Toyota 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 Service Manual – PDF DOWNLOAD

Description

Toyota 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Toyota 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 Service Manual – PDF DOWNLOAD

Size : 18.0 MB
Format : PDF
Language : English
Number of Pages: 275 Pages

DESCRIPTION:

Toyota 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 Service Manual – PDF DOWNLOAD

MANUAL DESIGN:

The Toyota Reach 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 name of the manual (Toyota Reach Service Manual)
•  the current Chapter Title (e.g.. this page How to Use This Manual)
•  the current topic (e.g., this page Marmal Design)

1. We suggest you get in the habit of turning to the START page first when you use this manual.
2. The START page asks a few simple questions to guide you to the proper chapter.
3. How to Use This Manual explains the manual format and design and contains the Table of Contents and START page.
4.  Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.
5.  Systems Overview includes truck specifications and functional overview of the major systems.
6.  Scheduled Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently.
7.  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.
8.  The START TROUBLESHOOTING chart (on page 5—20) will guide you to the individual troubleshooting symptom chart you need.

TABLE OF CONTENTS:

Toyota 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 Service Manual – PDF DOWNLOAD

Page Revision Record vii
How To Use This Manual 1-1
Map of the Manual 1-2
Manual Design 1-3
Abbreviations & Symbols 1-4
START Page 1-6
Safety 2-1
Definitions2-2
General Safety 2-3
Battery Safety 2-6
Jacking Safety 2-8
Tractor Section 2-8
Fork Section 2-8
Tie-Down for Transport 2-9
Towing 2-10
Static Safety 2-11
Welding Safety 2-12
Systems Overview 3-1
Introduction 3-2
Truck Model Identification 3-3
Lift Truck Specifications 3-4
General System Data 3-5
Special Tools 3-7
Service Key 3-7
Operator Display and Programming 3-8
Special Truck Mode 3-8
Hour Meter (H) 3-8
Error Codes (E) 3-8
Changing Truck Parameters (P)3-9
Service Input/Output Displays 3-15
Digital Inputs/Outputs from Traction Amplifier and VM 3-16
Toyota FlashWare 3-18
Overview 3-18
Requirements 3-18
Installing FlashWare on PC 3-18
Connecting PC to Truck 3-18
Starting FlashWare 3-18
Configuration and Truck Setup Options 3-20
Planned Maintenance4-1
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
Contactor Tip Inspection 4-7
Grease Fittings (All Models) 4-8
Grease Fittings (Trucks without Composite Bushings Only) 4-9
Table of Contents Toyota Pallet Truck Service Manual
ii 00700-CL398-09, Issued: 04 Sep 2009
Troubleshooting 5-1
How to Use This Section 5-2
Troubleshooting Flowcharts 5-3
TS1: START TROUBLESHOOTING 5-3
GEN1: General Troubleshooting5-4
END1: End of Troubleshooting Procedure 5-5
Electrical Troubleshooting Guidelines 5-6
Troubleshooting the CAN Bus 5-6
Shorts to Frame Test 5-8
Fuses 5-11
Test/Inspection 5-11
DC Electric Motors 5-12
DC Motor Types 5-12
Inspection 5-12
Service5-12
Open Circuit Motor Test 5-14
