Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up – PDF DOWNLOAD

Description

Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up – PDF DOWNLOAD

Language : English
Pages : 140
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up – PDF DOWNLOAD

PREFACE:

This manual indudes information required for maintenance, troubleshooting, and repair of the Model 6HBW20. The object is to insure safe maintenance and repair practices and procedures for this Toyota product.

MANUAL OVERVIEW:

• This manual consists of both a Service Manual and a Parts Manual for the specific
  equipment listed on the cover.
• The Table of Contents provides easy location of all subject matter within the
  manual.
• The following symbols are used throughout this manual to represent a condition
  or hazard of which the operator should be aware.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift 6HBW20 Truck Service & Parts Manual SN 10011 and up – PDF DOWNLOAD

R/M 6HBW20 SN: 10,011-17,000....................................................................  1
	Table of Contents...........................................................................  5
	General Information......................................................................... 14
		General Maintenance Instructions........................................................ 14
		Maintenance Practices................................................................... 14
		Specifications.......................................................................... 15
		Hydraulic............................................................................... 15
		Component Identification................................................................ 16
		Standard Torque Data For Bolts.......................................................... 19
		Conversion Table........................................................................ 20
		Decals.................................................................................. 21
		Decimal Equivalent Chart................................................................ 23
		Planned Maintenance (PM)................................................................ 24
		Inspection Form......................................................................... 24
		PM Schedule and Procedure............................................................... 24
		Daily Inspection........................................................................ 24
		Monthly PM Service (or 100 Hrs.)........................................................ 25
		Semiannual Service (or 500 Hrs.)........................................................ 25
		Annual PM Service (or 1000 Hrs.)........................................................ 25
		Lubrication Points...................................................................... 26
		Fill Points............................................................................. 27
		PM Chart................................................................................ 28
		Lubrication Equivalency Chart........................................................... 29
	Scheduled Maintenance....................................................................... 30
		Batteries............................................................................... 30
			Battery Cleaning.................................................................... 30
			Electrolyte Process................................................................. 30
			Battery Cleaning Procedure.......................................................... 30
			Battery Electrical Leakage To Frame Test............................................ 31
			Battery Charging.................................................................... 31
				Charging Process................................................................ 31
			Hydrometer Use...................................................................... 32
				Procedure....................................................................... 32
			Voltage Check....................................................................... 32
			Adding Water To Battery............................................................. 33
				Guidelines...................................................................... 33
			Battery History Record.............................................................. 33
		Motors.................................................................................. 34
			Motor Cleaning...................................................................... 34
			Brush Care.......................................................................... 35
			Maintenance Schedule................................................................ 35
			Motor Maintenance Inspection Chart.................................................. 35
			Brush Replacement................................................................... 37
			Motor Overheating................................................................... 38
			Motor Test for Open Circuit......................................................... 39
			Motor Open Circuit Test Procedure................................................... 39
			Short Circuit Test - Motors......................................................... 40
			Short Circuit Test.................................................................. 40
			Armature Shorts..................................................................... 40
			Motor Grounds Test.................................................................. 41
			Grounds - General................................................................... 41
		Hydraulic............................................................................... 42
			Oil Selection....................................................................... 42
			Changing Reservoir Fluid............................................................ 42
	Power Section............................................................................... 43
		Special Tools........................................................................... 43
			Flush Grease Fitting Adapter........................................................ 43
			Battery-Pak Lifter.................................................................. 43
			Bearing Installation Tool........................................................... 43
		Control Head Unit....................................................................... 44
		Removal and Installation................................................................ 44
		Head Unit Removal....................................................................... 44
			Cold Storage Requirements........................................................... 44
		Control Handle Removal.................................................................. 45
		Travel Control Switches................................................................. 46
		Horn, Lift/Lower Switches............................................................... 46
		Load Wheel.............................................................................. 47
			Repair and Replacement.............................................................. 47
		Pull Rod Bushings Removal and Replacement............................................... 48
		Carrier Frame Linkage and Bushings...................................................... 48
		Drive Wheel............................................................................. 49
			Removal............................................................................. 49
		Installation............................................................................ 50
		Drive Unit.............................................................................. 51
			Removal............................................................................. 51
			Installation........................................................................ 52
		Axle Seal Removal....................................................................... 53
			Installation........................................................................ 53
			Drive Unit Assembly................................................................. 54
		Drive Unit.............................................................................. 55
			Disassembly......................................................................... 55
			Assembly............................................................................ 56
		Drive Motor............................................................................. 57
			Removal............................................................................. 57
			Drive Motor Brush Replacement....................................................... 57
			Drive Motor Disassembly............................................................. 57
			Installation........................................................................ 58
		Controller Assembly..................................................................... 60
			Throttle Potentiometer Setting...................................................... 60
				Example......................................................................... 60
		Battery Replacement..................................................................... 61
		Battery Wiring Hookup................................................................... 62
	Brake....................................................................................... 63
		Brake Adjustment........................................................................ 63
		Brake Interlock Switch.................................................................. 64
		Brake Linkage Removal................................................................... 64
		Brake Linkage Installation.............................................................. 64
		Brake Shoe Removal and Installation..................................................... 65
	Lift/Lower.................................................................................. 66
		Description............................................................................. 66
		Theory of Operation..................................................................... 66
			Lift................................................................................ 66
			Hydraulic........................................................................... 66
		Electrical.............................................................................. 67
			Control Circuits.................................................................... 67
