Toyota 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50 Pallet Truck and Tow Tractor Service Manual

Name: Toyota 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50 Pallet Truck and Tow Tractor Service Manual
Brand: MidWestTech
SKU: 00700-CL398-09
Price: 69.51 USD
Availability: InStock

281 pages · Publication 00700-CL398-09

$69.51

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Models: 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50
Serial coverage: 40001 and up
Manual type: Service Manual
Pages: 281
Publication: 00700-CL398-09
Condition: Brand new

Toyota 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50 Pallet Truck and Tow Tractor Service Manual, publication 00700-CL398-09

What's inside

From the manual's own table of contents: 13 sections, 489 entries. See sample pages (PDF, 470 KB)

Search the contents

General1 topic

Document Revision History

Service Bulletins List

Product Improvement Notices List

Section 1. How To Use This Manual4 topics

Map of the Manual
Manual Design
Abbreviations & Symbols
START Page

Section 2. Safety12 topics

Definitions
General Safety
Battery Safety
Jacking Safety
- Tractor Section
- Fork Section
Tie-Down for Transport
Figure 2-1. Tie-Down for Transport
Towing
Static Safety
Figure 2-2. Anti-Static Kit (P/N 1-187-059) With Wrist Strap and Mat
Welding Safety

Section 3. Systems Overview48 topics

Introduction
Truck Model Identification
Figure 3-1. Model 8HBW30 Low Lift Walk-Behind
Figure 3-2. Model 8HBE30/40 End Rider
Figure 3-3. Model 8HBC30/40 Center Rider
Figure 3-4. Model 8TB50 Tow Tractor
Lift Truck Specifications
Figure 3-5. Lift Truck Specification Plate - Models 8HBW, 8HBE, and 8HBC Pallet Trucks
Figure 3-6. Lift Truck Specification Plate - Model 8TB50 Tow Tractor
General System Data
Figure 3-7. Model 8HBE30/40 (Long-John Forks Shown)
Figure 3-8. Model 8HBE30/40 Control Handle
Special Tools
- Service Key
Figure 3-9. Service Key
Operator Display and Programming
Figure 3-10. Operator Display
- Special Truck Mode
- Hour Meter (H)
- Error Codes (E)
- Changing Truck Parameters (P)
- Service Input/Output Displays
Figure 3-11. Service Key Connection Point
Figure 3-12. Operator Display
- Digital Inputs/Outputs from Traction Amplifier and VM
Toyota FlashWare
- Overview
- Requirements
- Installing FlashWare on PC
- Connecting PC to Truck
- Starting FlashWare
Figure 3-13. Truck Opening Screen with Menu
- Configuration and Truck Setup Options
Figure 3-14. Typical Truck Setup Screen
- Changing Truck Parameters
Figure 3-15. Change Parameter
Figure 3-16. Send Changes Button
- Software Management
Figure 3-17. Truck Setup Screen Software Button
Figure 3-18. Truck Software Window
- Erase Vehicle Manager
Figure 3-19. Erase Vehicle Manager Software Screen
- Reset Defaults
- Diagnostics
- Error Log
- RE_Read Truck Settings
- SAVE Settings to File
- SEND Changes to Truck

Section 4. Planned Maintenance13 topics

Maintenance Guidelines
Initial 90 Day/250 Deadman Hours (HD) Maintenance
Every 180 Days or 500 Deadman Hours
Every 360 Days or 2000 Deadman Hours (HD)
Contactor Tip Inspection
Grease Fittings (All Models)
Figure 4-1. Caster Grease Fittings
Figure 4-2. Load Wheel Grease Fittings
Grease Fittings (Trucks without Composite Bushings Only)
Figure 4-3. Upper Bell Crank Grease Fittings (Between Tractor and Fork Section)
Figure 4-4. Lower Bell Crank Grease Fittings-left side shown (Between Tractor and Fork Section)
Figure 4-5. Lower Bell Crank Grease Fittings-left side shown (Between Tractor and Fork Section)
Figure 4-6. Fork Grease Fittings (Top View)

