Toyota 6HBC30, Service Manual

Page 1: ...Pallet Trucks 6HBW30 27 000 and up 6HBE30 27 000 and up 6HBE40 27 000 and up 6HBC30 27 000 and up 6HBC40 27 000 and up 6TB50 27 000 and up SERVICE MANUAL 00700 CL390 04 Issued 2 February 2004...

Page 2: ...hotocopying electronic retrieval or transfer or recording without the written permission of the publisher Toyota Industrial Equipment believes the information in this manual is accurate and current as...

Page 3: ...onal Speed Control 3 7 Strip Curtain Bypass Models 6HBE30 40 only 3 8 Manual Coast Mode Standard on 6HBE30 40 Optional on 6HBW30 3 8 Motor Controller 3 9 Scheduled Maintenance 4 1 Introduction 4 2 Mai...

Page 4: ...rogrammable Maintenance Tool 5 13 Program Mode 5 13 Monitor Mode 5 15 Faults Mode 5 16 Functions Mode 5 17 Information Mode 5 17 Programmer Mode 5 17 List of Troubleshooting Charts 5 19 Symptom Tables...

Page 5: ...ulic Solenoids 6 22 Removal 6 22 Installation 6 22 Manual Coast 6 23 Removal 6 23 Installation 6 23 Gauges 6 24 Hour Meter 6 24 Combination Hour Battery Discharge Meter 6 24 Control Handle 6 26 Return...

Page 6: ...llet Entry Sliders 6 65 Replacement 6 65 Fork Height Adjustment 6 66 6000 Lb Models Single Pallet 6 66 Long John Models Double Pallet 6 66 Hydraulic Components 6 69 General Guidelines 6 69 Hydraulic F...

Page 7: ...let Truck Service Manual How To Use This Manual 00700 CL390 04 Issued 2 February 2004 vii Torque Chart Metric A 4 Decimal Equivalent Chart A 5 Standard Metric Conversions A 7 Electrical Schematics A 9...

Page 8: ...How To Use This Manual Toyota Pallet Truck Service Manual viii 00700 CL390 04 Issued 2 February 2004 This page intentionally left blank...

Page 9: ...Toyota Pallet Truck Service Manual How to Use This Manual 00700 CL390 04 Issued 2 February 2004 1 1 Section 1 How to Use This Manual...

Page 10: ...the Manual 1 How to Use This Manual Safety Systems Overview Component Procedures Appendix Index Map of the Manual Manual Design Table of Contents Start Page Vehicle Specifications Theory of Operations...

Page 11: ...truck working most efficiently Troubleshooting is a set of decision tree charts and tables designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component...

Page 12: ...How to Use This Manual Toyota Pallet Truck Service Manual 1 4 00700 CL390 04 Issued 2 February 2004 This page intentionally left blank...

Page 13: ...Toyota Pallet Truck Service Manual How To Use This Manual START Page 00700 CL390 04 Issued 2 February 2004 1 5 Section 1 How To Use This Manual START Page...

Page 14: ...START 2 Yes To do scheduled maintenance To examine specifications or theory of operations To troubleshoot a problem No No No No Go to Chapter 2 Safety Go to Chapter 3 Systems Overview Go to Chapter 4...

Page 15: ...y 2004 1 7 1 To test inspect adjust remove install a component Yes No START 2 To find general reference information To locate an object or procedure by name Go to Chapter 6 Component Procedures Go to...

Page 16: ...How To Use This Manual Toyota Pallet Truck Service Manual 1 8 00700 CL390 04 Issued 2 February 2004 This page intentionally left blank...

Page 17: ...Toyota Pallet Truck Service Manual Safety 00700 CL390 04 Issued 2 February 2004 2 1 Section 2 Safety...

Page 18: ...manual you will see two kinds of safety reminders Warning means a potentially hazardous situation exists that if not avoided could result in death or serious injury Caution means a potentially hazardo...

Page 19: ...they do Do not operate this truck if it needs repair or if it is in any way unsafe Operate this truck only from the operator s position Before working on this truck always turn the key switch to OFF...

Page 20: ...ot use an open flame near the truck Do not use gasoline or other flammable liquids for cleaning parts Clean up any hydraulic fluid oil or grease that has leaked or spilled on the floor Always park thi...

Page 21: ...uses burns If any electrolyte comes in contact with your clothing or skin flush the area immediately with cold water If the solution gets on your face or in your eyes flush the area with cold water an...

Page 22: ...condition to avoid shorts and sparks Keep filler plugs firmly in place at all times except when the electrolyte level is checked when water is added to the cells or when the specific gravity is check...

Page 23: ...Truck Service Manual Safety Battery Safety 00700 CL390 04 Issued 2 February 2004 2 7 Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual 2DSR...

