 93
Inspection Covers .................................................................................................... 95
Battery Roller (Optional) ........................................................................................ 103
Battery Cover, Optional (6BWS11 “EE” Trucks Only) ......................................... 105
Inspection ................................................................................................... 105
Removal ..................................................................................................... 105
Installation .................................................................................................. 106
Battery Rollers .................................................................................................... 106
Inspection ................................................................................................... 106
Replacement .............................................................................................. 106
Driver Controls, One Spool .................................................................................... 107
Removal .............................................................................................................. 109
Installation ........................................................................................................... 110
Table of Contents
Toyota
5
2002-08-01 Master Service Manual
Driver Controls, Two Spool .................................................................................... 111
Removal .............................................................................................................. 114
Installation ........................................................................................................... 115
Decals ...................................................................................................................... 117
Decal with Protective Sheet ................................................................................ 117
Decal without Protective Sheet ........................................................................... 117
Motor Maintenance
Schedule/Troubleshooting ..................................................................................... 119
General Information ............................................................................................ 119
Operating Conditions .......................................................................................... 119
Troubleshooting .................................................................................................. 120
Motor Repair ............................................................................................................ 127
Pump Motor ....................................................................................................... 127
Pump Motor Removal ................................................................................ 128
Pump Motor Installation ............................................................................. 128
Drive Motor ......................................................................................................... 129
Brush Replacement .................................................................................... 133
Drive Motor Removal ................................................................................. 133
Drive Motor Installation .............................................................................. 134
Component Repair .............................................................................................. 136
Disassembly .............................................................................................. 136
Inspection ............................................................................................................ 138
Drive End head .......................................................................................... 138
Commutator End Head .............................................................................. 138
Bearings ..................................................................................................... 138
Brush and Commutator .............................................................................. 139
Armature .................................................................................................... 141
Frame and Field Assembly ........................................................................ 142
Assembly/Testing ....................................................................................... 143
Transmission ........................................................................................................... 145
System Description ............................................................................................. 145
Troubleshooting .................................................................................................. 145
Kick Panel .................................................................................................. 146
Transmission Repair ........................................................................................... 147
Removal ..................................................................................................... 148
Installation .................................................................................................. 149
Transmission Assembly ...................................................................................... 151
Disassembly ............................................................................................... 152
Assembly .................................................................................................... 152
Axle Seal ............................................................................................................. 154
Removal ..................................................................................................... 154
Installation .................................................................................................. 154
Parking Brake System ............................................................................................ 157
Brake Theory of Operation .................................................................................. 159
Table of Contents
6
2002-08-01 Master Service Manual
Brake Adjustment ................................................................................................ 160
Brake Shoe Removal / Installation ...................................................................... 161
Drive Wheel ............................................................................................................. 163
Removal .............................................................................................................. 163
Installation ........................................................................................................... 164
Tire Pressing Procedure ..................................................................................... 165
Support/Swivel Wheel ............................................................................................ 167
Maintenance and Adjustments ............................................................................ 170
Caster Adjustment ...................................................................................... 171
Troubleshooting .................................................................................................. 172
Stabilizing Caster ....................................................................................... 172
Load Wheels ............................................................................................................ 173
Removal and Installation ..................................................................................... 176
Caster Assembly ..................................................................................................... 177
Disassembly ........................................................................................................ 178
Inspection ............................................................................................................ 179
Assembly ............................................................................................................ 180
Installation ........................................................................................................... 181
Steering Arm/Wheel, Tiller Arm ............................................................................. 183
Removal .............................................................................................................. 184
Inspection ............................................................................................................ 185
Installation ........................................................................................................... 186
Steering Arm/Wheel, Head ..................................................................................... 187
Control Handle Head .......................................................................................... 188
Removal ..................................................................................................... 188
Installation .................................................................................................. 188
Direction Control Switches .................................................................................. 189
Raise, Lower, and Horn Switches ....................................................................... 191
Potentiometer ...................................................................................................... 194
Removal ..................................................................................................... 194
Installation .................................................................................................. 195
Reverser Assembly Replacement ....................................................................... 199
Electrical Functions ................................................................................................ 201
General ............................................................................................................... 201
Adjustable Settings .................................................................................... 201
References ................................................................................................. 201
Key Switch S17 in ON Position .................................................................. 202
Operating Arm in Drive Position, S10, Brake Switch Closed ..................... 202
