Toyota 8HBW30 8HBE30 8HBC30 8HBE40 8HBC40 8TB50 Pallet Truck Service Repair Factory Manual INSTANT (SN: 36001 and up,40

Pallet Trucks 8HBW30 36,001 and up 8HBE30 36,001 and up 8HBE40 36,001 and up 8HBC30 36,001 and up 8HBC40 36,001 and up 8TB50 36,001 and up SERVICE MANUAL 00700-CL398-07, Issued: 9 August 2007

1071582A © 2007 by Toyota Industrial Equipment All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher. Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

Table of Contents

Toyota Pallet Truck Service Manual Table of Contents 00700-CL398-07, Issued: 9 August 2007 i Table of Contents How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Abbreviations & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Static Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Maximum Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-3 Every 180 Days or 500 Deadman Hours . . . . . . . . . . . . . . . . . . . . . . 4-4 Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . . 4-6 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3 DC Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AC Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-10 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Operator Display and Programming . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Service Input/Output Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Traction Power Amplifier LED Diagnostics . . . . . . . . . . . . . . . . . . . . 5-26 Traction Power Amplifier Flash Codes . . . . . . . . . . . . . . . . . . . . . . . 5-27 Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Caution and Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . 5-59 Symptom Tables: Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Tractor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Table of Contents Toyota Pallet Truck Service Manual ii 00700-CL398-07, Issued: 9 August 2007 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Key Switch (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Brake (Deadman) Switch (SW2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Lift-Limit Switch (SW8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Grab Rail Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Hydraulic Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Jog Pick Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 AMP Harness/Traction Power Amplifier Connector . . . . . . . . . . . . . 6-27 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 Casters (Torsion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Casters (Spring-Loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Pallet Entry Sliders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72 Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . . 6-77 Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . . A-6 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Toyota Pallet Truck Service Manual How To Use This Manual 00700-CL398-07, Issued: 9 August 2007 1-1 Section 1. How To Use This Manual

Toyota Pallet Truck Service Manual 00700-CL398-07 Issued: 9 August 2007 1-2 Map of the Manual 1Map.wmf How to Use This Manual Safety Systems Overview Scheduled Maintenance Trouble- Shooting Component Procedures Appendix Index Map of the Manual Table of Contents and Page Revision Record Vehicle Specifications Theory of Operations General System Data Component Locator Photos Alphabetical List of Component Procedures Fault Codes & Caution & Error Codes Control Handle Display & Programming Definitions Electrical & Hydraulic T.S. Guidelines Troubleshooting Charts and Symptom Tables Manual Design Start Page

Toyota Pallet Truck Service Manual How To Use This Manual Manual Design 00700-CL398-07, Issued: 9 August 2007 1-3 Manual Design The Toyota Pallet Truck Service Manual is designed with the following objectives in mind: • Provide technical coverage for expected levels of user expertise • Anticipate your needs and reduce your decisions regarding maintenance • Reduce page flipping thru a “one-stop shopping” approach The two-line running page header at the top of each page tells you: • Name of the manual (Toyota Pallet Truck Service Manual) • Current section title (for example, this page How to Use This Manual) • Current topic (for example, this page Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual. • The START page asks a few questions to guide you to the correct section. How to Use This Manual explains the manual format and contains the START page. Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding. Systems Overview includes truck specifications and theory of operation information. Planned Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently. Troubleshooting is a set of fault, caution, and error codes, charts and tables designed to take you from a symptom to a specific sequence of actions in order to isolate a failing component. • The chart “Traction Power Amplifier Flash Codes” on page 5-27 will guide you thru the flash codes displayed on the LED’s installed on the TA. • The section “Caution and Error Codes” on page 5-33 defines the various codes displayed on the operator display. • The chart “TS1: START TROUBLESHOOTING” on page 5-29 will guide you to the symptom chart you need. • When you’re familiar with the symptoms listed, you may simply look up the symptom from the “Troubleshooting” on page 5-29. • As you work with a troubleshooting chart, code, or table, you may be instructed to test various electrical connector pins. The pinout matrix chart lists information on functions and normal voltages of terminals and harness connector pins. See “Pinout Matrix” on page 5-69. • When you complete a troubleshooting procedure, perform the steps in the “END1: End of Troubleshooting Procedure” on page 5-31. Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order that considers: • Frequency of attention • Physical attachment (for example, remove the brake before the traction motor) • Functional relation (for example, traction motor and drive unit components are grouped together) To find a component procedure, you may use one of three methods: • Look up the component name in the “List of Component Procedures” on page 6-2. • Find the component in the “Component Locator Photos” on page 6-5. • Look up component name in the “Index”. Appendix contains reference information such as torque values, lubricants, and schematics. Index lists subjects alphabetically.

How To Use This Manual Toyota Pallet Truck Service Manual Abbreviations & Symbols 1-4 00700-CL398-07, Issued: 9 August 2007 Abbreviations & Symbols These abbreviations, acronyms and symbols are used in this manual. Term/Symbol Definition Term/Symbol Definition A Ampere AC Alternating Current amp Ampere or amplifier ANSI American National Standards Institute approx approximately aux auxiliary AWG American Wire Gauge BSOC Battery State-of-Charge CAN Controller Area Network CCW counterclockwise cm centimeter COP Computer Operating Program CV checkvalve CW clockwise DC Direct Current DGND digital ground EE UL Electric Truck Type Certification Rating where electrical equipment is completely enclosed ESD Electrostatic Discharge ETAC Electronic Tiller Arm Control (See Vehicle Manager) ft. foot or feet gal. gallon or gallons Gnd ground HD hours on deadman in. inch or inches kg kilogram(s) km/hr kilometers per hour kPa kilo Pascal lb. pound or pounds LED Light Emitting Diode L/H Load Holding L/L Lift/Lower mA milliampere mm millimeter mph miles per hour ms millisecond(s) N/A Not Applicable or Not Available N•m newton meter OD Operator’s Display OSHA Occupational Safety and Health Administration oz. ounce pot potentiometer psi pounds per square inch PWM Pulse Width Modulation P/N Part Number RAM Random Access Memory RCFP Relay Control Fuse Panel ROM Read Only Memory RPM Revolutions per Minute R/R Remove and Replace SOL Solenoid spec specification SPI Service Port Interface

Toyota 8HBW30 8HBE30 8HBC30 8HBE40 8HBC40 8TB50 Pallet Truck Service Repair Factory Manual INSTANT (SN: 36001 and up,40

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