Section 5. Troubleshooting33 topics

How to Use This Section
Troubleshooting Flowcharts
- TS1: START TROUBLESHOOTING
Figure 5-1. TS1: START TROUBLESHOOTING
- GEN1: General Troubleshooting
Figure 5-2. GEN1: General Troubleshooting
- END1: End of Troubleshooting Procedure
Figure 5-3. END1: End of Troubleshooting Procedure
Electrical Troubleshooting Guidelines
- Troubleshooting the CAN Bus
- Shorts to Frame Test
Fuses
Figure 5-4. Fuse Location
- Test/Inspection
DC Electric Motors
- DC Motor Types
Figure 5-5. Motor Circuits
- Inspection
- Service
- Open Circuit Motor Test
- Grounded Motor Test
- Short-Circuited Armature
- Short-Circuited Winding
AC Electric Motors
- AC Motor Type
Figure 5-6. AC Traction Motor circuit - Phase A
Figure 5-7. AC Traction Motor circuit - Phase B
- Open Winding
- Shorted Winding
Hydraulic Troubleshooting Guidelines
Symptom Tables: Lift/Lower System
Symptom Tables: Travel (Forward/Reverse) System
Symptom Tables: Wiring System

Section 6. Messages and Codes8 topics

List of Messages and Codes
Traction Amplifier LED Diagnostics
Figure 6-1. Traction Amplifier Status Indicator LED
Traction Amplifier Flash Codes
Caution and Error Codes
Figure 6-2. Operator Display
Caution Codes
Error Codes

