Toyota 8HBW30 8HBE40 8HBC40 8HBE30 8HBC30 8TB50 Pallet Trucks Service Manual 00700-CL398-07 – PDF DOWNLOAD
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Toyota 8HBW30 8HBE40 8HBC40 8HBE30 8HBC30 8TB50 Pallet Trucks Service Manual 00700-CL398-07 – PDF DOWNLOAD
Language : English
Pages : 258
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota 8HBW30 8HBE40 8HBC40 8HBE30 8HBC30 8TB50 Pallet Trucks Service Manual 00700-CL398-07 – PDF DOWNLOAD
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
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 through 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 Chapter 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 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 services to keep your truck working most efficiently.
- Troubleshooting is a set of “decision-tree” charts and tables designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.
TABLE OF CONTENTS:
Toyota 8HBW30 8HBE40 8HBC40 8HBE30 8HBC30 8TB50 Pallet Trucks Service Manual 00700-CL398-07 – PDF DOWNLOAD
Front Cover................................................................................................. 1 Table of Contents........................................................................................... 4 Section 1. How To Use This Manual .......................................................................... 7 Map of the Manual ...................................................................................... 8 Manual Design .......................................................................................... 9 Abbreviations & Symbols ................................................................................ 10 START Page ............................................................................................. 13 Section 2. Safety .......................................................................................... 16 Definitions ............................................................................................ 17 General Safety ......................................................................................... 18 Battery Safety ......................................................................................... 21 Jacking Safety ......................................................................................... 24 Tie-Down for Transport ................................................................................. 25 Figure 2-1. Tie-Down for Transport ................................................................. 25 Towing ................................................................................................. 26 Welding Safety ......................................................................................... 27 Static Safety .......................................................................................... 28 Figure 2-2. Anti-Static Kit (P/N 00590-04849-71) With Wrist Strap and Mat .......................... 28 Section 3. Systems Overview ................................................................................ 31 Truck Model Identification ............................................................................. 32 Vehicle Specifications ................................................................................. 33 Maximum Speeds ......................................................................................... 34 Tractor First ...................................................................................... 34 Forks First ........................................................................................ 34 General System Data .................................................................................... 35 Figure 3-1. Model 8HBE30/40 (Long-John Forks Shown) ................................................ 35 Figure 3-2. Model 8HBE30/40 Control Handle ......................................................... 36 Special Tools .......................................................................................... 37 Service Key ........................................................................................ 37 Figure 3-3. Service Key ........................................................................ 37 Theory of Operation .................................................................................... 38 Vehicle Manager (VM) ............................................................................... 38 Traction Power Amplifier (TPA) ..................................................................... 38 Traction System .................................................................................... 38 Emergency Reverse (Model 8HBW30 and 8HBE30/40) ..................................................... 39 Strip Curtain Bypass (Model 8HBE30/40 only) ........................................................ 39 Lift/Lower System .................................................................................. 40 Jog Pick Mode ...................................................................................... 40 Model 8HBE30/40 only ............................................................................... 41 Manual Jog Pick .................................................................................... 41 Section 4. Planned Maintenance ............................................................................. 44 Maintenance Guidelines ................................................................................. 45 Initial 90 Day/250 Deadman Hours (HD) Maintenance ...................................................... 46 Every 180 Days or 500 Deadman Hours .................................................................... 47 Every 360 Days or 2000 Deadman Hours (HD) .............................................................. 49 Grease Fittings ........................................................................................ 50 Figure 4-1. Caster Grease Fittings ................................................................. 50 Figure 4-2. Upper Bell Crank Grease Fittings (Between Tractor and Fork Section) .................... 50 Figure 4-3. Lower Bell Crank Grease Fittings-left side shown (Between Tractor and Fork Section) .... 50 Figure 4-4. Load Wheel Grease Fittings and Fork Grease Fittings (Top View-8K trucks) ............... 51 Section 5. Troubleshooting ................................................................................. 53 How to Use This Section ................................................................................ 54 Electrical Troubleshooting Guidelines .................................................................. 55 Troubleshooting the CAN Bus ........................................................................ 55 Checking for Shorts from Battery to Truck Frame .................................................... 57 Checking for Shorts from Components to Truck Frame ................................................. 58 DC Electric Motor Tests ................................................................................ 