Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD
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Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD
Language : English
Pages : 194
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD
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 Manual)
- Current chapter title
(for example this page How to Use This Manual) - Current topic
(for example this page Manual Design)
- 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD
Pallet Trucks................................................................................................... 1 Table of Contents............................................................................................... 3 Section 1. How to Use This Manual.............................................................................. 9 Map of the Manual........................................................................................... 10 Manual Design............................................................................................... 11 START Page.................................................................................................. 13 Section 2. Safety.............................................................................................. 17 Definitions................................................................................................. 18 General Safety.............................................................................................. 19 Battery Safety.............................................................................................. 21 Jacking Safety.............................................................................................. 24 Figure 21. Blocking the Fork Section................................................................... 24 Figure 22. Jacking Tractor Section..................................................................... 24 Tie-down for Transport...................................................................................... 25 Towing...................................................................................................... 26 Welding Safety.............................................................................................. 27 Section 3. Systems Overview.................................................................................... 29 Truck Model Identification.................................................................................. 30 Vehicle Specifications...................................................................................... 31 General System Data......................................................................................... 32 Figure 31. Model 6HBE30................................................................................ 32 Figure 32. Model 6HBC30................................................................................ 33 Special Tools............................................................................................... 34 Figure 33. Programmable Maintenance Tool............................................................... 34 Theory of Operation......................................................................................... 35 Section 4. Scheduled Maintenance............................................................................... 39 Introduction................................................................................................ 40 Figure 41. Caster Grease Fittings...................................................................... 44 Figure 42. Upper Bell Crank Grease Fittings (Between Tractor and Fork Section)......................... 44 Figure 43. Lower Bell Crank Grease Fittings-Left side shown (Between Tractor and Fork Section)......... 44 Figure 44. Load Wheel Grease Fittings and Fork Grease Fittings (Top View).............................. 45 Figure 45. Drive Unit Grease Fittings (2), 180° Apart (front location shown)........................... 45 Section 5. Troubleshooting..................................................................................... 47 How to Use This Chapter..................................................................................... 48 Electrical Troubleshooting Guidelines....................................................................... 49 Figure 51. Battery Shorts to Frame Testing............................................................. 49 Figure 52. Component Shorts to Frame, testing.......................................................... 50 Hydraulic Troubleshooting Guidelines........................................................................ 51 Definitions................................................................................................. 52 Figure 53. Brake (Deadman) Switch and Brake Actuation, 6HBW30 and 6HBE30 or 6HBE40..................... 52 Electrical Connector Locator Chart.......................................................................... 56 Fault Codes................................................................................................. 57 Figure 54. Fault Code LED Indicator.................................................................... 57 Programmable Maintenance Tool............................................................................... 59 Figure 55. Programmable Maintenance Tool............................................................... 59 List of Troubleshooting Charts.............................................................................. 65 No Lift, Lift Motor Does Not Run, Travel OK (from control handle or grab rail switch) 5-25.............. 65 No Lift or Slow Lift, Lift Motor Does Run 5-26.......................................................... 65 No Lower, Lift and Travel OK 5-26....................................................................... 65 Unable to Pick Up a Load 5-27........................................................................... 65 Slow Lower 5-27......................................................................................... 65 Load Drifting/Settling 5-27............................................................................. 65 No Travel, Lift/Lower OK, Main Contactor Does Not Close. Motor Controller LED is Flashing Once Ev....... 65 No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 3,1 5-28...................... 65 No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 1,3 5-28...................... 65 No Travel in Either Direction, Lift/Lower OK. Motor Controller Fault Code 1,2 5-29...................... 65 No Travel, Main Contactor Does Not Close. Motor Controller Fault Code 3,4 5-29.......................... 65 No Travel, Main Contactor Does Close. Motor Controller Fault Code 2,1 5-29.............................. 65 Slow Travel, Lift/Lower OK. No Fault Codes 5-30......................................................... 65 No Emergency Reverse, Travel/Lift/Lower OK. No Motor Controller Fault Codes 5-30........................ 