SERVICE MANUAL Pallet Trucks 8HBW30 40,001 and up 8HBE30 40,001 and up 8HBE40 40,001 and up 8HBC30 40,001 and up 8HBC40 40,001 and up 8TB50 40,001 and up 00700-CL398-13 Issued: 6 May 2013
2013 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. 00700-CL398-13 Issued: 6 May 20131106243B
Service Manual Change History Description Page # Date 1 Split out service manual sections all 6/30/13 2 Updated Information Bulletins page 3 11/30/13 3 Updated Information Bulletins page 3 1/31/14 4 Updated Information Bulletins page 3 3/31/14 5 Updated Information Bulletins page 3 7/31/14 6 Updated Information Bulletins page 3 8/15/14
Service Information Bulletin 1 SIB BF10-003R Tractor Cover Mounting update kit Section 7 2 SIB BF10-004 Fork Crack Repair For Demanding Applications Section 7 3 SIB BR13-001 Fixed Handle Adjustable Brake Potentiometer Section 7 4 SIB BR13-002 Handle Operating Range Section 7 5 SIB CC12-002 Pre-Programmed ETAC Card No Longer Available Section 7 6 SIB CC13-001 Software Update Information and Descriptions Section 6 7 SIB CC13-005 Power Steering Software Update (V1.9) Section 6 8 SIB CC14-005 8HBC & 8TB50 Floormatt Switch Operation Section 3 & 8 9 SIB CC14-006 Power Steering Unit Repair Instructions Section 6 & 7 10 SIB CE13-003 C81 Code Steer Potentiometer Section 6 11 SIB CC13-007 Vehicle Manager and Traction Amp Software Updates Section 6 12 SIB CE14-001 Twist Grip Shimming Section 7 13 SIB CE14-002 Power Steer Handle Bezel Update Section 7 14 SIB CE14-003 Solid State Steering Potenitomenter Instructions Section 7 Technical News Brief 1 TNB-2007-07 Setting Parameters in ETAC Card Units 2 TNB-2008-02 Change To All Metric Hardware 3 TNB-2008-03 Tandem Load Wheel Block Grease Fitting 4 TNB-2008-08 Excessive Throttle Play In Neutral 5 TNB-2008-09 Steer Bearing Shimming 6 TNB-2008-14 Use of Loctite on Pinion Nut 7 TNB-2008-18 Motor Controller Overtemp Hotline Tech Tips 1 HTT-2007-11 Parameters 2 HTT-2008-04 Pinched Drive Motor Cables 3 HTT-2008-07 Using Loctite on Pinion Nut 4 HTT-2008-08 Truckcomm Software 5 HTT-2008-11 Drive Unit Tightening Sequence 6 HTT-2009-02 Rebuilding Cast style Lift cylinder 7 HTT-2009-03 Water In Grab Rail 8 HTT-2009-07 Gluing of Cushioned Floor Mat 9 HTT-2009-10 Travel Speed And Acceleration Parameters 10 HTT-2010-02 Fix For Loose Keyless Switch 11 HTT-2010-03 Curtis Handset Connection Procedure 12 HTT-2010-04 Static Return To Off; Reducing Steer Effort 13 HTT-2010-05 Parameter 24 Explained 14 HTT-2010-07 Greaseable Steer Bearing 15 HTT-2011-01 Motor Temperature Sensor Replacement 16 HTT-2011-07 Programming ETAC Card; Troubleshooting AMP LED Codes 17 HTT-2011-12 New ETAC Card Installation
Toyota Pallet Truck Service Manual Table of Contents Table of Contents Document Revision History.................................. xi 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......................................... 2-8 Fork Section........................................ 2-8 Tractor Section...................................... 2-8 Tie-Down for Transport................................... 2-9 Towing.............................................. 2-10 Without Brake Release Bolts........................... 2-10 With Brake Release Bolts............................. 2-10 Static Safety.......................................... 2-11 Welding Safety........................................ 2-12 Systems Overview...................................... 3-1 Introduction........................................... 3-2 Truck Model Identification................................ 3-3 Lift Truck Specifications.................................. 3-4 Special Tools.......................................... 3-5 Service Key........................................ 3-5 Operator Display and Programming......................... 3-6 Special Truck Mode.................................. 3-6 Hour Meter (H)...................................... 3-6 Error Codes (E)...................................... 3-6 Changing Truck Parameters (P).......................... 3-7 Service Input/Output Displays......................... 3-17 Digital Inputs/Outputs from Traction Amplifier and VM...... 3-17 Toyota FlashWare...................................... 3-20 Overview.......................................... 3-20 Requirements...................................... 3-20 Installing FlashWare on PC............................ 3-20 Connecting PC to Truck.............................. 3-20 Starting FlashWare.................................. 3-21 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)................. 4-7 Contactor Tip Inspection................................. 4-8 Grease Fittings (All Models)............................... 4-9 Grease Fittings (Trucks without Composite Bushings Only)...... 4-10 Undercarriage Pin and Bushing Inspection Points.............. 4-11 00700-CL398-13, Issued: 6 May 2013 i
