Toyota 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40 Service Manual

...

SERVICE MANUAL

Pallet Trucks

8HBW30 8HBE40 8HBC40

36,001 and up

8HBE30 8HBC30 8TB50

36,001 and up

00700-CL398-07, Issued: 9 August 2007

Toyota Pallet Truck Service Manual Table of Contents

Table of Contents

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Abbreviations & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Static Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Maximum Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-3

Every 180 Days or 500 Deadman Hours . . . . . . . . . . . . . . . . . . . . . . 4-4

Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . . 4-6

Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

How to Use This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3

DC Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

AC Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-10

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Operator Display and Programming . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Service Input/Output Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Traction Power Amplifier LED Diagnostics . . . . . . . . . . . . . . . . . . . . 5-26

Traction Power Amplifier Flash Codes . . . . . . . . . . . . . . . . . . . . . . . 5-27

Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Caution and Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . 5-59

Symptom Tables: Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Tractor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

00700-CL398-07, Issued: 9 August 2007 i

Table of Contents Toyota Pallet Truck Service Manual

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Key Switch (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Brake (Deadman) Switch (SW2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Lift-Limit Switch (SW8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Grab Rail Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Hydraulic Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Jog Pick Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

AMP Harness/Traction Power Amplifier Connector . . . . . . . . . . . . . 6-27

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Control Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

Casters (Torsion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

Casters (Spring-Loaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69

Pallet Entry Sliders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72

Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

Adjusting Hydraulic Pump Relief Valve Pressure . . . . . . . . . . . . . . . 6-77

Hydraulic Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89

Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . . A-6

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

ii 00700-CL398-07, Issued: 9 August 2007

Toyota Pallet Truck Service Manual How To Use This Manual

Section 1. How To Use This Manual

00700-CL398-07, Issued: 9 August 2007 1-1

Toyota Pallet Truck Service Manual

Map of the Manual

Table of Contents

and Page

Revision Record

How to Use This

Manual

Safety

Map of the Manual

Manual Design

Start Page

Systems

Overview

Scheduled

Maintenance

Trouble-

Shooting

Component

Procedures

Appendix

Vehicle

Specifications

General System

Data

Theory of

Operations

Alphabetical List

of Component

Procedures

Component

Locator Photos

Electrical &

Hydraulic T.S.

Guidelines

Definitions

Control Handle

Display &

Programming

Fault Codes &

Caution & Error

Codes

Index

Troubleshooting

Charts and

Symptom Tables

1Map.wmf

00700-CL398-07 Issued: 9 August 2007 1-2

Toyota Pallet Truck Service Manual How To Use This Manual

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 thru 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 section title (for example, this page How to Use This Manual)

• Current topic (for example, this page Manual Design)

We suggest you get in the habit of turning to the START page first when you use this manual.

•The START page asks a few questions to guide you to the correct section.

How to Use This Manual explains the manual format and contains the START page.

Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding.

• The section “Caution and Error Codes”

on page 5-33 defines the various codes displayed on the operator display.

•The chart “TS1: START TROUBLESHOOTING” on page 5-29 will guide you to the symptom chart you need.

• When you’re familiar with the symptoms listed, you may simply look up the symptom from the “Troubleshooting” on page 5-29.

• As you work with a troubleshooting chart, code, or table, you may be instructed to test various electrical connector pins. The pinout matrix chart lists information on functions and normal voltages of terminals and harness connector pins. See “Pinout Matrix” on page 5-69.

• When you complete a troubleshooting procedure, perform the steps in the

“END1: End of Troubleshooting Procedure” on page 5-31.

Component Procedures gives step-by-step

procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order that considers:

• Frequency of attention

• Physical attachment (for example, remove the brake before the traction motor)

• Functional relation (for example, traction motor and drive unit components are grouped together)

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 fault, caution, and error codes, charts and tables designed to take you from a symptom to a specific sequence of actions in order to isolate a failing component.

•The chart “Traction Power Amplifier Flash Codes” on page 5-27 will guide you thru the flash codes displayed on the LED’s installed on the TA.

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 Locator Photos” on page 6-5.

• Look up component name in the “Index”.

Appendix contains reference information such as torque values, lubricants, and schematics.

Index lists subjects alphabetically.

00700-CL398-07, Issued: 9 August 2007 1-3

How To Use This Manual Toyo ta Pallet Truck Service Manual

Abbreviations & Symbols

These abbreviations, acronyms and symbols are used in this manual.