			Power Wiring........................................................................ 67
		Lower................................................................................... 68
			Hydraulic and Electrical............................................................ 68
		Equipment Recommended for Normal Servicing.............................................. 69
		Pump and Motor.......................................................................... 70
			Removal and Installation............................................................ 70
			Pump Motor Brush Removal............................................................ 70
		Relief Valve............................................................................ 72
		Removing Solenoid Valve................................................................. 72
		Installing Solenoid Valve............................................................... 72
		Removing Pump and Motor Assembly........................................................ 72
			Removing Reservoir.................................................................. 72
			Removing the Pump................................................................... 72
		Installing the Pump..................................................................... 73
		Installing the Reservoir................................................................ 73
		Check Valve............................................................................. 73
		Cylinder Assembly Removal Installation.................................................. 73
		Cylinder Removal........................................................................ 73
		Hydraulic Cylinder...................................................................... 74
			Cylinder Disassembly................................................................ 74
			Inspection.......................................................................... 74
			Cylinder Assembly................................................................... 75
			Cylinder Installatin................................................................ 76
		Lift Limit Switch....................................................................... 76
		Troubleshooting......................................................................... 77
			No Lift............................................................................. 77
			Forks Do Not Lower.................................................................. 79
			Forks Will Not Hold Load............................................................ 79
	Traction System............................................................................. 80
		Transistor Control (Motor Controller)................................................... 80
			Current Limiting.................................................................... 81
			Low Voltage Cutback................................................................. 81
			Thermal Protection.................................................................. 81
			Runaway Protection.................................................................. 82
			Static Return to Neutral Protection................................................. 82
			Plugging............................................................................ 82
			Controller Keyswitch Input.......................................................... 82
			Controller Thumbwheel Throttle Inputs............................................... 82
			"Emergency Reverse" Plug Breaking Inhibit........................................... 82
		Traction System Adjustments............................................................. 83
		Adjustment Panel........................................................................ 83
		Potentiometer Adjustments............................................................... 83
		Theory.................................................................................. 84
		Preparing to Travel..................................................................... 84
		Directional/Speed Control Forward....................................................... 85
		Directional/Speed Control Reverse....................................................... 86
		Emergency Reverse....................................................................... 87
		Contactor Tip/Bar Replacement........................................................... 88
		Troubleshooting......................................................................... 89
			Vehicle is dead - nothing operates.................................................. 89
			No travel - horn and lift/lower operates OK......................................... 89
			No forward travel - forward contactor does not energize............................. 90
			No forward travel - forward contactor closed........................................ 91
			No reverse travel - reverse contactor does not energize, forward travel operates.... 92
			No reverse travel - reverse contactor closed........................................ 93
			No Emergency Reverse................................................................ 94
	Troubleshooting............................................................................. 95
		Wiring Inspection Procedure............................................................. 97
		Miscellaneous Troubleshooting........................................................... 98
		Battery Charger......................................................................... 99
			Electrical Testing.................................................................. 99
				Equipment Required.............................................................. 99
				Instructions.................................................................... 99
				Acceptable Charge Values........................................................ 99
		Open Circuit Voltage Test...............................................................100
		Short Circuit Amperage Test.............................................................100
		Testing Components......................................................................101
			Diodes..............................................................................101
			Capacitor...........................................................................101
			Timer...............................................................................102
			Overcharging Problems...............................................................102
			Charger and Battery not Properly Matched............................................102
			Defective Battery or Poor DC Connection.............................................102
			Battery Charts......................................................................103
	Controller..................................................................................104
		Description.............................................................................104
		Low Current.............................................................................106
		High Current............................................................................107
		Adjustment Panel........................................................................107
		Manually Adjustable Potentiometers......................................................107
			Programmer Connector................................................................107
			Status LED..........................................................................107
		Power Wiring............................................................................108
		Control Wiring..........................................................................108
		0-5kOhm Throttle ("Type 3").............................................................109
		Plug Current in Over-Temperature........................................................110
		High Speed Parameter....................................................................110
		Ramp Shape Parameter....................................................................110
		Initial Check...........................................................................112
		Programming and Adjustment..............................................................114
			Programming.........................................................................114
			Manual Adjustments..................................................................115
			Current Limit Setting...............................................................115
			Plug Current Adjustment.............................................................116
			Acceleration Adjustment.............................................................116
	Maintenance.................................................................................117
	Safety......................................................................................117
	Cleaning....................................................................................117
	Diagnostic History..........................................................................117
	Diagnostics and Troubleshooting.............................................................118
		LED Diagnostics.........................................................................118
		Programmer Diagnostics..................................................................119
		Programmer Operation....................................................................121
		Operating Modes.........................................................................123
		Peace-of-mind Programming...............................................................126
		Programmer Self Test....................................................................126
		Programmer Menus........................................................................127
		Diagnostics and Special Diagnostics "Menu"..............................................128
	Appendix....................................................................................129
		Hydraulic Schematic.....................................................................129
		Electrical Schematic....................................................................130
		Motor Controller Specifications.........................................................131
	Glossary....................................................................................132
	Alphabetical Index..........................................................................138

Customer Support: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V