Travel Request, Forks First ........................................................................ 202
Travel Request, Forks Trailing ................................................................... 202
Reversing/Motor Brake Forks First to Forks Trailing Direction ................... 203
Reversing/Motor Brake Forks Trailing to Forks First Direction ................... 203
Table of Contents
Toyota
7
2002-08-01 Master Service Manual
Reverser switch .......................................................................................... 203
Lifting Forks ................................................................................................ 203
Lowering Forks ........................................................................................... 204
Horn ........................................................................................................... 204
Options ................................................................................................................ 204
Lifting Forks (Manual Valve) ...................................................................... 204
Tilting Forks ................................................................................................ 204
Side Shifting Forks ..................................................................................... 204
Extend/Retract Forks ................................................................................. 205
Electrical Symbols .................................................................................................. 207
Electrical Schematics ............................................................................................. 213
Battery ...................................................................................................................... 219
Removal .............................................................................................................. 219
Installation ........................................................................................................... 220
Battery Maintenance ........................................................................................... 221
Battery Inspection and Care ....................................................................... 221
Battery Exterior Cleaning ........................................................................... 222
Charging ..................................................................................................... 222
Storage ............................................................................................................... 223
Battery History Record ........................................................................................ 223
Battery Connector ................................................................................................... 225
Location .............................................................................................................. 225
Inspection ............................................................................................................ 226
Installation ........................................................................................................... 226
200 Amp System Line Contactor .......................................................................... 229
Replacement ....................................................................................................... 229
Removal ..................................................................................................... 229
Installation .................................................................................................. 229
300 Amp System Line Contactor (6BWC15/20 only) .......................................... 231
Maintenance ....................................................................................................... 231
Removal/Replacement of Contact Tips ...................................................... 232
200/300 Amp System “EE” Line Contactor ......................................................... 233
Maintenance ....................................................................................................... 233
Removal/Replacement of Contact Tips ...................................................... 234
Battery Controller/Hourmeter/Lift Interrupt .......................................................... 237
General Information ............................................................................................ 237
Electrical ............................................................................................................. 238
Voltage ....................................................................................................... 238
Battery Controller (BC) ........................................................................................ 239
General Information ................................................................................... 239
Reset .......................................................................................................... 241
Table of Contents
8
2002-08-01 Master Service Manual
Key Switch ................................................................................................. 241
Hourmeter .................................................................................................. 242
Troubleshooting .................................................................................................. 242
Battery Discharge Indicator (BDI) .............................................................. 242
Hourmeter .................................................................................................. 245
Start/Stop Switches ................................................................................................ 247
General ............................................................................................................... 247
Test/Inspection ........................................................................................... 247
Master Control On/Off Switch (S21) .................................................................... 249
Inspection ................................................................................................... 249
Removal ..................................................................................................... 249
Installation .................................................................................................. 249
Light Assemblies .................................................................................................... 251
Warning Lights (Option) ...................................................................................... 251
Removal ..................................................................................................... 253
Installation .................................................................................................. 253
Travel/Back-up Alarm (Option) ............................................................................ 254
Removal ..................................................................................................... 254
Installation .................................................................................................. 254
Transistor Controller .............................................................................................. 255
Basics Of Circuit Operation ................................................................................. 255
Control Features ........................................................................................ 257
Maintenance ....................................................................................................... 258
Safety ......................................................................................................... 258
Cleaning ..................................................................................................... 258
Motor Circuit ........................................................................................................ 259
Control Circuit ..................................................................................................... 260
Troubleshooting Guidelines ................................................................................ 261
General ...................................................................................................... 263
Shorts to Frame Test .......................................................................................... 264
Definitions ........................................................................................................... 268
Diagnostics and Troubleshooting ........................................................................ 269
Handset Diagnostics .................................................................................. 269
Troubleshooting ......................................................................................... 269
Troubleshooting Chart ................................................................................ 271
Technical Specification .............................................................................. 276
Troubleshooting Chart Using Handset ....................................................... 277
Transistor Controller Troubleshooting ................................................................. 279
Troubleshooting Chart Index ............................................................................... 279
Troubleshooting Charts ....................................................................................... 280
Hydraulic System .................................................................................................... 299
General ............................................................................................................... 299
Description of Function ....................................................................................... 299
Main Components ............................................................................................... 300
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$37.99
Toyota Electric Truck 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15 Workshop Service Manual
Viewed 61 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$37.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
Illustrated Factory Workshop Service Manual for Toyota Electric Walkie High Lifter Truck Type 6BWC, 6BWS, 6BWR. This manual contains high-quality images, circuit diagrams, and instructions for operating, maintaining, and repairing your truck. It is useful for both professional mechanics and DIY enthusiasts.
