Toyota Forklift 6HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 22000 and up – PDF DOWNLOAD

Description

Toyota Forklift 6HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 22000 and up – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 6HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 22000 and up – PDF DOWNLOAD

Language : English
Pages : 151
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 6HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 22000 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 Model 6HBW23 Service Manual)
• Current chapter title
  (e.g.this page How to Use This Manual)
• Current topic
  (e.g.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 6HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 22000 and up – PDF DOWNLOAD

R/M 6HBW23 SN: 22,000 & UP..........................................................................  1
	Table of Contents...............................................................................  4
	Section 1. How To Use This Manual...............................................................  6
		Map of the Manual...........................................................................  7
		Manual Design...............................................................................  8
		START Page.................................................................................. 10
	Section 2. Safety............................................................................... 12
		Definitions................................................................................. 13
		General Safety.............................................................................. 14
		Battery Safety.............................................................................. 17
		Jacking Safety.............................................................................. 20
			Fork Section............................................................................ 20
			Tractor Section......................................................................... 20
		Towing...................................................................................... 21
		Welding Safety.............................................................................. 22
	Section 3. Systems Overview..................................................................... 24
		Truck Model Identification.................................................................. 25
			Figure 3-1. Model 6HBW23 Pallet Truck................................................... 25
		Vehicle Specifications...................................................................... 25
		General Information......................................................................... 26
			Figure 3-2. Model 6HBW23 General Information............................................ 26
		Special Tools............................................................................... 27
			Programmable Maintenance Tool........................................................... 27
				Figure 3-3. Programmable Maintenance Tool........................................... 27
			Service Key............................................................................. 27
				Figure 3-4. Service Key............................................................. 27
		Theory of Operation......................................................................... 28
			Truck Starting.......................................................................... 28
			Lift/Lower.............................................................................. 28
			Direction/Speed Control................................................................. 28
			Power Amplifier......................................................................... 30
			Electronic Tiller Arm Card (ETAC)....................................................... 30
	Section 4. Planned Maintenance.................................................................. 32
		Maintenance Guidelines...................................................................... 33
			Maintenance Manual...................................................................... 33
			Planned Maintenance Schedule............................................................ 33
			Time Requirements....................................................................... 33
			General Truck Operation................................................................. 33
			Daily................................................................................... 34
			Every Two Months or 250 Operating Hours................................................. 35
			Annually or Every 1500 Operating Hours.................................................. 36
			Grease Fittings......................................................................... 36
				Figure 4-1: Load Wheel Axle (Cold Storage and Corrosion Protection Options only).... 36
	Section 5. Troubleshooting...................................................................... 38
		How to Use This Chapter..................................................................... 39
		Electrical Troubleshooting Guidelines....................................................... 40
			Checking for Shorts from Battery to Truck Frame......................................... 40
			Checking for Shorts from Components to Truck Frame...................................... 40
		Hydraulic Troubleshooting Guidelines........................................................ 42
		Definitions................................................................................. 43
			Acceleration............................................................................ 43
			Arm Angle Switches...................................................................... 43
				Figure 5-1. Arm Angle Switches and Brake Actuation.................................. 43
			Continuity.............................................................................. 43
			Creep Speed............................................................................. 43
			Current Limiting........................................................................ 43
			Deceleration............................................................................ 43
			Emergency Reverse....................................................................... 43
			ETAC (Electronic Tiller Arm Card)....................................................... 43
			Fault Codes............................................................................. 44
			Open Circuit............................................................................ 44
			Overvoltage Cutoff...................................................................... 44
			PIN-Key Code............................................................................ 44
			Short Circuit or “Short”................................................................ 44
			Speed Limiting.......................................................................... 44
			Thermal Cutback (Power Amplifier)....................................................... 44
