Toyota Electric Pallet Truck 6HBW20 Service Manual PDF – Serial Number 10011-17000

Complete Guide – Toyota Electric Pallet Truck 6HBW20 Service Manual PDF S/N 10011-17000

Models / Serial Covered: 6HBW20 SN: 10011 – 17000

File Type: PDF (Digital Download)
Language: English
Device Support: Windows, Mac, iOS, Android
Download: Instant access after purchase

The Toyota Electric Pallet Truck 6HBW20 Service Manual PDF is the complete factory guide for professional maintenance, repair, and troubleshooting.

This digital manual provides step-by-step repair instructions, wiring diagrams, hydraulic system servicing, and safety guidelines. Ideal for technicians, warehouse operators, and workshop professionals, it ensures factory-standard repairs, reduces downtime, and keeps your electric pallet truck operating efficiently.

Whether you are performing routine inspections, major component repairs, or electrical diagnostics, this manual offers all the information needed for accurate and reliable maintenance.

Contents Include:
. 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