Section 7. Component Procedures295 topics

List of Component Procedures by Truck System
Component Locator Photos
Figure 7-1. Inside Tractor, Rear View
Figure 7-2. Inside Tractor, Right Side
Figure 7-3. Inside Tractor, Left Side
Control Handle - Model 8HBW30
Figure 7-4. Model 8HBW30 Control Head Assembly - Exploded View
- Control Handle Disassembly
- Changing Horn Button/Switch [26, 27]
Figure 7-5. Horn Button Removal
- Changing Lift/Lower Button [22]
Figure 7-6. Lift/Lower Button Removal
- Changing Push Button [19]
Figure 7-7. Push Button Removal
Spring-Loaded Handle Design
- Removal
Figure 7-8. Control Handle Base Cover Removal
Figure 7-9. Control Handle Wire Harness
Figure 7-10. Remove Jam Nut at Coast Link
Figure 7-11. Return Spring Rod Removal
- Installation
- Return Spring Adjustment
Figure 7-12. Return Spring Adjustment
Fixed-Position Handle Design - Models 8HBC30/40 and 8TB50
- Removal
- Installation
Control Handle Assemblies - Models 8HBE, 8HBC and 8TB50
Figure 7-13. Control Handle and Head Assembly - Model 8HBE30/40
Figure 7-14. Control Handle with Hand Brake - Model 8HBC30/40 and 8TB50 (Fixed Handle)
Figure 7-15. Control Handle with Deadman Brake - Model 8HBC30/40 and 8TB50 (Spring-Loaded Handle)
Figure 7-16. Control Head Assembly (Models 8HBE30/40, 8HBC30/40, and 8TB50) - Exploded View
- Control Head Removal
- Changing Horn Button/Switch [24]
Figure 7-17. Horn Button Removal
- Changing Lift/Lower Switch Activator [14]
Figure 7-18. Lift/Lower Button Removal
- Changing the Push Button [3]
Figure 7-19. Push Button Removal
Figure 7-20. Handle with Jog Option
- Changing the Jog Trigger Switch [44]
- Changing the Jog Trigger and Spring
Drive Unit
- Removal
Figure 7-21. Drive Unit Fill Plug
Figure 7-22. Drive Unit Drain Plug
Figure 7-23. Drive Unit Mounting (Traction Motor Removed)
Steering Bearing
- Removal
Figure 7-24. Drive Unit (Shown installed in Tractor Frame)
Figure 7-25. Drive Unit Bottom View
Figure 7-26. Drive Unit, Steering Bearing Removed
- Installation
Figure 7-27. Main Case Cover, Six Hole-Type, Installed
Figure 7-28. Gear Housing and Cover
- Gear Assembly
Figure 7-29. Lower Drive Unit, Cross-Sectional View
- Checking the Gears
- Adjusting Tooth Pattern of Drive Unit
Figure 7-30. Drive Unit Gear Tooth Pattern
- Installation
Figure 7-31. Drive Unit Gauge and Shimming Locations
Figure 7-32. Drive Unit Mounting Screw Torque Sequence
Figure 7-33. Drive Unit Drain Plug
- Drive Housing Lubrication
Drive Wheel
- Removal
Figure 7-34. Drive Wheel and Tire
- Cushion Tire Replacement
Figure 7-35. Cushion Tire Replacement
Caster Adjustment
Casters (without Springs)
- Caster Removal
Figure 7-36. Removing Caster Wheel Assembly
- Wheel Replacement
Figure 7-37. Caster Assembly, Disassembled
- Caster Assembly
Figure 7-38. Caster Assembly, Assembled
- Caster Installation
Figure 7-39. Securing Caster To Tractor
Casters (Spring-Loaded)
- Removal
Figure 7-40. Removing Spring-Loaded Caster
- Wheel Replacement
Figure 7-41. Removing Tension Pin
Figure 7-42. Removing Axle Shaft
Figure 7-43. Removed Wheel and Shims
- Caster Disassembly
Figure 7-44. Compressing Caster Springs
Figure 7-45. Relieving Pivot Tension
Figure 7-46. Removing Pivot Pin Retainer Screw
Figure 7-47. Removing Pivot Pin
Figure 7-48. Separated Caster
- Caster Assembly
Figure 7-49. Removing Bolts from Springs
- Wheel Installation
Figure 7-50. Installing New Wheel
Figure 7-51. Installing Axle Shaft
Figure 7-52. Installing Tension Pin
- Caster Installation
Figure 7-53. Caster, Shims and Mounting Bolts
Figure 7-54. Securing Caster To Tractor
Brake
- Spring-Loaded Handle
Figure 7-55. Brake Release Bolt Storage Location
- Removal
Figure 7-56. Brake Release Bolts, Installed
Figure 7-57. Brake Release Bolts, Installed
- Installation
- Checking the Gap
Figure 7-58. Measuring Brake Gap
- Replacing the Rotor
Battery
- With Battery Gates and Rollers (Optional)
- Battery Gates (Optional)
- Battery Rollers (Optional)
- Without Battery Gates and Rollers
- Battery Exterior Cleaning
Figure 7-59. Battery Filler Plugs and Vent Holes
- Testing, Charging, and Maintenance
- Maintenance-Free Batteries
- Storage
Power Cables
- Power Cable Repair
Figure 7-60. Short Barrel Terminal
Figure 7-61. Long Barrel Terminals
Wiring Harness
- Terminology
- Inspection
- Repair
- Soldering Procedures
AMP Water-Resistant Connectors
Figure 7-62. AMP Water-Resistant Connector
- Pin Extraction
Figure 7-63. AMP Pin Extraction
Figure 7-64. Removing Wire
- Pin Insertion
Figure 7-65. Wire Seal
Figure 7-66. Wire Insertion
- Seals
Figure 7-67. Sealing Plug
Figure 7-68. Interface Seal
Figure 7-69. Latching AMP Connector
AMP Harness/Traction Amplifier Connector
- Connector Components
