Description

Toyota 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15 Repair Manual

Format: PDF
Language: English
Model Covered: 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15

• Toyota 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15 Repair Manual – 468 Pages
• Wiring Manual – 7 Pages

This manual covers the inspection, adjustment and repair procedures mainly for the overhaul of the engine, chassis and material handling system of the TOYOTA 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15 Stacker.
This repair manual contains the latest information available. Please under-stand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual.

Table of content of the TOYOTA 6BWC10, 6BWC15, 6BWC20, 6BWS11, 6BWS15, 6BWS20, 6BWR15 Stacker Manual:

Standard Codes ………………………………………………………………………………………….. 1
Warning Symbols ……………………………………………………………………………………….. 13
Warning Levels ………………………………………………………………………………………. 13
Prohibitory Symbols …………………………………………………………………………………… 14
Ordinance Symbols …………………………………………………………………………………. 14
Safety ………………………………………………………………………………………………………… 15
General Safety ……………………………………………………………………………………….. 15
Battery Safety …………………………………………………………………………………………….. 19
Static Safety ………………………………………………………………………………………………. 24
Welding Safety …………………………………………………………………………………………… 25
Introduction, Service Manual ………………………………………………………………………. 27
Contents, Section M …………………………………………………………………………………… 29
Machine Information ……………………………………………………………………………….. 29
General Product Information ………………………………………………………………………. 31
Presentation of Walkie Trucks. …………………………………………………………………. 31
Truck Side Views ……………………………………………………………………………. 32
Intended Truck Application ……………………………………………………………….. 32
Prohibited Truck Application …………………………………………………………….. 32
Truck Data ……………………………………………………………………………………… 33
6BWC10 Dimensions ………………………………………………………………………. 34
6BWC15 Dimensions ………………………………………………………………………. 35
6BWC20 Dimensions ………………………………………………………………………. 36
6BWS11 Dimensions ………………………………………………………………………. 37
6BWS15 Dimensions ………………………………………………………………………. 38
6BWS20 Dimensions ………………………………………………………………………. 39
6BWR15 Dimensions ………………………………………………………………………. 40
Data Plate ……………………………………………………………………………………… 41
Main Components …………………………………………………………………………………… 42
Inch (SAE) and Metric Fasteners ………………………………………………………………… 45
Introduction ……………………………………………………………………………………………. 45
Nomenclature, Threads ……………………………………………………………………………. 46
Strength Identification ……………………………………………………………………………… 47
Conversion of Metric and English Units ……………………………………………………… 54
Technical Service Data ……………………………………………………………………………….. 57
Ordering Spare Parts ………………………………………………………………………………….. 61
Contents, Section P ……………………………………………………………………………………. 63
Planned Maintenance ……………………………………………………………………………… 63
Introduction, Maintenance ………………………………………………………………………….. 65
Jacking Truck Off The Floor ……………………………………………………………………… 66
Elevate Rear of Truck ……………………………………………………………………… 66
Elevate Either Side of Truck ……………………………………………………………… 66
Lubricants ……………………………………………………………………………………………… 67
Standard ………………………………………………………………………………………… 67
Corrosion ……………………………………………………………………………………….. 67
Cold Storage ………………………………………………………………………………….. 68
Service Schedule ……………………………………………………………………………………….. 71
Planned Maintenance Schedule ……………………………………………………………….. 71
Planned Maintenance Procedures …………………………………………………………….. 76
Services Performed Daily or Every 8 Operating Hours …………………………. 76
Services Performed Monthly or Every 120 Operating Hours. ………………… 77
Services Performed Every 480 or 960 Operating Hours ……………………….. 80
Services Performed Annually or Every 1400 Operating Hours ………………. 81
Lubrication Chart ……………………………………………………………………………………….. 83
Oil and Grease Specifications …………………………………………………………………….. 84
Approved Oils and Grease ……………………………………………………………………….. 84
6BWC Grease & Mast Adjustment Points Location ……………………………………… 85
6BWS Grease & Mast Adjustment Points Location ……………………………………… 86
6BWR Grease & Mast Adjustment Points Location ……………………………………… 87