			Tractor................................................................................. 44
			Truck Off Delay (Keypad only)........................................................... 44
			Undervoltage Cutoff..................................................................... 45
		List of Electrical Symbols.................................................................. 46
		Control Handle Display and Programming...................................................... 47
			Figure 54. Control Handle Display...................................................... 47
			Special Truck Mode...................................................................... 47
			Hour Meter (H).......................................................................... 47
			Error Codes (E)......................................................................... 47
			Parameters (P).......................................................................... 53
			Display Part Numbers (Pn)............................................................... 57
		Service Display............................................................................. 58
		Power Amplifier Fault Codes................................................................. 61
		Programmable Maintenance Tool (PMT)......................................................... 63
			Figure 5-8. Programmable Maintenance Tool............................................... 63
			Figure 5-9. Connecting PMT to Power Amplifier........................................... 63
			Program Mode............................................................................ 63
			Monitor Mode............................................................................ 64
			Faults Mode............................................................................. 64
			Functions Mode.......................................................................... 65
			Information Mode........................................................................ 65
			Programmer Mode......................................................................... 65
		List of Troubleshooting Charts/Tables....................................................... 68
			Troubleshooting Charts.................................................................. 68
			Hydraulic Symptom Tables................................................................ 68
			Travel Symptom Tables................................................................... 68
		Troubleshooting Flowcharts.................................................................. 70
		Symptom Tables: Lift/Lower System........................................................... 74
		Symptom Tables: Travel (Forward/Reverse) System............................................. 78
	Section 6. Component Procedures................................................................. 80
		Component Locator Photo..................................................................... 82
			Figure 6-1. Tractor Interior............................................................ 82
		Battery..................................................................................... 83
			Swingout Battery Pack................................................................... 83
				Figure 6-2. Multiple Battery Wiring Hookup.......................................... 83
			Maintenance-Free Batteries.............................................................. 84
			Battery Maintenance..................................................................... 84
				Figure 6-3. Battery Filler Plugs and Vent Holes..................................... 84
		Tractor Covers.............................................................................. 88
			Figure 6-4. Top Cover Removal (decals omitted).......................................... 88
		Power Cables................................................................................ 89
			Figure 6-5. Power Cables................................................................ 89
		Wiring Harness.............................................................................. 90
			Figure 6-6. Wiring Harness.............................................................. 90
		Fuses....................................................................................... 91
			Figure 6-7. Fuse/Circuit Breaker Location............................................... 91
		Circuit Breaker............................................................................. 92
			Test/Inspection......................................................................... 92
				Figure 6-8. Circuit Breaker Location................................................ 92
		Control Handle.............................................................................. 93
			Control Handle Disassembly.............................................................. 94
				Figure 6-9. Horn Button Removal..................................................... 94
				Figure 6-10. Lift/Lower Button Removal.............................................. 95
				Figure 6-11. Push Button Removal.................................................... 95
			Control Handle Stem..................................................................... 95
				Figure 6-12. Removing Cover......................................................... 95
				Figure 6-13. Cover Removed.......................................................... 95
				Figure 6-14. Allen Head Cap Screws.................................................. 96
		Horn........................................................................................ 97
			Figure 6-15. Horn Location.............................................................. 97
		Power Amplifier............................................................................. 98
			Figure 6-16. Power Amplifier Location................................................... 98
		Contactors.................................................................................. 99
			Main Contactor.......................................................................... 99
				Figure 6-17. Main Contactor K10..................................................... 99
			Lift Motor Contactor.................................................................... 99
				Figure 6-18. Lift Motor Contactor K30............................................... 99
		Master Control Relay........................................................................100
			Inspection/Test.........................................................................100
				Figure 6-19. Master Control Relay...................................................100
		Switches (General)..........................................................................102
			Test/Inspection.........................................................................102
			Master Control ON/OFF Switch............................................................102
				Figure 6-20. Master Control ON/OFF Switch Location..................................102