Grounded Motor Test 5-15
Short-Circuited Armature 5-15
Short-Circuited Winding 5-15
AC Electric Motors 5-16
AC Motor Type 5-16
Open Winding 5-16
Shorted Winding 5-16
Hydraulic Troubleshooting Guidelines 5-17
Symptom Tables: Lift/Lower System 5-18
Symptom Tables: Travel (Forward/Reverse) System 5-21
Symptom Tables: Wiring System 5-26
Messages and Codes 6-1
List of Messages and Codes 6-2
Traction Amplifier LED Diagnostics6-3
Traction Amplifier Flash Codes 6-4
Caution and Error Codes 6-6
Caution Codes 6-7
Error Codes 6-21
Component Procedures 7-1
List of Component Procedures by Truck System7-2
Component Locator Photos 7-5
Steering and Controls 7-9
Control Handle – Model 8HBW30 7-10
Control Handle Disassembly 7-11
Changing Horn Button/Switch7-11
Changing Lift/Lower Button 7-12
Changing Push Button 7-12
Spring-Loaded Handle Design 7-13
Removal 7-13
Installation 7-14
Return Spring Adjustment 7-14
Fixed-Position Handle Design – Models 8HBC30/40 and 8TB50 7-16
Removal 7-16
Installation 7-16
Toyota Pallet Truck Service Manual Table of Contents
00700-CL398-09, Issued: 04 Sep 2009 iii
Control Handle Assemblies – Models 8HBE, 8HBC and 8TB50 7-17
Changing Horn Button/Switch 7-21
Changing Lift/Lower Switch Activator 7-22
Changing the Push Button 7-22
Changing the Jog Trigger Switch 7-23
Changing the Jog Trigger and Spring 7-23
Drive and Brake 7-25
Drive Unit 7-26
Removal 7-26
Steering Bearing 7-27
Removal 7-27
Installation 7-27
Gear Assembly 7-28
Checking the Gears 7-31
Adjusting Tooth Pattern of Drive Unit 7-31
Installation 7-32
Drive Housing Lubrication 7-33
Drive Wheel 7-34
Removal 7-34
Cushion Tire Replacement 7-34
Caster Adjustment 7-36
Casters (without Springs) 7-37
Caster Removal 7-37
Wheel Replacement 7-37
Caster Assembly 7-37
Caster Installation 7-38
Casters (Spring-Loaded) 7-39
Removal 7-39
Wheel Replacement 7-39
Caster Disassembly 7-40
Caster Assembly 7-41
Wheel Installation 7-41
Caster Installation 7-41
Brake 7-43
Spring-Loaded Handle 7-43
Removal 7-43
Installation 7-43
Checking the Gap7-44
Replacing the Rotor 7-44
Electrical Components 7-45
Battery 7-46
With Battery Gates and Rollers (Optional)7-46
Battery Gates (Optional) 7-46
Battery Rollers (Optional) 7-46
Without Battery Gates and Rollers 7-46
Battery Exterior Cleaning 7-47
Testing, Charging, and Maintenance 7-47
Maintenance-Free Batteries 7-48
Storage 7-48
Power Cables 7-49
Table of Contents Toyota Pallet Truck Service Manual
iv 00700-CL398-09, Issued: 04 Sep 2009
Wiring Harness 7-51
Terminology 7-51
Inspection 7-51
Repair7-51
Soldering Procedures 7-52
AMP Water-Resistant Connectors 7-53
Pin Extraction 7-53
Pin Insertion 7-54
Seals 7-54
AMP Harness/Traction Amplifier Connector 7-56
Connector Components 7-56
Disassembly (Contact Removal) 7-56
Contact Insertion 7-56
Assembly 7-56
Testing7-58
Brake Potentiometer (VR1) 7-59
Removal 7-59
Installation 7-59
Lift-Limit Switch (SW8) 7-60
Adjustment 7-60
Grab Rail Switches – Model 8HBE30/40 7-61
Removal 7-61
Installation 7-61
Hydraulic Solenoids 7-62
Jog Pick Solenoid – Model 8HBE30/40 Option7-63
Removal 7-63
Installation 7-64
Jog Pick Solenoid Switch/Spring 7-64
Jog Pick Canister 7-64