Table of Contents Toyota Pallet Truck Service Manual Troubleshooting........................................ 5-1 How to Use This Section................................... 5-2 Troubleshooting Flowcharts................................ 5-3 TS1: START TROUBLESHOOTING........................ 5-3 GEN1: General Troubleshooting.......................... 5-4 END1: End of Troubleshooting Procedure................... 5-5 Electrical Troubleshooting Guidelines........................ 5-6 General............................................ 5-6 Troubleshooting the CAN Bus............................ 5-6 Shorts to Frame Test.................................. 5-9 Fuses................................................ 5-12 Test/Inspection..................................... 5-12 DC Electric Motors...................................... 5-13 DC Motor Types..................................... 5-13 Inspection......................................... 5-13 Service............................................ 5-13 Open Circuit Motor Test............................... 5-15 Grounded Motor Test................................. 5-16 Short-Circuited Armature.............................. 5-16 Short-Circuited Winding............................... 5-16 AC Electric Motors...................................... 5-17 AC Motor Type...................................... 5-17 Open Winding...................................... 5-17 Shorted Winding..................................... 5-17 Hydraulic Troubleshooting Guidelines....................... 5-18 Symptom Tables: Lift/Lower System........................ 5-19 Symptom Tables: Travel (Forward/Reverse) System........................... 5-22 Symptom Tables: Wiring System......................................... 5-27 Messages and Codes..................................... 6-1 List of Messages and Codes................................ 6-2 Traction Amplifier LED Diagnostics.......................... 6-5 Traction Amplifier Flash Codes.............................. 6-6 Caution and Error Codes.................................. 6-8 Caution Codes.......................................... 6-9 Code GATE......................................... 6-9 Code SLO.......................................... 6-9 Code Sro (C14)...................................... 6-9 Code C19.......................................... 6-10 Code HPd (C20)..................................... 6-10 Code C21.......................................... 6-10 Code C22.......................................... 6-11 Code C24.......................................... 6-11 Code C25.......................................... 6-11 Code C26.......................................... 6-12 Code C27.......................................... 6-12 Code C30.......................................... 6-12 Code C31.......................................... 6-13 Code C32.......................................... 6-13 Code C33.......................................... 6-13 Code C34.......................................... 6-14 ii 00700-CL398-13, Issued: 6 May 2013
Toyota Pallet Truck Service Manual Table of Contents Code C35......................................... 6-14 Code C36 (Model 8TB50 with Power Steer)................ 6-14 Code Lo (C41)...................................... 6-15 Code Hi (C42)...................................... 6-15 Code Hot1 (C44).................................... 6-16 Code Hot2 (C45).................................... 6-16 Code C50......................................... 6-17 Code C51......................................... 6-17 Code C52......................................... 6-17 Code C57......................................... 6-18 Code C60......................................... 6-18 Code C61......................................... 6-18 Code C62......................................... 6-19 Code C63......................................... 6-19 Code C64......................................... 6-19 Code C65......................................... 6-20 Code C66......................................... 6-20 Code C67......................................... 6-20 Code C68......................................... 6-21 Code C70......................................... 6-21 Code C71......................................... 