Figure 7-70. JPT1 Connector Components
- Disassembly (Contact Removal)
Figure 7-71. AMP Connector (JT1 or JL1)
- Contact Insertion
- Assembly
Figure 7-72. Contact Insertion
Figure 7-73. Wedge Lock Latches
Figure 7-74. Wedge Lock Flush With Housing
- Testing
Brake Potentiometer (VR1)
- Removal
Figure 7-75. Pot Cover Screw Locations
Figure 7-76. Brake Control Assembly - Exploded View
- Installation
Lift-Limit Switch (SW8)
Figure 7-77. Lift-Limit Switch
- Adjustment
Grab Rail Switches - Model 8HBE30/40
- Removal
Figure 7-78. Grab Rail Switch Removal, Left Side
Figure 7-79. Grab Rail Switch Removal, Right Side
- Installation
Hydraulic Solenoids
Figure 7-80. Hydraulic Solenoids (typical unit)
Jog Pick Solenoid - Model 8HBE30/40 Option
- Removal
Figure 7-81. Jog Pick Solenoid Location
Figure 7-82. Socket Head Cap Screws
Figure 7-83. Removed Solenoid Mechanism
- Installation
Figure 7-84. Install Ball Bearings
- Jog Pick Solenoid Switch/Spring
- Jog Pick Canister
Figure 7-85. Canister Spacing
- Repair
Figure 7-86. Special Compression Tool
Figure 7-87. Cylinder Secured In Hydraulic Press
Figure 7-88. Removing Snap Ring
Figure 7-89. Jog Pick Canister Components
Figure 7-90. Assembling Coast PRO Canister
Traction Amplifier
Figure 7-91. Traction Amplifier Location
- Removal
Figure 7-92. Removing the Traction Amplifier
- Installation
- Programming
Motors, General
- Terminal Nuts
Figure 7-93. Traction Motor Terminal Connections
Figure 7-94. Lift and Auxiliary Motor Terminal Nuts
Traction Motor
- Removal
Figure 7-95. Control Handle Base Cover Removal
Figure 7-96. Control Handle Base Cover Removal
Figure 7-97. Traction Motor Power Cables
Figure 7-98. Traction Motor Removal
Figure 7-99. Drive Unit Pinion Gear
- Installation
Figure 7-100. Main Case Location
Lift Motor
- General Data
- Removal
Figure 7-101. Bolts Securing Motor To Adapter
Figure 7-102. Separated Reservoir and Motor (typical)
- Installation
Figure 7-103. Coupling Cavity
Figure 7-104. Indexing Pin
Hydraulic Components
- General Guidelines
Figure 7-105. Hydraulic Unit (typical shown)
Hydraulic Fluid
- Checking Hydraulic Fluid Level
Hydraulic Unit
- Removal
Figure 7-106. Hydraulic Unit (typical shown)
- Installation
Hydraulic Reservoir
- Removal
Figure 7-107. Adapter Cap Screws
Figure 7-108. Removed Reservoir
- Installation
Filter Screen and Suction Tube
- Removal
Figure 7-109. Pump Housing Components
Figure 7-110. Cleaning Filter Screen
- Installation
Hydraulic Pump
- Removal
Figure 7-111. Pump and Adapter Body
- Installation
Figure 7-112. Pump Drive Coupling
Figure 7-113. Installing Pump In Adapter
Adjusting Hydraulic Pump Relief Valve Pressure
Figure 7-114. Checking Relief Valve Pressure
- Checking Relief Valve Setting
- Alternate Method Using Rated Load on Pallets
Hydraulic Ram
- Inspection
- Removal
Figure 7-115. Removing Lower Bell Crank Pins
Figure 7-116. Disconnecting Upper Clevis Brackets
Figure 7-117. Hydraulic Ram Area, Forks Removed
Figure 7-118. Hydraulic Line Connection
Figure 7-119. Vent Hose Connections
- Installation
Figure 7-120. Hydraulic Ram Removal/Installation
Figure 7-121. Hydraulic Line Connection (installed)
Hydraulic Cylinder Seals
- Disassembly
Figure 7-122. Remove Outer Spiral Lock Ring
Figure 7-123. Remove the Spacer
Figure 7-124. Remove Head Lock Ring From Cylinder
Figure 7-125. Rod and Head Assembly Out of Cylinder
Figure 7-126. Remove the Piston Jam Nut
Figure 7-127. Piston Rod Components
- Assembly
Figure 7-128. Correct Piston Seal Orientation
Figure 7-129. Securing Piston Jam Nut
Figure 7-130. Installing the Head Lock Ring
Figure 7-131. Installing the Outer Lock Ring
Top Linkage Subassembly
- Removal
Figure 7-132. Blocking Fork Section
Figure 7-133. Removing Lower Bell Crank Pins
Figure 7-134. Disconnecting Upper Clevis Brackets
Figure 7-135. Hydraulic Ram Area, Forks Removed
- Installation
Figure 7-136. Hydraulic Ram Area, Installation
Pull Rod Subassembly
- Removal
Figure 7-137. Blocking Fork Section
Figure 7-138. Removing Lower Bell Crank Pins
Figure 7-139. Eccentric Pin and Retaining Screw
Figure 7-140. Machined Fork Trail Assembly
Figure 7-141. Machined Fork Trail Assembly
- Installation
Figure 7-142. Hydraulic Ram Removal/Installation
Load Wheel Suspension - Model 8TB50
- Removal
Figure 7-143. Model 8TB50 Load Wheel Suspension - Exploded View
- Installation
Fork Height Adjustment
Figure 7-144. Fork Height Adjustment at Lower Bell Crank
- Measurement
Figure 7-145. Measure Fork Height at Load Wheel
Figure 7-146. Measure Fork Height at Battery Compartment
- Adjustment
Figure 7-147. Eccentric Pin Adjustment
Figure 7-148. Eccentric Pin Height Reference
Figure 7-149. Downstop adjustment
Cold Storage Conditioning