Covered models:
- 6BWC10
- 6BWC15
- 6BWC20
- 6BWR15
- 6BWS11
- 6BWS15
- 6BWS20
Format: 468 Pages
Language: English
Contents:
- Standard Codes
- Warning Symbols
- Warning Levels
- Prohibitory Symbols
- Ordinance Symbols
- Safety
- General Safety
- Battery Safety
- Static Safety
- Welding Safety
- Introduction, Service Manual
- Contents, Section M
- Machine Information
- General Product Information
- Presentation of Walkie Trucks
- Truck Side Views
- Intended Truck Application
- Prohibited Truck Application
- Truck Data
- 6BWC10 Dimensions
- 6BWC15 Dimensions
- 6BWC20 Dimensions
- 6BWS11 Dimensions
- 6BWS15 Dimensions
- 6BWS20 Dimensions
- 6BWR15 Dimensions
- Data Plate
- Main Components
- Inch (SAE) and Metric Fasteners
- Introduction
- Nomenclature, Threads
- Strength Identification
- Conversion of Metric and English Units
- Technical Service Data
- Ordering Spare Parts
- Contents, Section P
- Planned Maintenance
- Introduction, Maintenance
- Jacking Truck Off The Floor
- Elevate Rear of Truck
- Elevate Either Side of Truck
- Lubricants
- Standard
- Corrosion
- Cold Storage
- Service Schedule
- Planned Maintenance Schedule
- Planned Maintenance Procedures
- Services Performed Daily or Every 8 Operating Hours
- Services Performed Monthly or Every 120 Operating Hours
- Services Performed Every 480 or 960 Operating Hours
- Services Performed Annually or Every 1400 Operating Hours
- Lubrication Chart
- Oil and Grease Specifications
- Approved Oils and Grease
- 6BWC Grease & Mast Adjustment Points Location
- 6BWS Grease & Mast Adjustment Points Location
- 6BWR Grease & Mast Adjustment Points Location
- Contents, Section S
- Service Instructions
- Frame/Chassis
- General
- Main Components
- Inspection Covers
- Battery Roller (Optional)
- Battery Cover, Optional (6BWS11 EE Trucks Only)
- Inspection
- Removal
- Installation
- Battery Rollers
- Inspection
- Replacement
- Driver Controls, One Spool
- Removal
- Installation
- Driver Controls, Two Spool
- Removal
- Installation
- Decals
- Decal with Protective Sheet
- Decal without Protective Sheet
- Motor Maintenance
- Schedule/Troubleshooting
- General Information
- Operating Conditions
- Troubleshooting
- Motor Repair
- Pump Motor
- Pump Motor Removal
- Pump Motor Installation
- Drive Motor
- Brush Replacement
- Drive Motor Removal
- Drive Motor Installation
- Component Repair
- Disassembly
- Inspection
- Drive End head
- Commutator End Head
- Bearings
- Brush and Commutator
- Armature
- Frame and Field Assembly
- Assembly/Testing
- Transmission
- System Description
- Troubleshooting
- Kick Panel
- Transmission Repair
- Removal
- Installation
- Transmission Assembly
- Disassembly
- Assembly
- Axle Seal
- Removal
- Installation
- Parking Brake System
- Brake Theory of Operation
- Brake Adjustment
- Brake Shoe Removal / Installation
- Drive Wheel
- Removal
- Installation
- Tire Pressing Procedure
- Support/Swivel Wheel
- Maintenance and Adjustments
- Caster Adjustment
- Troubleshooting
- Stabilizing Caster
- Load Wheels
- Removal and Installation
- Caster Assembly
- Disassembly
- Inspection
- Assembly
- Installation
- Steering Arm/Wheel, Tiller Arm
- Removal
- Inspection
- Installation
- Steering Arm/Wheel, Head
- Control Handle Head
- Removal
- Installation
- Direction Control Switches
- Raise, Lower, and Horn Switches
- Potentiometer
- Removal
- Installation
- Reverser Assembly Replacement
- Electrical Functions
- General
- Adjustable Settings
- References
- Key Switch S17 in ON Position
- Operating Arm in Drive Position, S10, Brake Switch Closed
- Travel Request, Forks First
- Travel Request, Forks Trailing
- Reversing/Motor Brake Forks First to Forks Trailing Direction
- Reversing/Motor Brake Forks Trailing to Forks First Direction
- Reverser switch
- Lifting Forks
- Lowering Forks
- Horn
- Options
- Lifting Forks (Manual Valve)
- Tilting Forks
- Side Shifting Forks
- Extend/Retract Forks
- Electrical Symbols
- Electrical Schematics