6-21 Code C72......................................... 6-22 Code C74 (Model 8TB50 with Power Steer)................ 6-22 Code C75 (Model 8TB50 with Power Steer)................ 6-22 Code C76 (Model 8TB50 with Power Steer)................ 6-23 Code C77 (Model 8TB50 with Power Steer)................ 6-23 Code C78 (Model 8TB50 with Power Steer)................ 6-23 Code C79 (Model 8TB50 with Power Steer)................ 6-24 Code C80 (Model 8TB50 with Power Steer)................ 6-24 Code C81 (Model 8TB50 with Power Steer)................ 6-25 Code C82 (Model 8TB50 with Power Steer)................ 6-25 Code C83 (Model 8TB50 with Power Steer)................ 6-25 Code C84 (Model 8TB50 with Power Steer)................ 6-26 Code C85 (Model 8TB50 with Power Steer)................ 6-26 Code C86 (Model 8TB50 with Power Steer)................ 6-26 Code C87 (Model 8TB50 with Power Steer)................ 6-27 Code C88 (Model 8TB50 with Power Steer)................ 6-27 Code C89 (Model 8TB50 with Power Steer)................ 6-27 Code C90 (Model 8TB50 with Power Steer)................ 6-28 Code C94 (Model 8TB50 with Power Steer)................ 6-28 Error Codes.......................................... 6-29 Code E101........................................ 6-29 Code E106........................................ 6-29 Code E107........................................ 6-30 Code E108........................................ 6-30 Code E140........................................ 6-30 Code E141........................................ 6-31 Code E150........................................ 6-31 Code E157........................................ 6-31 Code E159........................................ 6-32 Code E160........................................ 6-32 Code E201........................................ 6-32 00700-CL398-13, Issued: 6 May 2013 iii
Table of Contents Toyota Pallet Truck Service Manual Code E202......................................... 6-33 Code E203......................................... 6-33 Code E220......................................... 6-33 Code E221......................................... 6-34 Code E222......................................... 6-34 Code E223......................................... 6-34 Code E224......................................... 6-35 Code E225......................................... 6-35 Code E228......................................... 6-35 Code E230......................................... 6-36 Code E232......................................... 6-36 Code E233......................................... 6-36 Code E235......................................... 6-37 Code E252......................................... 6-37 Code E253......................................... 6-37 Component Procedures.................................. 7-1 List of Component Procedures by Truck System................. 7-2 Component Locator Photos................................. 7-5 Steering and Controls.................................. 7-11 Electric Power Steering................................... 7-12 Replacing the Pinion Gear............................. 7-12 Replacing the Power Steer Unit.......................... 7-13 Learn Steer......................................... 7-13 Checking the Steer Position............................ 7-14 Steer Home Proximity Sensor (SW23)..................... 7-15 Electric Power Steer Handle and Post Assembly............. 7-16 Control Head....................................... 7-18 Control Handle - Model 8HBW30........................... 7-24 Control Handle Disassembly............................ 7-25 Changing Horn Button/Switch.......................... 7-25 Changing Lift/Lower Button............................ 7-26 Changing Push Button................................ 7-26 Spring-Loaded Handle Design - Models 8HBE30/40............. 7-27 Removal........................................... 7-27 Installation......................................... 7-28 Fixed-Position Handle Design - Models 8HBC30/40 and 8TB50.... 7-30 Removal........................................... 7-30 Installation......................................... 7-30 Control Handle Assemblies - Models 8HBE, 8HBC, and 8TB50..... 7-31 Control Head Removal................................ 7-34 Changing Horn Button/Switch.......................... 7-34 Changing Lift/Lower Switch Activator..................... 7-35 Changing the Push Button............................. 7-35 Changing the Jog Trigger Switch........................ 7-36 Changing the Jog Trigger and Spring..................... 7-36 Throttle Spring Replacement........................... 7-37 iv 00700-CL398-13, Issued: 6 May 2013
