Toyota 6HBW30 User manual

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

1019035A
© 2004 by Toyota Industrial Equipment
All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other
means, including photocopying, 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 of the publication
date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any
errors that may appear in the manual.

Toyota Pallet Truck Service Manual How To Use This Manual
00700-CL390-04, Issued: 2 February 2004 iii
Section 1. How To Use This Manual
Table of Contents
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Fork Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Programmable Maintenance Tool . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Lift/Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Directional/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
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General Truck Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Perform Daily or Every Eight (8) Operating Hours . . . . . . . . . . . . 4-3
Perform Every Two Months or 250 Operating Hours . . . . . . . . . . 4-4
Perform Annually or Every 1500 Operating Hours . . . . . . . . . . . . 4-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Checking for Shorts from Battery to Truck Frame . . . . . . . . . . . . 5-3
Checking for Shorts from Components to Truck Frame . . . . . . . . 5-4
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Acceleration Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Brake Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Emergency Reverse

How To Use This Manual Toyota Pallet Truck Ser vice Manual
iv 00700-CL390-04, Issued: 2 February 2004
(6HBW30 and 6HBE30/40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
High Pedal Disable (HPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Overtemperature (Motor Controller) . . . . . . . . . . . . . . . . . . . . . . . 5-7
Overvoltage Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Plugging (Plug Braking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Ramp Shape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Sequencing Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Short Circuit or “Short” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Static Return To Off (SRO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Throttle Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Undertemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Undervoltage Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Programmable 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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Symptom Tables: Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Symptom Tables: Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tractor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Trucks Equipped with Battery Gates and Rollers (optional) . . . . . . 6-8
Trucks Without Battery Gates and Rollers . . . . . . . . . . . . . . . . . . 6-9
Battery Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Maintenance-Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Battery/Charger/Truck Connectors . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Toyota Pallet Truck Service Manual How To Use This Manual
00700-CL390-04, Issued: 2 February 2004 v
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Test/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Test/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Lift Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Grab Rail Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Hydraulic 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 Spring Adjustment
6HBW30, 6HBE30 and 6HBE40 . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Emergency Reverse Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Travel Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Main Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Models 6HBW30, 6HBE30, and 6HBE40. . . . . . . . . . . . . . . . . . 6-35
Models 6HBC30, 6HBC40, and 6TB50 . . . . . . . . . . . . . . . . . . . 6-36
Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Motor Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

How To Use This Manual Toyota Pallet Truck Ser vice Manual
vi 00700-CL390-04, Issued: 2 February 2004
Terminal Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Tooth Pattern of Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Drive Unit Vent Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Drive Housing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Drive Housing Steering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Load Wheels
Model 6TB50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Pallet 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 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Changing Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . . 6-72
Relief Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Hydraulic Cylinder Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Filter Screen and Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Toyota Pallet 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
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

How To Use This Manual Toyota Pallet Truck Ser vice Manual
viii 00700-CL390-04 Issued: 2 February 2004
This page intentionally left blank.

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

How to Use This Manual Toyota Pallet Truck Service Manual
Map of the Manual
1-2 00700-CL390-04, Issued: 2 February 2004
Map of 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
General System
Data
Component
Location Photos
Alphabetical List
of Component
Procedures
Planned
Maintenance
Trouble-
shooting

Toyota Pallet Truck Service Manual How to Use This Manual
Manual Design
00700-CL390-04, Issued: 2 February 2004 1-3
Manual Design
The Toyota Pallet Truck 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:
• Name of the manual
(Toyota Pallet Truck Service Manual)
• Current Chapter Title
(for example, this page How to Use This
Manual)
• Current topic
(for example, this page Manual Design)
It is recommended that you go to the START
page for guidance to the correct chapter.
•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
services to keep your 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.
• Chart “TS1: START
TROUBLESHOOTING” on page 5-22
will guide you to the individual
troubleshooting symptom chart you
need.
• When you’re familiar with the
symptoms listed, you may instead
simply find the symptom chart. See
“List of Troubleshooting Charts” on
page 5-19.
• When you complete a troubleshooting
procedure, be sure to follow the steps in
chart “END1: End of Troubleshooting
Procedure” on page 5-24.
•Component Procedures gives
step-by-step procedures for testing,
removal, installation, and adjustment of
individual truck components. Components
are listed in an order which considers:
• Frequency of attention
• Physical attachment (for example,
brake must be removed before drive
motor)
• Functional relation (for example, drive
motor and drive unit components are
grouped together)
To find a component procedure, you may
use one of three methods:
• Look up the component name in the
“List of Component Procedures” on
page 6-2.
• Find the component in the
“Component Locators” on page 6-5.
• Look up the component name in the
maintenance manual Index.
•Appendix contains reference information
such as torque values, lubricants and
schematics.
•Index lists subjects alphabetically.

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

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

How To Use This Manual Toyota Pallet Truck Ser vice Manual
START Page
1-6 00700-CL390-04, Issued: 2 February 2004
1
START: Why are you here?
Go to Chart
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
"Planned Maintenance"
Go to Chapter 5
"Troubleshooting"
Yes
Yes
Yes
List of Troubleshooting Charts
START Troubleshooting
To review safety
precautions?

Toyota Pallet Truck Service Manual How To Use This Manual
START Page
00700-CL390-04, Issued: 2 February 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 the
"Appendix"
Go to the Index
Yes
Yes
No
Alphabetical List of
Component Procedures
Component Locator

How To Use This Manual Toyota Pallet Truck Ser vice Manual
1-8 00700-CL390-04 Issued: 2 February 2004
This page intentionally left blank.

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

Safety Toyota Pallet Truck Service Manual
Definitions
2-2 00700-CL390-04, Issued: 2 February 2004
Definitions
Throughout this 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 hazardous
situation exists that, if not avoided,
could result in minor or moderate injury
or in damage to the truck or nearby
objects.

Toyota Pallet Truck Service Manual Safety
General Safety
00700-CL390-04, Issued: 2 February 2004 2-3
General Safety
Do not operate or work on this truck unless you
are trained, qualified and authorized to do so.
Know the truck’s controls and what 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 and disconnect the truck’s
battery connector (unless this manual tells you
otherwise).
Do not wear watches, rings, or jewelry when
working on this truck.
Follow the scheduled lubrication, maintenance
and inspection steps.
223L6S008
2O-6
2O-7
2S-1
2
2

Safety Toyota Pallet Truck Service Manual
General Safety
2-4 00700-CL390-04, Issued: 2 February 2004
Follow exactly the safety and repair instructions
in this manual. Do not take “shortcuts.”
Do not 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 this truck indoors.
Do not wash this truck with a hose.
Do not add to or modify this truck until you
contact your local Toyota Dealer to receive
written manufacturer approval.
2
223L6S012
2
2O-63