- Battery
- Removal
- Installation
- Battery Maintenance
- Battery Inspection and Care
- Battery Exterior Cleaning
- Charging
- Storage
- Battery History Record
- Battery Connector
- Location
- Inspection
- Installation
- 200 Amp System Line Contactor
- Replacement
- Removal
- Installation
- 300 Amp System Line Contactor (6BWC15/20 only)
- Maintenance
- Removal/Replacement of Contact Tips
- 200/300 Amp System EE Line Contactor
- Maintenance
- Removal/Replacement of Contact Tips
- Battery Controller/Hourmeter/Lift Interrupt
- General Information
- Electrical
- Voltage
- Battery Controller (BC)
- General Information
- Reset
- Key Switch
- Hourmeter
- Troubleshooting
- Battery Discharge Indicator (BDI)
- Hourmeter
- Start/Stop Switches
- General
- Test/Inspection
- Master Control On/Off Switch (S21)
- Inspection
- Removal
- Installation
- Light Assemblies
- Warning Lights (Option)
- Removal
- Installation
- Travel/Back-up Alarm (Option)
- Removal
- Installation
- Transistor Controller
- Basics Of Circuit Operation
- Control Features
- Maintenance
- Safety
- Cleaning
- Motor Circuit
- Control Circuit
- Troubleshooting Guidelines
- General
- Shorts to Frame Test
- Definitions
- Diagnostics and Troubleshooting
- Handset Diagnostics
- Troubleshooting
- Troubleshooting Chart
- Technical Specification
- Troubleshooting Chart Using Handset
- Transistor Controller Troubleshooting
- Troubleshooting Chart Index
- Troubleshooting Charts
- Hydraulic System
- General
- Description of Function
- Main Components
- Lift (Solenoid valve)
- Lift (Mechanical Valve)
- Lower (Solenoid Valve)
- Lower (Mechanical Valve)
- Relief Pressure
- Compensating Cylinder
- Reach (Solenoid valve)
- Tilt (Solenoid valve)
- Sideshift (Solenoid valve)
- Maintenance
- Adjustments
- Troubleshooting
- Primary Malfunctions
- Definitions
- Removal
- Installation
- Hydraulic Schematics
- Hydraulic Fluid
- Hydraulic Fluid Selection
- Changing Hydraulic System Fluid
- System Draining
- Refilling System
- Bleeding Hydraulic System
- Hydraulic Tank
- Removal
- Installation
- Hydraulic Pump Assembly
- Disassembly
- Inspection
- Assembly
- One Spool Control Valve
- Operators Controls Removal
- Control Valve Disassembly and Inspection
- Operators Controls Installation
- Two Spool Control Valve
- Operators Controls Removal
- Control Valve Disassembly and Inspection
- Operators Controls Installation
- Lift Cylinder, Two Stage Mast
- Removal
- Disassembly
- Assembly
- Installation
- Two Stage Full Freelift Mast Cylinder Repair
- Removal
- Disassembly
- Assembly
- Installation
- Two Stage Full Freelift Mast Staging Cylinder Repair
- Removal
- Disassembly
- Assembly
- Installation
- Lift Cylinder, Three Stage Mast
- Repair
- Removal
- Disassembly
- Assembly
- Installation
- Reach Cylinder, 6BWR15
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Tilt Cylinder
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Shimming Carriage with Mast on Truck
- Repair
- Removal
- Disassembly
- Assembly
- Installation
- Lift Chain
- Lift Chain Adjustment:
- Lift Chain Maintenance
- Lift Chain Inspection
- Lift Chain Replacement
- Mast, Three Stage
- Shimming Carriage with Mast on Truck
- Repair
- Removal
- Disassembly
- Assembly
- Installation
- Lift Chain
- Sideshifter
- Mounting Instructions
- Installation
- Operation
- Maintenance
- Carriage Removal
- Upper Pad Replacement
- Lower Pad Replacement
- Cylinder
- Troubleshooting
- No Sideshifting
- Very Slow Sideshifting
- Irregular Sideshifting
- Single Reach, 6BWR
- Maintenance
- Inspection
- Adjustment
- Repair
- Disassembly
- Assembly
- Carriage Bumpers
- Reach Adjustment
- Fork Carriage Pivot Pins
- Carriage Roller Bearings
- Removal
- Installation
- Removal
- Inspection
- Installation
- Load Backrest
- Removal
- Installation
- Handset Operation
- Operating Modes
- Revert to Previous Settings
- Handset Self Test
- Electrical Controllers (Handset)
- Display Screen
- Menu Navigation Key