Page 24: ...ks beneath it to support it DO NOT rely on the jack alone to support the truck Fork Section 6 Using the lift button raise the forks to maximum height 7 Block the fork section as shown in Figure 2 1 Th...

Page 25: ...ion the adjustable chain over and through the battery compartment 4 Position an additional adjustable chain over and through the battery compartment 5 Position the chain ends of one chain toward the f...

Page 26: ...Toyota pallet truck 1 Lower the forks and remove any load 2 Turn the key switch OFF and disconnect the battery connector 3 Using a suitable towing vehicle lift the tractor end of the pallet truck unt...

Page 27: ...know the location of the nearest eyewash station the key switch is turned OFF and the battery is disconnected before you attempt to inspect service or repair the lift truck Discharge residual charge...

Page 28: ...Safety Toyota Pallet Truck Service Manual 2 12 00700 CL390 04 Issued 2 February 2004 This page intentionally left blank...

Page 29: ...Toyota Pallet Truck Service Manual Systems Overview 00700 CL390 04 Issued 2 February 2004 3 1 Section 3 Systems Overview...

Page 30: ...l Truck Model Identification 3 2 00700 CL390 04 Issued 2 February 2004 Truck Model Identification 3111s eps Model 6HBC30 and Model 6HBC40 Center Rider Model 6TB50 Tow Tractor Model 6HBW30 Low Lift Pal...

Page 31: ...n 290 3 cm 53 11 in 134 9 cm Overall Width 32 5 in 82 6 cm 36 in 91 cm 32 5 in 82 6 cm Max Lift Height 9 in 22 9 cm N A Coast Travel Speed N A 3 5 mph 4 kph Max Regular Speed 3 9 mph 6 3 kph 6 0 mph 9...

Page 32: ...w Toyota Pallet Truck Service Manual General System Data 3 4 00700 CL390 04 Issued 2 February 2004 General System Data Figure 3 1 Model 6HBE30 Fork Section Grab Bar Tractor Gauge Console Battery Locat...

Page 33: ...Service Manual Systems Overview General System Data 00700 CL390 04 Issued 2 February 2004 3 5 Figure 3 2 Model 6HBC30 Fork Section Battery Location Control Handle Tractor Operator Compartment Load Wh...

Page 34: ...ol The optional Programmable Maintenance Tool P N 00590 49981 71 permits you to test diagnose and program the motor controller in this pallet truck The Programmable Maintenance Tool PMT is powered by...

Page 35: ...tor coil is de energized stopping the lift motor and pump The forks are held in position by hydraulic fluid trapped in the lift cylinders by the check valve static position of the relief valve and the...

Page 36: ...direction is applied to the drive motor Travel in forks first direction will continue until the emergency reverse switch SW7 is released When the emergency reverse mode is activated the motor controll...

Page 37: ...motor direction by manipulating the drive motor field polarity according to the directional switch inputs SW3 SW4 Throttle Control section controls the drive motor speed and torque by monitoring relat...

Page 38: ...Systems Overview Toyota Pallet Truck Service Manual 3 10 00700 CL390 04 Issued 2 February 2004 This page intentionally left blank...

Page 39: ...Toyota Pallet Truck Service Manual Scheduled Maintenance 00700 CL390 04 Issued 2 February 2004 4 1 Section 4 Scheduled Maintenance...

Page 40: ...ng the suggested intervals the intervals given in this guide are based on normal operating conditions When operating under abnormal or severe conditions perform these services more often as required t...

Page 41: ...Forks Inspect for damage bending cracking or signs of unauthorized modification Check for minimum thickness Hydraulic System Check hydraulic connections and hoses for leaks Lift Items Inspect lift cyl...

Page 42: ...truck frame Check for shorts to truck frame Check for dielectric grease when cold storage Check for correct cable tie installation General Operation Check the condition of cables and hoses Check for...

Page 43: ...ours Item Annually or Every 2000 Hour Checklist Daily Checklist Perform Daily 8 hour Checklist on Page 4 3 250 Hour Checklist Perform the Monthly 250 hour Checklist on Page 4 4 Hydraulic System Change...

Page 44: ...y 2004 Lubrication Points Figure 4 1 through Figure 4 5 show the lubrication points on the truck 4 Figure 4 1 Caster Grease Fittings 4 Figure 4 2 Upper Bell Crank Grease Fittings Between Tractor and F...

Page 45: ...anual Scheduled Maintenance Introduction 00700 CL390 04 Issued 2 February 2004 4 7 4 Figure 4 4 Load Wheel Grease Fittings and Fork Grease Fittings Top View 4 Figure 4 5 Drive Unit Grease Fittings 2 1...

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