Toyota Pallet Truck Service Manual Table of Contents Drive and Brake...................................... 7-39 Drive Unit............................................ 7-40 Drive Unit Removal.................................. 7-40 Steering Bearing Removal............................. 7-42 Steering Bearing Installation........................... 7-42 Drive Unit Disassembly............................... 7-43 Drive Unit Assembly................................. 7-44 Checking the Gears.................................. 7-46 Adjusting Tooth Pattern of Drive Unit.................... 7-46 Drive Unit Installation................................ 7-47 Drive Housing Lubrication............................ 7-49 Drive Wheel.......................................... 7-50 Removal.......................................... 7-50 Cushion Tire Replacement............................ 7-50 Shim Caster Adjustment................................. 7-52 Adjustable Caster Adjustment............................ 7-53 Casters (Poly Block).................................... 7-54 Caster Removal..................................... 7-54 Wheel Replacement.................................. 7-54 Caster Installation.................................. 7-54 Casters (Spring-Loaded)................................. 7-55 Spring-Loaded Caster Removal......................... 7-55 Wheel Replacement.................................. 7-55 Caster Disassembly................................. 7-56 Caster Assembly.................................... 7-57 Wheel Installation................................... 7-57 Spring-Loaded Caster Installation....................... 7-58 Brake............................................... 7-59 Brake Removal..................................... 7-59 Brake Installation................................... 7-60 Checking the Gap................................... 7-60 Replacing the Rotor.................................. 7-60 Electrical Components................................. 7-61 Battery.............................................. 7-62 Trucks With Battery Gates and Rollers (Optional)........... 7-62 Battery Gates (Optional).............................. 7-62 Battery Rollers (Optional)............................. 7-62 Trucks Without Battery Gates and Rollers................ 7-62 Battery Exterior Cleaning............................. 7-63 Testing, Charging, and Maintenance..................... 7-64 Maintenance-Free Batteries........................... 7-64 Battery Storage..................................... 7-64 Power Cables......................................... 7-65 Wiring Harness........................................ 7-67 Wiring Harness Inspection............................ 7-67 Wiring Harness Repair............................... 7-67 AMP Water-Resistant Connectors.......................... 7-70 AMP Connector Pin Extraction......................... 7-70 AMP Connector Pin Insertion.......................... 7-71 AMP Connector Seals................................ 7-71 00700-CL398-13, Issued: 6 May 2013 v
Table of Contents Toyota Pallet Truck Service Manual AMP Harness/Traction Amplifier Connector................... 7-73 AMP Harness Connector Components..................... 7-73 AMP Harness Connector Disassembly (Contact Removal)...... 7-73 AMP Harness Connector Assembly....................... 7-74 Testing AMP Harness Connectors........................ 7-75 Brake Potentiometer (VR1)................................ 7-76 VR1 Removal....................................... 7-76 VR1 Installation..................................... 7-76 Brake Potentiometer Calibration......................... 7-77 Lift-Limit Switch (SW8)................................... 7-79 Limit Switch Adjustment.............................. 7-79 Grab Rail Switches - Model 8HBE30/40...................... 7-80 Grab Rail Switch Module Removal....................... 7-80 Grab Rail Switch Module Installation..................... 7-80 Load Backrest Switches - Model 8HBC30/40 Option............ 7-81 Removing Load Backrest Switches....................... 7-81 Installing Load Backrest Switches....................... 7-81 Hydraulic Solenoids..................................... 7-83 Jog Pick Solenoid - Model 8HBE30/40 Option................. 7-84 Jog Pick Solenoid Removal............................. 7-84 Jog Pick Solenoid Installation........................... 7-85 Jog Pick Solenoid Switch/Spring........................... 7-86 Jog Pick Switch/Spring Removal........................ 