Term/Symbol Definition Term/Symbol Definition

AAmpere AC Alternating Current amp Ampere or amplifier ANSI American National Standards

Institute approx approximately aux auxiliary AWG American Wire Gauge

BSOC Battery State-of-Charge

CAN Controller Area Network CCW counterclockwise cm centimeter COP Computer Operating Program CV checkvalve CW clockwise

DC Direct Current DGND digital ground

EE UL Electric Truck Type

Certification Rating where

electrical equipment is completely

enclosed ESD Electrostatic Discharge ETAC Electronic Tiller Arm Control (See

Vehicle Manager)

ft. foot or feet

gal. gallon or gallons Gnd ground

km/hr kilometers per hour kPa kilo Pascal

lb. pound or pounds LED Light Emitting Diode L/H Load Holding L/L Lift/Lower

mA milliampere

mm millimeter mph miles per hour ms millisecond(s)

N/A Not Applicable or Not Available N•m newton meter

OD Operator’s Display OSHA Occupational Safety and Health

Administration

oz. ounce

pot potentiometer psi pounds per square inch PWM Pulse Width Modulation P/N Part Number

RAM Random Access Memory RCFP Relay Control Fuse Panel ROM Read Only Memo ry RPM Revolutions per Minute R/R Remove and Replace

HD hours on deadman

in. inch or inches

kg kilogram(s)

SOL Solenoid spec specification SPI Service Port Interface

1-4 00700-CL398-07, Issued: 9 August 2007

Toyota Pallet Truck Service Manual How To Use This Manual

Abbreviations & Symbols

Term/Symbol Definition

TPA Traction Power Amplifier temp Temperature TM Traction Motor TS troubleshoot UL Underwriters Laboratories, Inc. V Volt or Volts VAC Volts Alternating Current VDC Volts Direct Current VM Vehicle Manager (ETAC)

wrt with respect to

@at ™ trademark © copyright + plus or positive – mi nus or negative ± plus or minus ° degrees °F degrees Fahrenheit °C degrees Celsius < less than > greater than % percent = equals

00700-CL398-07, Issued: 9 August 2007 1-5

Toyota Pallet Truck Service Manual How To Use This Manual

START Page

Section 1. How To Use This Manual

START Page

START: Why are you here?

Go to Section 2

To review safety

precautions?

Yes

"Safety"

To examine

specifications or

theory of

operations?

To do scheduled

maintenance?

To troubleshoot

a problem?

Yes

Go to Section 3

"Systems Overview"

Go to Section 4

"Scheduled Maintenance"

Go to Section 5

"Troubleshooting"

List of Caution and Error

Codes

Go to Chart

START-2

START Troubleshooting

1Startpg1.wmf

00700-CL398-07, Issued: 9 August 2007 1-7

How To Use This Manual Toyo ta Pallet Truck Service Manual

START Page

START-2

To test,

inspect, adjust,

remove/install a

component?

To find general

reference

information?

To locate

an object or

procedure by

name?

Yes

Go to Section 6

"Component Procedures"

Go to the

"Appendix"

Go to the Index

Alphabetical List of

Component Procedures

Component Locator

1Startpg2.wmf

1-8 00700-CL398-07, Issued: 9 August 2007

Toyota Pallet Truck Service Manual Safety

Section 2. Safety

00700-CL398-07, Issued: 9 August 2007 2-1

Safety Toyot a Pallet Truck Service Manual

Definitions

In this manual, you will see two kinds of safety reminders:

A warning specifies a potentially hazardous situation that, if not prevented, could result in death or serious injury.

A caution specifies a potentially hazardous situation that, if not avoided, could result in minor or moderate injury or in damage to the lift truck or nearby objects. A caution can also alert against unsafe practices.

2-2 00700-CL398-07, Issued: 9 August 2007

Toyota Pallet Truck Service Manual Safety

General Safety

Do not operate or work on this truck unless you are trained, qualified and authorized to do so, and have read the Owner/Operator Manual.

Know the truck’s controls and what they do.

Operate this truck only from the operator’s position.

2O-7.eps

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 operate this truck if it needs repair or if it is in any way unsafe.

2O-6.eps

2S-1.eps

Do not wear watches, rings, or jewelry when working on this truck.

21864 067.eps

00700-CL398-07, Issued: 9 August 2007 2-3

Safety Toyot a Pallet Truck Service Manual

General Safety

Obey the scheduled lubrication, maintenance, and inspection steps.

2Schedmnt.eps

Obey exactly the safety and repair instructions in this manual. Do not take “shortcuts.”

Do not use an open flame near the truck.

Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor.

2Spills.eps

Always park this truck indoors.

2O-63.eps

Do not park this truck in a cold storage area overnight.

223L6S012.eps

Do not use gasoline or other flammable liquids

Do not wash this truck with a hose.

for cleaning parts.

2-4 00700-CL398-07, Issued: 9 August 2007

+ 32 hidden pages