			Arm Angle Switches......................................................................103
				Figure 6-21. Arm Angle Switches.....................................................103
				Figure 6-22. Arm Angle Switch Screws................................................103
				Figure 6-23. Control Handle Cover Installed.........................................103
			Lift-Limit Switch.......................................................................104
				Figure 6-24. Lift-Limit Switch......................................................104
			Key Switch (Optional)...................................................................105
		Drive Unit..................................................................................106
			Transmission Assembly...................................................................106
				Figure 6-25. Control Handle Assembly Removal........................................106
				Figure 6-26: Terminal Block.........................................................106
				Figure 6-27. Transmission Assembly, Exploded View...................................108
			Drive Housing Lubrication...............................................................109
				Figure 6-28. Transmission Assembly Fill/Drain Plugs.................................109
			Drive Wheel.............................................................................110
				Figure 6-29. Drive Wheel Nuts.......................................................110
				Figure 6-30. Tire Replacement.......................................................110
		Electromagnetic Brake.......................................................................112
			Brake Disc Location.....................................................................112
				Figure 6-31. Brake Location.........................................................112
			Air Gap Adjustment......................................................................112
				Figure 6-32. Brake Gap Adjustment...................................................112
			Friction Disc Replacement...............................................................113
				Figure 6-33: Friction Disc Replacement..............................................113
			Mechanically Releasing the Brake........................................................113
		Motors, General.............................................................................114
			Drive Motor Brush Inspection............................................................114
				Figure 6-34. Drive Motor Brush, Typical Location....................................114
			Drive Motor Brush Spring Tension........................................................115
				Figure 6-35. Motor Brush Spring Tension Inspection..................................115
			Motor Commutator........................................................................115
				Figure 6-36. Mica Inspection........................................................115
			Terminal Nuts...........................................................................118
				Figure 6-37. Motor Terminal Nuts....................................................118
			Electric Motor Tests....................................................................118
				Figure 6-38. Motor Circuits.........................................................118
		Drive Motor.................................................................................121
			Figure 6-39: Drive Motor Brush Shield...................................................121
		Pallet Forks and Load Wheels................................................................124
			Load Wheels.............................................................................124
				Figure 6-40. Removing Set Screw.....................................................124
			Load Wheel Pull Rod.....................................................................124
				Figure 6-41. Wheel Fork Set Screw Location (top view)...............................124
			Carrier Frame Linkage...................................................................125
				Figure 6-42: Lower Links............................................................125
		Hydraulic Components........................................................................126
			General Guidelines......................................................................126
			Hydraulic Cylinder......................................................................126
				Figure 6-43. Hydraulic Cylinder (shown extended)....................................126
				Figure 6-44. Removing Hydraulic Line from Cylinder..................................126
				Figure 6-45. Hydraulic Cylinder Disassembly.........................................127
			Hydraulic Solenoid......................................................................128
				Figure 6-46. Hydraulic Solenoid.....................................................128
			Hydraulic Unit..........................................................................128
				Figure 6-47. Hydraulic Unit.........................................................129
			Hydraulic Reservoir.....................................................................129
			Filter Screen and Inlet Tube............................................................129
				Figure 6-48. Cleaning Filter Screen.................................................130
			Hydraulic Pump..........................................................................130
			Lift Motor..............................................................................130
			Hydraulic Fluid.........................................................................131
				Figure 6-49. Hydraulic Connections..................................................131
			Adjusting Hydraulic Pump Pressure Relief Valve..........................................132
				Figure 6-50. Checking Relief Valve Pressure.........................................132
		Cold Storage Conditioning...................................................................134
		Lubrication Equivalency Chart...............................................................137
		Torque Chart - Standard.....................................................................138
		Torque Chart - Metric.......................................................................139
		Decimal Equivalent Chart....................................................................140
		Standard/Metric Conversions.................................................................142
			Figure A-1. Electrical Schematic - Sheet 1 of 2.........................................145
			Figure A-2. Electrical Schematic - Sheet 2 of 2.........................................146
			Figure A-3. Hydraulic Schematic.........................................................147
	Index...........................................................................................148

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PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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