Traction Amplifier 7-67
Removal 7-67
Installation 7-67
Programming 7-68
Motors, General 7-69
Terminal Nuts 7-69
Traction Motor 7-70
Removal 7-70
Installation 7-72
Lift Motor 7-74
General Data 7-74
Removal 7-74
Installation 7-74
Hydraulic Components 7-77
Hydraulic Components 7-78
General Guidelines7-78
Hydraulic Fluid 7-79
Checking Hydraulic Fluid Level 7-79
Hydraulic Unit 7-80
Removal 7-80
Installation 7-80
Toyota Pallet Truck Service Manual Table of Contents
00700-CL398-09, Issued: 04 Sep 2009 v
Hydraulic Reservoir 7-81
Removal 7-81
Installation 7-81
Filter Screen and Suction Tube 7-82
Removal 7-82
Installation 7-82
Hydraulic Pump 7-83
Installation 7-83
Adjusting Hydraulic Pump Relief Valve Pressure 7-84
Checking Relief Valve Setting7-84
Alternate Method Using Rated Load on Pallets 7-84
Hydraulic Ram 7-86
Inspection 7-86
Removal 7-86
Installation 7-88
Hydraulic Cylinder Seals 7-90
Disassembly 7-90
Assembly 7-91
Mast 7-93
Top Linkage Subassembly 7-94
Removal 7-94
Installation 7-95
Pull Rod Subassembly 7-97
Removal 7-97
Installation 7-98
Load Wheel Suspension – Model 8TB50 7-100
Removal 7-100
Installation 7-101
Fork Height Adjustment 7-102
Measurement 7-102
Adjustment 7-102
Options 7-105
Cold Storage Conditioning 7-106
Theory of Operation 8-1
Definitions8-2
Acceleration Rate 8-2
Brake Lever Potentiometer (VR1)
(Models with Fixed Position Handles) 8-2
Brake (Deadman) Switch (Models with Spring-Loaded Handle) 8-2
Continuity 8-2
Controller Area Network (CAN)8-2
Current Limiting 8-2
Deceleration (Neutral Braking)8-2
Emergency Reverse (Models 8HBW30 and 8HBE30 or 8HBE40) 8-3
Fault Codes 8-3
High Pedal Disable (HPD) 8-3
Jog Speed 8-3
Open Circuit 8-3
Overvoltage Cutoff8-3
PIN-Key Code 8-3
Pulse Width Modulation 8-3
Ramp Shape 8-3
Table of Contents Toyota Pallet Truck Service Manual
vi 00700-CL398-09, Issued: 04 Sep 2009
Regenerative Braking 8-3
Sequencing Delay 8-4
Short Circuit or “Short” 8-4
Speed Limiting 8-4
Static Return to Off (SRO) 8-4
Thermal Cutback (Traction Amplifier) 8-4
Throttle Map 8-5
Truck Off Delay (Keypad only) 8-5
Undervoltage Cutoff8-5
VM (Vehicle Manager) 8-5
Traction System 8-6
Vehicle Manager (VM) 8-6
Traction Amplifier (TA) 8-6
Battery Plugged In 8-6
Key Switch ON and M1 Energized 8-6
Travel Request, Tractor-First 8-7
Travel Request, Forks-First 8-7
Strip Curtain Bypass (Model 8HBE30/40 only) 8-7
Emergency Reverse (Model 8HBW30 and 8HBE30/40) 8-8
Jog Mode 8-8
Jog Pick Mode 8-9
Lift/Lower System 8-10
Lift 8-10
Lower 8-10
Pinout Matrix 8-11
Appendix A-1
Lubrication Equivalency Chart A-2
Thread Adhesives, Sealants, and Lubricants A-3
Component Specific Service/Torque Chart A-4
Torque Chart – Standard (Ferrous)A-6
Torque Chart – Standard (Brass) A-7
Torque Chart – MetricA-8
Torque Chart – Thread-Forming Screws A-9
Decimal Equivalent Chart A-10
Standard/Metric Conversions A-12
List of Electrical Symbols A-14
Schematics A-17
Electrical SchematicsA-19
Power Distribution Diagram A-25
Hydraulic SchematicA-26
Index I-1

TOYOTA 8HBW30 8HBE30 8HBE40 8HBC30 8HBC40 8TB50 SERVICE MANUAL – PDF DOWNLOAD:

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