Toyota Electric Walkie Adjustable Straddle Stacker 6BWS10, 6BWS13; SN: 585890 - up Workshop 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-01 Date: September 01, 2003 Service Guide 6BWS10/13 Electric Walkie Adjustable Straddle Stacker Effective Serial Number 585890 - UP Front Cover

Table of Contents 1 2003-08-01 Service Guide Parts ordering instructions .......................................................................... 5 Technical Data ............................................................................................... 7 Introduction, Maintenance .......................................................................... 11 Service Program ....................................................................................... 13 Cleaning and Washing .............................................................................. 14 External Cleaning .................................................................................. 14 Motor Compartment Cleaning ............................................................... 15 Electrical Components .......................................................................... 15 Safe Jacking ............................................................................................. 16 Planned Maintenance .................................................................................. 17 Maintenance Schedule ............................................................................. 17 Lubrication Schedule ................................................................................ 22 Oil and Grease Specification ...................................................................... 23 Tools .............................................................................................................. 25 Super Seal Connectors ............................................................................. 25 AMP Connectors ................................................................................... 26 Other Tools ........................................................................................... 27 Support Arm Chassis .................................................................................. 29 General ..................................................................................................... 29 Main Components ..................................................................................... 30 Maintenance ............................................................................................. 30 Support Arm Width Adjustment ................................................................ 31 Support Arm Replacement ....................................................................... 32 Electric Drive Motor ..................................................................................... 35 Component Parts ...................................................................................... 35 Motor Dismantling from Truck ............................................................... 37 Assembling ............................................................................................ 37 Service/Repairs ........................................................................................ 38 Motor Dismantling ................................................................................. 38 Motor Assembling ................................................................................. 39 Cleaning ................................................................................................ 39 Technical Data .......................................................................................... 40 Drive Unit/Gear ............................................................................................. 41 Component Parts ...................................................................................... 42 Technical Data ...................................................................................... 44 Top Cover Leakage .................................................................................. 44 Drive Shaft Sealing Ring Replacement .................................................... 45 Table of Contents

Table of Contents 2 2003-08-01 Service Guide Electromagnetic Brake ................................................................................ 47 Brake Main Components .......................................................................... 47 Maintenance ............................................................................................. 48 Basic Gap Adjustment ........................................................................... 48 Brake Disc Replacement ....................................................................... 49 Steering ......................................................................................................... 51 Component Parts, Steering (Tiller) Arm .................................................... 51 Brake Microswitch Adjustments ................................................................ 52 Steering (Tiller) Arm Handle ..................................................................... 53 Dismantling/Assembling ........................................................................ 55 Electrical Systems ....................................................................................... 57 Electrical Parts .......................................................................................... 57 List of Symbols and Electrical Wiring Diagram ......................................... 59 Electrical Diagram 1(6) .......................................................................... 61 Electrical Diagram 2(6) .......................................................................... 62 Electrical Diagram 3(6) .......................................................................... 63 Electrical Diagram 4(6) .......................................................................... 64 Electrical Diagram 5(6) .......................................................................... 65 Electrical Diagram 6(6) .......................................................................... 66 Functional Description .............................................................................. 67 Starting the Truck .................................................................................. 67 Driving ................................................................................................... 67 Neutral Speed Reduction ...................................................................... 67 Picture 3 ................................................................................................ 67 Neutral Speed Reduction on Slopes ..................................................... 68 Braking .................................................................................................. 68 Forks Lifting ........................................................................................... 68 Forks Lowering ...................................................................................... 68 Horn ...................................................................................................... 68 Hour Meter ................................................................................................ 69 Fault Codes .............................................................................................. 69 Parameters ............................................................................................... 75 Driver Parameters ................................................................................. 76 Service Parameters ............................................................................... 77 Parameter Description .......................................................................... 78 Part Numbers ............................................................................................ 84 Transistor Panel ........................................................................................ 85 General ................................................................................................. 85 Diagnostic and Troubleshooting ............................................................... 86 Error Codes and Troubleshooting ......................................................... 86 Resetting Errors .................................................................................... 87 Technical Specifications – Curtis 1243 ..................................................... 88

Table of Contents 3 2003-08-01 Service Guide Hydraulic System ......................................................................................... 89 Hydraulic Diagram and Components ........................................................ 89 Main Components ................................................................................. 90 Description ............................................................................................ 90 Main lift chain system .................................................................................. 91 Checking the chain settings ...................................................................... 91 Chain inspection ....................................................................................... 91 Noise ..................................................................................................... 91 Surface rust ........................................................................................... 91 Rusty links ............................................................................................. 91 Stiff links ................................................................................................ 92 Pin rotation ............................................................................................ 92 Loose pins ............................................................................................. 92 Outline wear .......................................................................................... 93 Stretching .............................................................................................. 94 Damage ................................................................................................. 95 Damaged discs ..................................................................................... 95 Damaged pins ....................................................................................... 95 Dirty chain ............................................................................................. 95 Cleaning .................................................................................................... 96 Lubrication ................................................................................................ 96