59 DC Motor Types ..................................................................................... 59 Figure 5-1. Motor Circuits ..................................................................... 59 Open Circuit Motor Test ............................................................................ 59 Grounded Motor Test ................................................................................ 59 Short-Circuited Winding ............................................................................ 60 Short-Circuited Armature ........................................................................... 60 AC Electric Motor Tests ................................................................................ 61 Figure 5-2. AC Traction Motor circuits ............................................................. 61 AC Motor Type ...................................................................................... 61 Open Winding ....................................................................................... 61 Shorted Winding .................................................................................... 61 Hydraulic Troubleshooting Guidelines ................................................................... 62 Definitions ............................................................................................ 63 Figure 5-3. Brake (Deadman) Switch and Brake Actuation ............................................. 63 List of Electrical Symbols ............................................................................. 67 Operator Display and Programming ....................................................................... 69 Figure 5-4. Operator Display ....................................................................... 69 Special Truck Mode ................................................................................. 69 Hour Meter (H) ..................................................................................... 69 Error Codes (E) .................................................................................... 69 Changing Truck Parameters (P) ...................................................................... 70 Service Input/Output Displays .......................................................................... 75 Figure 5-5. Service Key Connection Point ........................................................... 75 Figure 5-6. Operator Display ....................................................................... 75 Digital Inputs/Outputs from Traction Power Amplifier and VM ........................................ 76 Traction Power Amplifier LED Diagnostics ............................................................... 78 Figure 5-7. Traction Power Amplifier Status Indicator LED .......................................... 78 Traction Power Amplifier Flash Codes ................................................................... 79 Troubleshooting Flowcharts ............................................................................. 81 Caution and Error Codes ................................................................................ 85 Figure 5-8: Operator Display ....................................................................... 85 Caution Codes ...................................................................................... 85 Error Codes ........................................................................................ 97 Symptom Tables: Lift/Lower System ......................................................................107 Symptom Tables: Travel (Forward/Reverse) System ........................................................111 Symptom Tables: Wiring System ..........................................................................120 Pinout Matrix ..........................................................................................121 Section 6. Component Procedures ............................................................................136 List of Component Procedures ...........................................................................137 Component Locator Photos ...............................................................................140 Figure 6-1. Inside Tractor, Rear View ..............................................................140 Figure 6-2. Inside Tractor, Right Side .............................................................141 Tractor Cover ..........................................................................................142 Figure 6-3. Cover Handle Hold Locations ............................................................142 Battery ................................................................................................143 With Battery Gates and Rollers (Optional) ..........................................................143 Battery Gates (Optional) ...........................................................................143 Battery Rollers (Optional) .........................................................................143 Without Battery Gates and Rollers ..................................................................143 Battery Exterior Cleaning ..........................................................................144 Figure 6-4. Battery Filler Plugs and Vent Holes ................................................144 Testing, Charging, and Maintenance .................................................................145 Maintenance-Free Batteries .........................................................................145 Storage ............................................................................................145 Power Cables ...........................................................................................146 Wiring Harness .........................................................................................147 Fuses ..................................................................................................149 Figure 6-5. Fuse Location ..........................................................................149 Switches (General) .....................................................................................150 Key Switch (SW1) .......................................................................................151 Figure 6-6. Key Switch Location ....................................................................151 Brake (Deadman) Switch (SW2) ...........................................................................152 Figure 6-7. Brake (Deadman) Switch, 8HBW30 and 8HBE30 or 8HBE40 ....................................152 Figure 6-8. Brake (Deadman) Switch Active, 8HBW30 and 8HBE30 or 8HBE40 .............................152 Lift-Limit Switch (SW8) ................................................................................154 Figure 6-9. Lift-Limit Switch ......................................................................154 Grab Rail Switches .....................................................................................155 