65 Slow Travel, Lift/Lower OK, Speed Limited to 15%. Motor Controller Fault Code 2,4 (Emergency Reve....... 65 No Rabbit Speed, Travel/Lift/Lower OK. No Fault Codes 5-31.............................................. 65 No Travel. Motor Controller Fault Code 4,2 (Excessive Battery Voltage) 5-32............................. 65 Slow or No Travel. Motor Controller Fault Code 4,1 (Low Battery Voltage) 5-32........................... 65 Slow or No Travel. Motor Controller Fault Code 4,3 (Thermal Cutback) 5-32............................... 65 No Travel. Motor Controller Fault Code 2,2 - Static Return To Off (SRO) 5-33............................ 65 No Travel. Motor Controller Fault Code 2,3 - High Pedal Disable 5-33.................................... 65 Plugging Does Not Operate Correctly. Truck Travels OK in Forward and Reverse 5-33....................... 65 Truck Does Not Accelerate Correctly 5-34................................................................ 65 Jog Speed Does Not Activate. Lift and Travel OK. (Center Rider Models Only) 5-34........................ 65 Jog Speed Does Not Function. Lift and Travel OK. (End Rider Model w/Manual Coast) 5-34.................. 65 Truck Functions Partially. Some Functions Do Not Work When Commanded 5-35............................... 65 Troubleshooting Flowcharts.................................................................................. 67 Symptom Tables: Lift/Lower System........................................................................... 71 Symptom Tables: Travel...................................................................................... 74 Symptom Tables: Wiring System............................................................................... 81 Section 6. Component Procedures................................................................................ 83 List of Component Procedures................................................................................ 84 B....................................................................................................... 84 C....................................................................................................... 84 D....................................................................................................... 84 E....................................................................................................... 84 F....................................................................................................... 84 G....................................................................................................... 84 H....................................................................................................... 84 K....................................................................................................... 84 L....................................................................................................... 84 M....................................................................................................... 84 P....................................................................................................... 85 R....................................................................................................... 85 S....................................................................................................... 85 T....................................................................................................... 85 W....................................................................................................... 85 Component Locators.......................................................................................... 87 Figure 61. Inside Tractor, Model 6HBE30/40 Shown....................................................... 87 Figure 62. Hydraulic Components........................................................................ 88 Tractor Cover............................................................................................... 89 Battery..................................................................................................... 90 Figure 63. Removing Battery with Hoist................................................................. 90 Figure 64. Battery Filler Plugs and Vent Holes......................................................... 91 Power Cables................................................................................................ 95 Battery/Charger/Truck Connectors............................................................................ 95 Wiring Harness.............................................................................................. 96 Figure 65. Fuse Location............................................................................... 96 Fuses....................................................................................................... 97 Switches (General).......................................................................................... 98 Key Switch.................................................................................................. 99 Brake Switch................................................................................................100 Figure 66. Brake Switch, 6HBW30 and 6HBE30 or 6HBE40...................................................100 Figure 67. Brake (Deadman) Switch, 6HBC30 or 6HBC40 and 6TB50).........................................100 Lift Cut-Out Switch.........................................................................................102 Figure 68. Lift Cut-Out Switch and Adjustment Screw....................................................102 Grab Rail Switches..........................................................................................103 Figure 69. Grab Rail Switch Removal, Left Side.........................................................103 Figure 610. Grab rail Switch Removal, Right Side.......................................................103 Hydraulic Solenoids.........................................................................................104 Figure 611. Hydraulic Solenoids........................................................................104 Manual Coast................................................................................................105 Figure 612. Coast Interlock Switches...................................................................105 Gauges......................................................................................................106 Control Handle..............................................................................................108 Figure 613. Control Handle Assembly, Models 6HBW30 and 6HBE30 or 6HBE40................................108 Figure 614. Control Handle Assembly, Models 6HBC30, 6HBC40 and 6TB50...................................108 Figure 615. Return Spring Adjustment...................................................................108 Horn........................................................................................................109 Figure 616. Horn Location..............................................................................109 Motor