Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD

Description

Toyota Forklift 6HBW30 6HBE30 6HBE40 6HBC30 6HBC40 6TB50 Pallet Trucks Service Manual SN 27000 and up – PDF DOWNLOAD

FILE DETAILS:

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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