Model 8HBE30/40 Only ...............................................................................155 Figure 6-10. Grab Rail Switch Removal, Left Side ...............................................155 Figure 6-11: Grab Rail Switch Removal, Right Side ..............................................155 Hydraulic Solenoids ....................................................................................156 Figure 6-12. Hydraulic Solenoids (typical unit) ....................................................156 Jog Pick Solenoid ......................................................................................157 Model 8HBE30/40 (Optional) .........................................................................157 Figure 6-13. Socket Head Cap Screws ............................................................157 Figure 6-14. Removed Solenoid Mechanism ........................................................157 Jog Pick Solenoid Switch ...........................................................................157 Canister ...........................................................................................158 Figure 6-15. Canister Spacing ..................................................................158 Horn ...................................................................................................159 Figure 6-16. Horn Location .........................................................................159 Traction Power Amplifier ...............................................................................160 Figure 6-17. Traction Power Amplifier Location .....................................................160 Figure 6-18. Removing the Traction Power Amplifier .................................................160 AMP Harness/Traction Power Amplifier Connector .........................................................162 Connector Components ...............................................................................162 Figure 6-19. JP1 Connector Components ..........................................................162 Figure 6-20. AMP JP1 Connector .................................................................162 Figure 6-21. Contact Insertion .................................................................163 Figure 6-22. Wedge Lock Latches ................................................................163 Figure 6-23. Wedge Lock Flush With Housing .....................................................164 Contactors .............................................................................................165 Figure 6-24. Disconnecting Main Contactor ..........................................................165 Main Contactor .....................................................................................165 Figure 6-25. Removing Top Cover ................................................................165 Figure 6-26. Removing Brass Lock Nuts ..........................................................166 Figure 6-27. Removing the Fixed Contacts .......................................................166 Figure 6-28. Installing Fixed Contacts .........................................................166 Figure 6-29. Main Contactor Components .........................................................166 Figure 6-30. Installing the Main Contactor .....................................................167 Control Handle Assembly ................................................................................168 Spring-Loaded Handle Design - Models 8HBW30 and 8HBE30 or 8HBE40 ...................................168 Figure 6-31. Control Handle Base Cover Removal .................................................168 Figure 6-32. Control Handle Wire Harness .......................................................168 Figure 6-33. Remove Jam Nut at Coast Link ......................................................168 Figure 6-34: Return Spring Rod Removal .........................................................169 Return Spring Adjustment ...........................................................................169 Figure 6-35. Return Spring Adjustment ..........................................................169 Fixed-Position Handle Design - Models 8HBC30/40 and 8TB50 ..........................................170 Control Handle .........................................................................................171 Figure 6-36. Handle and Control Head Assembly ......................................................171 Figure 6-37. Control Head Assembly -Exploded View ..................................................172 Control Head Removal ...............................................................................173 Figure 6-38. Horn Button Removal ...............................................................174 Figure 6-39. Lift/Lower Button Removal .........................................................174 Figure 6-40. Push Button Removal ...............................................................174 Figure 6-41. Handle with Jog Pick Option .......................................................175 Brake ..................................................................................................176 Spring-Loaded Handle - Models 8HBW30 and 8HBE30 or 8HBE40 ..........................................176 Figure 6-42. Brake Adjustment, location ........................................................176 Figure 6-43: Brake Adjusting Screw .............................................................176 Figure 6-44. Brake Drum With Control Handle and Brake Shield Removed ...........................177 Figure 6-45. Brake Adjusting Screw .............................................................177 Figure 6-46. Brake Adjusting Rod (Installed) ...................................................177 Fixed-Position Handle - Models 8HBC30/40 and 8TB50 .................................................178 Motors, General ........................................................................................180 Terminal Nuts ......................................................................................180 Figure 6-47. Traction Motor Terminal Connections ...............................................180 Figure 6-48. Lift and Aux Motor Terminal Nuts ..................................................180 Traction Motor .........................................................................................181 Figure 6-49. Control Handle Base Cover Removal .....................................................181 Figure 6-50. Control Handle Mounting Frame Removal .................................................181 Figure 6-51. Traction Motor Power Cables ...........................................................181 Figure 6-52. Traction Motor Removal ................................................................182 Figure 6-53. Drive Unit Pinion Gear ................................................................182 Figure 6-54. Main Case Location ....................................................................182 