Toyota Electric Pallet Truck Type 6HBW20 sn: 17001 and up Workshop Service Manual

Service Manual 6HBW20 4,000LB Powered Pallet Walkie Starting with Serial Number 17001

Toyota Powered Pallet Walkie Service Manual How to Use This Manual PDMM - 0105 Issued: 5/2 1 /01 How to Use This Manual

How To Use This Manual Toyota Powered Pallet Walkie Service Manual Map of the Manual Map of the Manual How to Use This 1 Manual Planned Maintenance Map of the Manual I General System I 1 Systems Overview Theoy of Operations Vehicle Specifications Manual Design Y Table of Contents Start Page tl 1 Definitions 1 Trouble Shooting Component Alphabetical List Procedures of Component Electrical & Hydraulic T.S. Guidelines Appendix Q I procedures I Component Location Photos I Fault Codes I Programmable Maintenance Tool Troubleshooting Charts , PDMM-0 1 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual How To Use This Manual Manual Design Manual Design The Toyota Powered Pallet Walkie Service Manual is designed with the following objectives in mind: Provide technical coverage for expected levels of user expertise Anticipate your needs and reduce your decisions regarding maintenance Reduce page flipping through a "one- stop shopping" approach The two-line running page header at the top of each page tells you the following: Name of the manual (Toyota Powered Pallet Walkie Senrice Manual) Current chapter title (e.g., this page How to Use This ManuaO Current topic (e.g., this page Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual. PDMM-0 105 Issued: 5/2 1 /0 1

How To Use This Manual Toyota Powered Pallet Walkie Service Manual Manual Design The START page asks a few simple questions to guide you to the proper chapter. How to Use This Manual explains the manual format and design and contains the Table of Contents and START page. Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding. Systems Overview includes truck specifications and theory of operation information. Planned Maintenance outlines the recommended schedule of preventive senices to keep your truck working most efficiently. Troubleshooting is a set of "decision-tree" charts designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component. TS 1 : START TROUBLESHOOTING on page 5- 28 will guide you to the individual troubleshooting symptom chart you need. Once you're familiar with the symptoms listed, you may instead simply find the symptom chart from the List of Troubleshooting Charts on page 5-25. When you complete a troubleshooting procedure, be sure to follow the steps in the END 1 : End of Troubleshooting Procedure on page 5-3 1. Component Procedures give step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order which considers: Frequency of attention Physical attachment (e.g., brake must be removed before drive motor) Functional relation (e.g., drive motor and drive unit components are grouped together) PDMM-0 1 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual How To Use This Manual Manual Design To find a component procedure, you may use one of three methods: Look up the component name. See List of Component Procedures on page 6-2 Find the component. See Component Locator Photos on page 6-5. Look up the component name in the Index on page I- 1. Appendix contains reference information such as torque values, lubricants and schematics. Index lists subjects alphabetically. PDMM-0 1 05 Issued: 5/2 1 /0 1

How To Use This Manual Toyota Powered Pallet Walkie Service Manual Manual Design This page intentionally left blank. PDMM-0 1 05 Issued: 5/2 1 /0 1

Toyota Powered Pallet Walkie Service Manual How To Use This Manual Table of Contents Table of Contents How to Use This Manual .......................................... Map of the Manual 1 - 2 ............................................. ManualDesign 1 - 3 ........................................... Table of Contents 1-7 .............................................. STARTPage 1- 11 Safety Definitions ................................................ 2 - 2 ............................................. Generalsafe ty 2 - 3 ............................................. Battery Safety 2 - 7 JackingSafe ty ............................................ 2- 11 ...................................... Tie-down for Transport 2 - 13 Towing .................................................. 2- 14 ............................................ Welding Safety 2- 15 Systems Overview .................................... Truck Model Identification 3.2 ........................................ Vehicle Specifications 3.2 ........................................ General System Data 3.3 .............................................. Special Tools 3.4 ......................................... Theory of Operation 3.5 Planned Maintenance ...................................... Maintenance Guidelines 4.2 ........................................ Maintenance Manual 4.2 Daily .................................................... 4 - 4 ............................ Every Month or 200 Operating Hours 4 - 5 ......................... Annually or Every 2400 Operating Hours 4- 7 ............................................. Grease Fittings 4 - 8 Troubleshooting ..................................... How to Use This Chapter 5- 2 Electrical Troubleshooting Guidelines ........................... 5-3 ........................... Hydraulic Troubleshooting Guidelines 5-6 Definitions ................................................ 5 - 7 ............................. Electrical Connector Locator Chart 5 - 12 ......................... Programmable Maintenance Tool (PMT) 5 - 13 PDMM-0 1 05 Issued: 5/2 1 /0 1 1 - 7

How To Use This Manual Toyota Powered Pallet Walkie Service Manual Table of Contents .............................................. Faultcodes 5 - 23 ................................ List of Troubleshooting Charts 5 - 25 .................................. Troubleshooting Flowcharts 5 - 27 Component Procedures ................................. List of Component Procedures 6 - 2 ................................... Component Locator Photos 6 - 5 .............................................. Tractor Cover 6 - 7 Battery .................................................. 6 - 8 ............................................ Power Cables 6 - 16 ........................................... Wiring Harness 6- 17 Diodes .................................................. 6 - 19 Fuse ................................................... 6 - 20 ........................................... Circuit Breaker 6 - 21 ......................................... Switches (General) 6- 22 .................................... Control Handle Switches 6 - 23 ....................................... Main ON/OFF Switch 6 - 25 Keyswitch ............................................... 6 - 26 .................................... Brake (Deadman) Switch 6 - 27 .......................................... Lift-Limit Switch 6 - 29 ........................................ Hydraulic Solenoid 6 - 30 Gauges ................................................. 6 - 31 ........................................... Control Handle 6-35 Horn ................................................... 6 - 38 .......................................... Motor Controller 6- 39 ............................................... Contactors 6 - 43 Brake .................................................. 6 - 51 ........................................... Motors. General 6 - 53 .............................................. Drive Motor 6 - 61 Driveunit ............................................... 6-65 ..................................... Hydraulic Components 6 - 77 ........................................... Hydraulic Fluid 6 - 78 Adjusting Hydraulic Pump Relief Valve Pressure .................. 6 - 80 ......................................... Hydraulic Cylinder 6- 82 ............................................ Hydraulic Unit 6 - 85 LiftMotor ................................................ 6 - 89 ................................... Cold Storage Conditioning 6 - 91 PDMM-0 1 05 Issued: 5/2 1 /0 1

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Toyota Electric Pallet Truck Type 6HBW20 sn: 17001 and up Workshop Service Manual

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