Toyota Electric Pallet Truck Type 6HBW20 Service Repair Manual (S/N: 10011-17000)

General Maintenance Instructions
Maintenance Practices
Specifications
Hydraulic
Component Identification
Standard Torque Data For Bolts
Conversion Table
Decals

Decimal Equivalent Chart
Planned Maintenance (PM)
Inspection Form
PM Schedule and Procedure
Daily Inspection
Monthly PM Service (or 100 Hrs)
Semiannual Service (or 500 Hrs)

Annual PM Service (or 1000 Hrs)
Lubrication Points
Fill Points
PM Chart
Lubrication Equivalency Chart
Scheduled Maintenance
Batteries
Battery Cleaning
Electrolyte Process

Battery Cleaning Procedure
Battery Electrical Leakage To Frame Test
Battery Charging
Charging Process
Hydrometer Use
Procedure
Voltage Check
Adding Water To Battery

Guidelines
Battery History Record
Motors
Motor Cleaning
Brush Care
Maintenance Schedule
Motor Maintenance Inspection Chart
Brush Replacement
Motor Overheating

Motor Test for Open Circuit
Motor Open Circuit Test Procedure
Short Circuit Test Motors
Short Circuit Test
Armature Shorts
Motor Grounds Test
Grounds General
Hydraulic
Oil Selection
Changing Reservoir Fluid
Power Section
Special Tools
Flush Grease Fitting Adapter
Battery-Pak Lifter
Bearing Installation Tool
Control Head Unit
Removal and Installation
Head Unit Removal
Cold Storage Requirements
Control Handle Removal
Travel Control Switches
Horn

Lift/Lower Switches
Load Wheel
Repair and Replacement
Pull Rod Bushings Removal and Replacement
Carrier Frame Linkage and Bushings
Drive Wheel
Removal
Installation
Drive Unit
Removal
Installation
Axle Seal Removal
Installation
Drive Unit Assembly
Drive Unit
Disassembly
Assembly
Drive Motor
Removal
Drive Motor Brush Replacement
Drive Motor Disassembly
Installation
Controller Assembly
Throttle Potentiometer Setting
Example
Battery Replacement
Battery Wiring Hookup
Brake
Brake Adjustment
Brake Interlock Switch
Brake Linkage Removal
Brake Linkage Installation
Brake Shoe Removal and Installation
Lift/Lower
Description
Theory of Operation
Lift

Hydraulic
Electrical
Control Circuits
Power Wring
Lower
Hydraulic and Electrical
Equipment Recommended for Normal Servicing
Pump and Motor
Removal and Installation

Pump Motor Brush Removal
Relief Valve
Removing Solenoid Valve
Installing Solenoid Valve
Removing Pump and Motor Assembly
Removing Reservoir
Removing the Pump
Installing the Pump

Installing the Reservoir
Check Valve
Cylinder Assembly Removal Installation
Cylinder Removal
Hydraulic Cylinder
Cylinder Disassembly
Inspection
Cylinder Assembly

Cylinder Installation
Lift Limit Switch
Troubleshooting
NoLi ft
Forks Do Not Lower
Forks Will Not Hold Load
Traction System
Transistor Control (Motor Controller)
Current Limiting
Low Voltage Cutback
Thermal Protection
Runaway Protection
Static Return to Neutral Protection
Plugging
Controller Keyswitch Input
Controller Thumbwheel Throttle Inputs
Emergency Reverse Plug Breaking Inhibit
Traction System Adjustments
Adjustment Panel
Potentiometer Adjustments
Theory
Preparing to Travel
Diredionalfipeed Control Forward
Directionalfipeed Control Reverse
Emergency Reverse
Contador Tip/Bar Replacement
Troubleshooting

Vehicle is dead nothing operates
No travel horn and lift/lower operates OK
No forward travel forward contador does not energize
No forward travel forward contador closed
No reverse travel reverse contactor does not energize forward travel operates

No reverse travel reverse contador closed
No Emergency Reverse
Troubleshooting
Wiring Inspection Procedure
Miscellaneous Troubleshooting
Battery Charger
Electrical Testing

Equipment Required
lnstrudions
Acceptable Charge Values
Open Circuit Voltage Test
Short Circuit Amperage Test
Testing Components
Diodes
Capacitor
Timer

Overcharging Problems
Charger and Battery not Properly Matched
Defective Battery or Poor DC Connection
Battery Charts
Controller
Description
Low Current
High Current

Adjustment Panel
Manually Adjustable Potentiometers
Programmer Connector
StatusLED
Power Wiring
Control Wiring
0-5kR Throttle (Type 3)
Plug Current in Over-Temperature

High Speed Parameter
Ramp Shap Parameter
Initial Check
Programming and Adjustment
Programming
Manual Adjustments
Current Limit Setting
Plug Current Adjustment

Acceleration Adjustment
Maintenance
Safety
Cleaning
Diagnostic History
Diagnostics and Troubleshooting
LED Diagnostics
Programmer Diagnostics
Programmer Operation

Operating Modes
Peace-of-mind Programming
Programmer Self Test
Programmer Menus
Diagnostics and Special Diagnostics Menu
Appendix
Hydraulic Schematic
Electrical Schematic
Motor Controller Specifications
Glossary
Alphabetical Index