7-86 Jog Pick Switch/Spring Installation...................... 7-86 Jog Pick Canister....................................... 7-87 Jog Pick Canister Removal............................. 7-87 Jog Pick Canister Installation........................... 7-87 Jog Pick Canister Repair............................... 7-87 Traction Amplifier (TA)................................... 7-90 Traction Amplifier Removal............................. 7-90 Traction Amplifier Installation.......................... 7-91 Programming the Traction Amplifier...................... 7-91 Motors, General........................................ 7-92 Terminal Nuts...................................... 7-92 Traction Motor......................................... 7-93 Removal - Models 8HBW and 8HBE30/40................. 7-93 Installation - Models 8HBW and 8HBE30/40............... 7-94 Removal - Models 8HBC30/40 and 8TB50................. 7-95 Installation - Models 8HBC30/40 and 8TB50............... 7-97 Temperature Sensor Replacement........................ 7-99 Terminal Board Removal and Replacement................ 7-100 Speed Sensor Replacement............................ 7-101 Motor Assembly.................................... 7-103 Lift Motor............................................ 7-107 General Data...................................... 7-107 Lift Motor Removal.................................. 7-107 Lift Motor Installation................................ 7-107 vi 00700-CL398-13, Issued: 6 May 2013
Toyota Pallet Truck Service Manual Table of Contents Hydraulic Components................................ 7-109 Hydraulic Components................................. 7-110 General Guidelines................................. 7-110 Hydraulic Fluid...................................... 7-111 Checking Hydraulic Fluid Level........................ 7-111 Hydraulic Unit....................................... 7-112 Hydraulic Unit Removal............................. 7-112 Hydraulic Unit Installation........................... 7-112 Hydraulic Reservoir................................... 7-113 Removal......................................... 7-113 Installation....................................... 7-113 Filter Screen and Suction Tube........................... 7-114 Removal......................................... 7-114 Installation....................................... 7-114 Hydraulic Pump...................................... 7-115 Hydraulic Pump Removal............................ 7-115 Hydraulic Pump Installation.......................... 7-115 Adjusting Hydraulic Pump Relief Valve Pressure.............. 7-116 Checking Relief Valve Setting......................... 7-116 Alternate Method Using Rated Load on Pallets............ 7-117 Hydraulic Ram....................................... 7-118 Inspection........................................ 7-118 Hydraulic Ram Removal............................. 7-118 Hydraulic Ram Installation........................... 7-120 Hydraulic Cylinder Seals............................... 7-122 Cylinder Disassembly............................... 7-122 Cylinder Assembly................................. 7-123 Cast Hydraulic Cylinder Repair........................... 7-124 Disassembly...................................... 7-124 Assembly........................................ 7-124 Mast.............................................. 7-125 Top Linkage Subassembly.............................. 7-126 Top Link Subassembly Removal....................... 7-126 Top Linkage Subassembly Installation.................. 7-127 Pull Rod Subassembly................................. 7-129 Removal......................................... 7-129 Installation....................................... 7-130 Load Wheels......................................... 7-132 Tandem Load Wheels Models 8HBE and 8HBC........... 7-133 Suspension Wheel Model 8TB50...................... 7-134 Fork Height Adjustment................................ 7-136 Downstop Installation............................... 7-138 Downstop Adjustment............................... 7-138 Pallet Entry/Exit Enhancements....................... 7-139 00700-CL398-13, Issued: 6 May 2013 vii