Controller............................................................................................110 Figure 617. Motor Controller Connections...............................................................110 Figure 618. Removing the Motor Controller..............................................................110 Figure 619. Travel Potentiometer Connections...........................................................111 Contactors..................................................................................................113 Figure 620. Severely Pitted Contactor Tips.............................................................113 Figure 621. Disconnecting Main Contactor...............................................................113 Figure 622. Removing Contactor Assembly................................................................113 Figure 623. Removing Top Cover.........................................................................114 Figure 624. Removing Brass Lock Nuts...................................................................114 Figure 625. Removing Fixed Contacts....................................................................114 Figure 626. Installing the Fixed Contacts..............................................................114 Figure 627. Main Contactor Components..................................................................115 Figure 628. Installing the Main Contactor..............................................................115 Brake.......................................................................................................117 Figure 629. Brake Adjustment...........................................................................117 Figure 630. Brake Shoes and Springs....................................................................117 Figure 631. Brake Adjustment...........................................................................118 Figure 632. Brake Cable and Clevis Pin.................................................................118 Figure 633. Brake Drum With Control Handle Removed.....................................................119 Figure 634. Brake Puller...............................................................................119 Figure 635. Brake Shoes and Springs....................................................................119 Figure 636. Brake Drum With Control Handle Removed.....................................................119 Figure 637. Brake Cable and Related Components.........................................................120 Motors, General.............................................................................................121 Figure 638. Motor Brush, Typical Location..............................................................121 Figure 639. Motor Brush Spring Tension Inspection......................................................122 Figure 640. Mica Undercutting..........................................................................122 Figure 641. Motor Terminal Nuts........................................................................125 Figure 642. Motor Circuits.............................................................................125 Drive Motor.................................................................................................128 Figure 643. Drive Unit Mounting Plate Bolts............................................................128 Figure 644. Drive Unit, Pinion Gear....................................................................128 Figure 645. Decal on Mounting Plate....................................................................129 Figure 646. Oil Seal Washer Location...................................................................129 Drive Unit..................................................................................................131 Figure 647. Drive Unit Fill Plug.......................................................................131 Figure 648. Jacking Tractor............................................................................131 Figure 649. Drive Unit Drain Plug......................................................................131 Figure 650. Drive Unit Mounting........................................................................132 Figure 651. Drive Unit mounting to Drive Motor.........................................................132 Figure 652. Drive Unit, Exploded View..................................................................133 Figure 653. Drive Unit Gear Tooth Pattern..............................................................135 Figure 654. Drive Unit Mounting to Drive Motor.........................................................136 Figure 655. Drive Unit Mounting........................................................................136 Figure 656. Drive Unit Drain Plug......................................................................137 Figure 657. Drive Unit Fill Plug and Vent Plug.........................................................137 Figure 658. Drive Unit Level Plug......................................................................137 Figure 659. Drive Unit Drain Plug......................................................................138 Figure 660. Dial Indicator on Deck Plate...............................................................138 Figure 661. Indicator Point on Transmission Cover (A)..................................................138 Figure 662. Indicator Point on Transmission Cover (B)..................................................139 Figure 663. Jacking Tractor End........................................................................139 Figure 664. Drive Wheel and Tire.......................................................................140 Figure 665. Cushion Tire Replacement...................................................................140 Casters.....................................................................................................143 Figure 666. Removing Caster............................................................................143 Figure 667. Caster Assembly, Disassembled..............................................................143 Figure 668. Caster Assembly, Assembled.................................................................143 Figure 669. Securing Caster to Tractor.................................................................144 Figure 670. Removing Tension Pin.......................................................................144 Load Wheels.................................................................................................145 Figure 671. Removing Axle From Load Arm Casting........................................................145 Figure 672. Removed Load Wheel and Components..........................................................145 Load Wheels Model 6TB50.....................................................................................146 Pallet Entry Sliders........................................................................................147 Figure 673. Replacing Pallet Entry