Section 8. Theory of Operation42 topics

Acceleration Rate
- Brake Lever Potentiometer (VR1) (Models with Fixed Position Handles)
- Brake (Deadman) Switch (Models with Spring-Loaded Handle)
Figure 8-1. Brake (Deadman) Switch and Brake Actuation
- Continuity
- Controller Area Network (CAN)
- Current Limiting
- Deceleration (Neutral Braking)
- Emergency Reverse (Models 8HBW30 and 8HBE30 or 8HBE40)
- Fault Codes
- High Pedal Disable (HPD)
- Jog Speed
- Open Circuit
- Overvoltage Cutoff
- PIN-Key Code
- Pulse Width Modulation
- Ramp Shape
- Regenerative Braking
- Sequencing Delay
- Short Circuit or “Short
- Speed Limiting
- Static Return to Off (SRO)
- Thermal Cutback (Traction Amplifier)
- Throttle Map
- Truck Off Delay (Keypad only)
- Undervoltage Cutoff
- VM (Vehicle Manager)
Traction System
- Vehicle Manager (VM)
- Traction Amplifier (TA)
- Battery Plugged In
- Key Switch ON and M1 Energized
- Travel Request, Tractor-First
- Travel Request, Forks-First
- Strip Curtain Bypass (Model 8HBE30/40 only)
- Emergency Reverse (Model 8HBW30 and 8HBE30/40)
- Jog Mode
- Jog Pick Mode
Lift/Lower System
- Lift
- Lower
Pinout Matrix

Section A. Appendix19 topics

Lubrication Equivalency Chart
Thread Adhesives, Sealants, and Lubricants
Component Specific Service/Torque Chart
Torque Chart - Standard (Ferrous)
Torque Chart - Standard (Brass)
Torque Chart - Metric
Torque Chart - Thread-Forming Screws
Decimal Equivalent Chart
Standard/Metric Conversions
List of Electrical Symbols
Electrical Schematics
- Figure A-1. Model 8HBW30 Standard
- Figure A-2. Model 8HBE30/40 Standard
- Figure A-3. Model 8HBC30/40 Standard
- Figure A-4. Model 8TB50 Standard
- Figure A-5. Options
- Figure A-6. Component Legend
- Power Distribution Diagram
- Hydraulic Schematic

Section I. Index

Class III repair manual updates 05-14-2010.pdf1 topic

Blank Page.pdf

Inside this manual

Real pages from this service manual (281 pages). Open the sample pages (PDF, 468 KB)

Sample pages from the Toyota 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50 Pallet Truck and Tow Tractor Service Manual: Troubleshooting, Specifications, Diagram, Color page, Color page, Foldout diagram

Troubleshooting, page 74: Section 5. Troubleshooting
Specifications, page 254: Section A. Appendix
Diagram, page 266: Section A. Appendix
Color page, page 133: Section 7. Component Procedures
Color page, page 194: Toyota Pallet Truck Service Manual
Foldout diagram, page 270: 00700-CL398-09, Issued: 04 Sep 2009

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual 00700-CL398-09$69.51

Parts manuals

Parts Catalog 00715-00140-12 · 267 pagesCovers 8HBW30, 8HBE30, 8HBE40, 8HBC30, 8HBC40, 8TB50Serial: 40001 and up; 8TB50 with power steer: 40302 and up$69.75Details

This is a service manual

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This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 281 pages

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