Figure 6-55. Traction Motor Installation ...........................................................183 AC Motor Service .......................................................................................184 AC Motor Temperature Sensor ........................................................................184 Drive Unit .............................................................................................186 Figure 6-56. Drive Unit Fill Plug ..................................................................186 Figure 6-57. Drive Unit Drain Plug .................................................................186 Figure 6-58. Drive Unit Mounting (Traction Motor Removed) ..........................................186 Steering Bearing ...................................................................................187 Figure 6-59. Drive Unit (Shown installed in Tractor Frame) .....................................187 Figure 6-60. Drive Unit Bottom View ............................................................187 Figure 6-61. Drive Unit, Steering Bearing Removed ..............................................187 Figure 6-62. Steering Bearing Locating Groove ..................................................187 Figure 6-63. Main Case Cover, Six Hole-Type, Installed .........................................188 Figure 6-64. Gear Housing and Cover ............................................................188 Figure 6-65. Lower Drive Unit, Cross-Sectional View, Model 8HBW30 and 8HBE30 or 8HBE40 .........189 Gear Assembly ......................................................................................190 Checking the Gears .................................................................................191 Figure 6-66. Drive Unit Gear Tooth Pattern .....................................................191 Figure 6-67. Drive Unit Mounting Location in Frame .............................................192 Figure 6-68. Drive Unit Installed In Frame .....................................................192 Figure 6-69. Drive Unit Shimming Locations .....................................................192 Figure 6-70. Drive Unit Drain Plug .............................................................193 Drive Housing Lubrication ..........................................................................193 Figure 6-71. Drive Unit Fill Level Dipstick ....................................................193 Figure 6-72. Drive Unit Drain Plug .............................................................193 Drive Wheel ............................................................................................195 Figure 6-73. Drive Wheel and Tire ..................................................................195 Figure 6-74. Cushion Tire Replacement ..............................................................195 Casters (Torsion) ......................................................................................198 Figure 6-75. Removing Caster Wheel Assembly ........................................................198 Caster Removal .....................................................................................198 Figure 6-76. Caster Assembly, Disassembled .....................................................198 Wheel Replacement ..................................................................................198 Figure 6-77. Caster Assembly, Assembled ........................................................199 Caster Assembly ....................................................................................199 Caster Installation ................................................................................199 Figure 6-78. Securing Caster To Tractor ........................................................199 Casters (Spring-Loaded) ................................................................................200 Figure 6-79. Removing Spring-Loaded Caster .........................................................200 Removal ............................................................................................200 Wheel Replacement ..................................................................................200 Figure 6-80. Removing Axle Shaft ...............................................................200 Figure 6-81. Removing Tension Pin ..............................................................200 Figure 6-82. Removed Wheel and Shims ...........................................................201 Figure 6-83. Compressing Caster Springs ........................................................201 Caster Disassembly .................................................................................201 Figure 6-84. Relieving Pivot Tension ...........................................................201 Figure 6-85. Removing Pivot Pin Retainer Screw .................................................201 Figure 6-86. Removing Pivot Pin ................................................................202 Figure 6-87. Separated Caster ..................................................................202 Caster Assembly ....................................................................................202 Figure 6-88. Removing Bolts from Springs .......................................................202 Figure 6-89. Installing New Wheel ..............................................................202 Wheel Installation .................................................................................203 Figure 6-90. Installing Axle Shaft .............................................................203 Figure 6-91. Installing Tension Pin ............................................................203 Figure 6-92. Caster, Shims and Mounting Bolts ..................................................203 Caster Installation ................................................................................203 Figure 6-93. Securing Caster To Tractor ........................................................203 Load Wheels ............................................................................................204 Figure 6-94. Removing Tension Pin ..................................................................204 Models 8HBW30, 8HBE30/40 and 8HBC30/40 .............................................................204 Figure 6-95. Removing Axle From Load Arm Casting ...............................................204 Figure 6-96. Removed Load Wheel and Components .................................................204 Model 8TB50 ........................................................................................205 Figure 6-97. Model 8TB50 Load Wheel Suspension-Exploded View ...................................205 Load Wheel Suspension (Optional) ...................................................................206 Figure 6-98. Model 8TB50 Optional Load Wheel Suspension-Exploded View ..........................206 Pallet Entry Sliders ...................................................................................207 Figure 6-99. Replacing