Slider..............................................................147 Fork Height Adjustment......................................................................................148 Figure 674. Fork Height Adjustment, 6000 Lb............................................................148 Figure 675. Location of shim stacks....................................................................148 Figure 676. Fork Height Adjustment at Lower Bell Crank.................................................149 Hydraulic Components........................................................................................151 Hydraulic Fluid.............................................................................................152 Figure 677. Hydraulic Unit.............................................................................152 Figure 678. Hydraulic Connections......................................................................152 Adjusting Hydraulic Pump Relief Valve Pressure..............................................................154 Figure 679. Checking Relief Valve Pressure.............................................................154 Hydraulic Ram...............................................................................................156 Figure 680. Blocking Fork Section For Ram Removal......................................................156 Figure 681. Removing Lower Bell Crank Pins.............................................................156 Figure 682. Disconnecting Upper Clevis Brackets........................................................157 Figure 683. Hydraulic Ram Area, Forks Removed..........................................................157 Figure 684. Hydraulic Line Connection..................................................................157 Figure 685. Vent Hose Connection.......................................................................157 Figure 686. Hydraulic Ram Removal/Installation.........................................................158 Figure 687. Hydraulic Line Connection (Installed)......................................................158 Figure 688. Hydraulic Vent Hose Connection (Installed).................................................159 Figure 689. Removing Outer Spiral Lock Ring............................................................159 Figure 690. Removing the Spacer........................................................................159 Figure 691. Removing Lock Ring from Cylinder...........................................................160 Figure 692. Rod and Head Assembly Out of Cylinder......................................................160 Figure 693. Remove the Piston Jam Nut..................................................................160 Figure 694. Piston Rod Components......................................................................160 Figure 695. Securing Piston Jam Nut....................................................................161 Figure 696. Installing the Head Lock Ring..............................................................161 Figure 697. Installing the Outer Lock Ring.............................................................161 Hydraulic Unit..............................................................................................162 Figure 698. Hydraulic Unit.............................................................................162 Figure 699. Adapter Cap Screws.........................................................................163 Figure 6100. Removed Reservoir.........................................................................163 Figure 6101. Pump Housing Components...................................................................163 Figure 6102. Cleaning Filter Screen....................................................................164 Figure 6103. Pump and Adapter Body.....................................................................164 Figure 6104. Pump Drive Coupling.......................................................................164 Figure 6105. Installing Pump in Adapter................................................................165 Lift Motor..................................................................................................166 Figure 6106. Bolts Securing Motor To Adapter...........................................................166 Figure 6107. Separated Reservoir and Motor.............................................................166 Figure 6108. Coupling Cavity...........................................................................167 Figure 6109. Indexing Pin..............................................................................167 Figure 6110. Securing the Motor and Adapter Body.......................................................167 Cold Storage Conditioning...................................................................................168 Section A. Appendix............................................................................................169 Lubrication Equivalency Chart...............................................................................170 Torque Chart - Standard (Ferrous)...........................................................................171 Torque Chart - Metric.......................................................................................172 Decimal Equivalent Chart....................................................................................173 Standard/Metric Conversions.................................................................................175 Electrical Schematics.......................................................................................177 Figure A1. Model 6HBW30 Electrical Schematic (Sheet 1 of 2)............................................178 Figure A1 (Cont.). Model 6HBW30 Electrical Schematic (Sheet 2 of 2)....................................179 Figure A2. Model 6HBE30/6HBE40 Electrical Schematic - No Coast (Sheet 1 of 2)..........................180 Figure A2 (Cont.). Model 6HBE30/6HBE40 Electrical Schematic - No Coast (Sheet 2 of 2)..................181 Figure A3. Model 6HBE30/6HBE40 Electrical Schematic - Coast (Sheet 1 of 2).............................182 Figure A3 (Cont.). Model 6HBE30/6HBE40 Electrical Schematic - Coast (Sheet 2 of 2).....................183 Figure A4. Model 6HBC30/6HBC40 Electrical Schematic (Sheet 1 of 2).....................................184 Figure A4 (Cont.). Model 6HBC30/6HBC40 Electrical Schematic (Sheet 2 of 2).............................185 Figure A5. Model 6TB50 Electrical Schematic (Sheet 1 of 2).............................................186 Figure A5 (Cont.). Model 6TB50 Electrical Schematic (Sheet 2 of 2).....................................187 Figure A6. Electrical Schematic - Legend (Sheet 1 of 2)................................................188 Figure A6 (Cont.). Electrical Schematic - Legend (Sheet 2 of 2)........................................189 Section I. Index...............................................................................................191
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