Table of Contents Toyota Pallet Truck Service Manual Options........................................... 7-141 Cold Storage Conditioning............................... 7-142 Battery Spacer Kit Installation............................ 7-143 Part Selection...................................... 7-144 Installation........................................ 7-145 Battery Gate Interlock Sensors............................ 7-147 Battery Gate Interlock Sensor Replacement............... 7-147 Battery Gate Interlock Sensor Adjustment................ 7-148 Theory of Operation..................................... 8-1 Definitions............................................. 8-2 Acceleration Rate..................................... 8-2 Brake Lever Potentiometer (VR1) (Models with Fixed Position Handle) 8-2 Brake (Deadman) Switch (Models 8HBW30, 8HBE30, or 8HBE40 with Spring-Loaded Handle)................................. 8-2 Continuity.......................................... 8-2 Controller Area Network (CAN)........................... 8-2 Current Limiting...................................... 8-2 Emergency Reverse (Models 8HBW30 and 8HBE30 or 8HBE40).. 8-2 Fault Codes......................................... 8-3 High Pedal Disable (HPD)............................... 8-3 Jog Speed........................................... 8-3 Neutral Plugging Rate (Deceleration)....................... 8-3 Open Circuit......................................... 8-3 Overvoltage Cutoff.................................... 8-3 PIN-Key Code........................................ 8-3 Pulse Width Modulation................................ 8-3 Ramp Shape........................................ 8-3 Regenerative Braking.................................. 8-4 Sequencing Delay..................................... 8-4 Short Circuit or Short................................ 8-4 Speed Limiting....................................... 8-4 Static Return To Off (SRO).............................. 8-4 Thermal Cutback (Traction Amplifier)...................... 8-4 Throttle Map......................................... 8-5 Truck Off Delay (Keypad only)............................ 8-5 Undervoltage Cutoff................................... 8-5 VM (Vehicle Manager).................................. 8-5 Walking Speed....................................... 8-5 Traction System......................................... 8-6 Vehicle Manager (VM).................................. 8-6 Traction Amplifier (TA)................................. 8-6 Battery Plugged In.................................... 8-6 Key Switch ON and M1 Energized......................... 8-6 Travel Request, Tractor-First............................ 8-7 Travel Request, Forks-First.............................. 8-7 Strip Curtain Bypass (Model 8HBE30/40 only)............... 8-7 Emergency Reverse (Model 8HBW30 and 8HBE30/40)......... 8-8 Jog Mode........................................... 8-8 Jog Pick Mode....................................... 8-9 viii 00700-CL398-13, Issued: 6 May 2013
Toyota Pallet Truck Service Manual Table of Contents Lift/Lower System..................................... 8-10 Lift.............................................. 8-10 Lower............................................ 8-10 Theory of Operation - Electric Power Steering................. 8-11 Power Steering Potentiometers......................... 8-11 Floor Mat Switch (SW25) - Model 8TB50 option............. 8-11 Travel Speed Reduction............................... 8-11 PSU: Power Steering Unit............................. 8-11 Steering.......................................... 8-12 Pinout Matrix......................................... 8-13 Appendix............................................. A-1 Lubrication Equivalency Chart............................. A-2 Thread Adhesives, Sealants, and Lubricants................... A-3 Adhesives............................................. A-4 Component Specific Service/Torque Chart.................... A-5 Torque Chart - Standard (Ferrous).......................... A-8 Torque Chart - Standard (Brass)............................ A-9 Torque Chart - Metric................................... A-10 Torque Chart - Thread-Forming Screws..................... A-11 Torque Chart - Hydraulic Fittings.......................... A-12 Torque Chart - Straight Thread Face Seal O-Rings............. A-13 Decimal Equivalent Chart................................ A-14 Standard/Metric Conversions............................. A-16 List of Electrical Symbols................................ A-18 Schematics......................................... A-21 Electrical Schematics................................... A-23 Power Distribution Diagram.............................. A-30 Hydraulic Schematic................................... A-31 Index................................................ I-1 00700-CL398-13, Issued: 6 May 2013 ix
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