Pallet Entry Slider (6000 lb. Standard Model Shown) .........................207 Fork Height Adjustment .................................................................................208 Figure 6-100. Fork Height Adjustment at Lower Bell Crank ...........................................208 Measurement ........................................................................................208 Adjustment .........................................................................................208 Hydraulic Components ...................................................................................210 General Guidelines .................................................................................210 Figure 6-101. Hydraulic Unit (typical shown) ...................................................210 Hydraulic Fluid ........................................................................................211 Figure 6-102. Hydraulic Connections ................................................................211 Adjusting Hydraulic Pump Relief Valve Pressure .........................................................212 Figure 6-103. Checking Relief Valve Pressure .......................................................212 Relief Valve Settings ..............................................................................212 Check Valve ........................................................................................213 Hydraulic Ram ..........................................................................................214 Figure 6-104. Blocking Fork Section For Ram Removal ................................................214 Figure 6-105. Removing Lower Bell Crank Pins .......................................................214 Figure 6-106. Disconnecting Upper Clevis Brackets ..................................................215 Figure 6-107. Hydraulic Ram Area, Forks Removed ....................................................215 Figure 6-108. Hydraulic Line Connection ............................................................215 Figure 6-109. Vent Hose Connections ................................................................215 Figure 6-110. Hydraulic Ram Removal/Installation ...................................................216 Figure 6-111. Hydraulic Line Connection (installed) ................................................216 Hydraulic Cylinder Seals ...........................................................................217 Figure 6-112. Remove Outer Spiral Lock Ring ....................................................217 Figure 6-113. Remove the Spacer ................................................................217 Figure 6-114. Remove Head Lock Ring From Cylinder ..............................................217 Figure 6-115. Rod and Head Assembly Out of Cylinder ............................................218 Figure 6-116. Remove the Piston Jam Nut ........................................................218 Figure 6-117. Piston Rod Components ............................................................218 Figure 6-118. Securing Piston Jam Nut ..........................................................218 Figure 6-119. Installing the Head Lock Ring ....................................................219 Figure 6-120. Installing the Outer Lock Ring ...................................................219 Hydraulic Unit .........................................................................................220 Figure 6-121. Hydraulic Unit (typical shown) .......................................................220 Hydraulic Reservoir ................................................................................221 Figure 6-122. Adapter Cap Screws ...............................................................221 Figure 6-123. Removed Reservoir ................................................................221 Figure 6-124. Pump Housing Components ..........................................................221 Filter Screen and Suction Tube .....................................................................222 Figure 6-125. Cleaning Filter Screen ...........................................................222 Figure 6-126. Pump and Adapter Body ............................................................222 Hydraulic Pump .....................................................................................222 Figure 6-127. Pump Drive Coupling ..............................................................222 Figure 6-128. Installing Pump In Adapter .......................................................223 Lift Motor .............................................................................................224 General Data .......................................................................................224 Figure 6-129. Bolts Securing Motor To Adapter ..................................................224 Figure 6-130. Separated Reservoir and Motor (typical) ..........................................224 Figure 6-131. Coupling Cavity ..................................................................225 Figure 6-132. Indexing Pin .....................................................................225 Cold Storage Conditioning ..............................................................................226 Section A. Appendix ........................................................................................229 Lubrication Equivalency Chart ..........................................................................230 Torque Chart - Standard (Ferrous) ......................................................................231 Torque Chart - Standard (Brass) ........................................................................232 Torque Chart - Metric ..................................................................................233 Torque Chart - Thread-Forming Screws ...................................................................234 Decimal Equivalent Chart ...............................................................................235 Standard/Metric Conversions ............................................................................237 Electrical Schematics ..................................................................................240 Figure B-1. Model 8HBW30 Electrical Schematic (Sheet 1 of 2) .......................................241 Figure B-2. Model 8HBE30/40 End Rider Electrical Schematic (Sheet 1 of 2) ..........................243 Figure B-3. Model 8HBC30/40 Center Rider Electrical Schematic (Sheet 1 of 2) .......................245 Figure B-4. Model 8TB50 Electrical Schematic (Sheet 1 of 2) ........................................247 Figure B-5. Electrical Schematic - Legend (Sheet 1 of 2) ...........................................249 Figure B-6. Hydraulic Schematic ....................................................................251 Section I. Index ...........................................................................................253
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