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Parts ordering instructions F-code Section C-code Version no T-code 001 5 2003-08-01 Service Guide Parts ordering instructions How to order When you order parts, supply the part number, quantity, model, chassis serial number, and mast serial number of your machine. The serial number on the figure refers to either the Mast serial number or Chassis serial number (see figure below for location of serial numbers) and not the truck serial number (shown on next page). Supplying this information will assure prompt, efficient handling of your order. The pictorial reference number is not needed and including it can only add confusion. Field modifications The regulations imposed by OSHA make it mandatory that alteration of industrial trucks be done only as approved in advance and in writing by the manufacturer. Their regulations apply to counter-weighting, changes in masts when such changes affect capacity and any other safety modifications. It is mandatory that nameplate and instructions be changed accordingly (1910.178 (a)(4)). Toyota will review such changes requested as we can properly evaluate and rerate as to capacity. A change will be Mast Serial Number Chassis Serial Number

001 Version no T-code F-code Section C-code Parts ordering instructions 6 2003-08-01 Service Guide evaluated upon receipt of a written request which includes truck and mast serial number and a description of all proposed changes. If the change is approved, authorization will be sent, as will new nameplates or other labeling where appropriate. The new nameplates should be installed over the earlier nameplate. The modifier should send confirmation of the change to the factory along with pictures of the revised truck. Explanation, truck serial number 6BWS10-1 0001 Truck number Capacity (2000lb) Model (6BWS) Straddle Stacker Truck

Technical Data PS M F-code Section C-code Version no T-code 001 354 7 2003-08-01 Service Guide Technical Data Model 6BWS10/13 Drive Motor Type TSL140S-DS30 Output, hp (kW) 1.6 (1.2) Duty cycle S2, 60 min Minimum carbon brush length, inch (mm) 0.5 (13) Nominal commutator diameter, inch (mm) 2 (50) Minimum commutator diameter, inch (mm) 1.85 (47) Resistance, shunt field winding, Ω at 77° F (25° C) 0.49 Resistance armature winding, Ω at 75° F (24° C) 0.0156 Insulation resistance between the windings and motor casing >=1 Mohm Weight, lb (kg) 30 (14) Brakes Type BFK457-08 Braking force, ft-lbs (N•m) 8.85 (12) Output, W 25 Resistance coil , Ω 23 Nominal play in actuated position, inch (mm) 0.078-0.157 (0.2-0.4) Minimum thickness brake disc, inch (mm) 0.216 (5.5) Thickness of a new brake disc, inch (mm) 0.275 (7.0) Transmission/Drive Gear Type 2-stage angle transmission Gear ratio 19,14:1 Oil volume, gallon (liter) 0.26 (1.0) Oil type at normal temperature at temperature < 5° F (-15° C) Hypoid oil SAE 80W/90 SAE 75W

PS M 001 354 Version no T-code F-code Section C-code Technical Data 8 2003-08-01 Service Guide Wheels Drive wheel, inch (mm) Dia 8.5 x 3 (215 x 70) Axle pressure without load, lbs (kg) 1521 (690) Axle pressure at rated load, lbs (kg) 1620 (735) Tightening torque for wheel bolts, ft-lbs (N•m) 47 (65) Support arm wheel, inch (mm) Dia 14 x 3 (100 x 75) Axle pressure without load, lbs (kg) 2 x 355 (240) Axle pressure at rated load, lbs (kg) 2 x 1510 (240) Hydraulic System Output, hp (kW) 2.95 (2.2) Duty cycle,% 5 Minimum carbon brush length, inch (mm) 0.5 (12) Minimum commutator thickness/diameter, inch (mm) 0.187 (4.75) Pressure at rated load, psi (bar) 2800 (193) Overflow pressure, psi (bar) 3046 (210) Pump flow, gpm (liter/minute) 1.32 (5.0) Tank volume, gpm (liter/minute) 1.19 (4.5) Oil type: at normal temperature at temperature < 5° F (-15° C) Hydraulic oil ISO-L-HM32 ISO-L-HV32 Fuses Drive motor circuits, A 125 Pump motor circuits, A 125 Control circuits, A 7.5 Battery Compartment, Batteries Dimensions LxWxH, inch (mm), 180 Ah 240 Ah 320 Ah 7.72 x 25.31 x 17.80 (196 x 643 x 452) 7.72 x 25.31 x 22.52 (196 x 643 x 572) 9.60 x 25.31 x 22.52 (244 x 643 x 572) Capacity, Ah 180-255 Weight, lbs (kg) 290-600 (131-272) Model 6BWS10/13

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Toyota Electric Walkie Adjustable Straddle Stacker 6BWS10, 6BWS13; SN: 585890 - up Workshop Service Manual

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