Contents, Section S ……………………………………………………………………………………. 89
Service Instructions …………………………………………………………………………………. 89
Frame/Chassis …………………………………………………………………………………………… 91
General …………………………………………………………………………………………………. 93
Main Components …………………………………………………………………………………… 93
Inspection Covers ………………………………………………………………………………………. 95
Battery Roller (Optional) ……………………………………………………………………………. 103
Battery Cover, Optional (6BWS11 “EE” Trucks Only) ………………………………….. 105
Inspection ……………………………………………………………………………………… 105
Removal ……………………………………………………………………………………….. 105
Installation …………………………………………………………………………………….. 106
Battery Rollers ………………………………………………………………………………………. 106
Inspection ……………………………………………………………………………………… 106
Replacement …………………………………………………………………………………. 106
Driver Controls, One Spool ………………………………………………………………………… 107
Removal ……………………………………………………………………………………………….. 109
Installation …………………………………………………………………………………………….. 110
Driver Controls, Two Spool ………………………………………………………………………… 111
Removal ……………………………………………………………………………………………….. 114
Installation …………………………………………………………………………………………….. 115
Decals ………………………………………………………………………………………………………. 117
Decal with Protective Sheet …………………………………………………………………….. 117
Decal without Protective Sheet ………………………………………………………………… 117
Motor Maintenance
Schedule/Troubleshooting …………………………………………………………………………. 119
General Information ……………………………………………………………………………….. 119
Operating Conditions ……………………………………………………………………………… 119
Troubleshooting …………………………………………………………………………………….. 120
Motor Repair ……………………………………………………………………………………………… 127
Pump Motor …………………………………………………………………………………………. 127
Pump Motor Removal …………………………………………………………………….. 128
Pump Motor Installation ………………………………………………………………….. 128
Drive Motor …………………………………………………………………………………………… 129
Brush Replacement ………………………………………………………………………… 133
Drive Motor Removal ……………………………………………………………………… 133
Drive Motor Installation …………………………………………………………………… 134
Component Repair …………………………………………………………………………………. 136
Disassembly …………………………………………………………………………………. 136
Inspection ……………………………………………………………………………………………… 138
Drive End head ……………………………………………………………………………… 138
Commutator End Head …………………………………………………………………… 138
Bearings ……………………………………………………………………………………….. 138
Brush and Commutator …………………………………………………………………… 139
Armature ………………………………………………………………………………………. 141
Frame and Field Assembly ……………………………………………………………… 142
Assembly/Testing …………………………………………………………………………… 143
Transmission …………………………………………………………………………………………….. 145
System Description ………………………………………………………………………………… 145
Troubleshooting …………………………………………………………………………………….. 145
Kick Panel …………………………………………………………………………………….. 146
Transmission Repair ………………………………………………………………………………. 147
Removal ……………………………………………………………………………………….. 148
Installation …………………………………………………………………………………….. 149
Transmission Assembly ………………………………………………………………………….. 151
Disassembly ………………………………………………………………………………….. 152
Assembly ………………………………………………………………………………………. 152
Axle Seal ………………………………………………………………………………………………. 154
Removal ……………………………………………………………………………………….. 154
Installation …………………………………………………………………………………….. 154
Parking Brake System ……………………………………………………………………………….. 157
Brake Theory of Operation ………………………………………………………………………. 159
Brake Adjustment …………………………………………………………………………………… 160
Brake Shoe Removal / Installation ……………………………………………………………. 161
Drive Wheel ………………………………………………………………………………………………. 163
Removal ……………………………………………………………………………………………….. 163
Installation …………………………………………………………………………………………….. 164
Tire Pressing Procedure …………………………………………………………………………. 165
Support/Swivel Wheel ……………………………………………………………………………….. 167
Maintenance and Adjustments …………………………………………………………………. 170
Caster Adjustment ………………………………………………………………………….. 171
Troubleshooting …………………………………………………………………………………….. 172
Stabilizing Caster …………………………………………………………………………… 172
Load Wheels ……………………………………………………………………………………………… 173
Removal and Installation …………………………………………………………………………. 176
Caster Assembly ……………………………………………………………………………………….. 177
Disassembly ………………………………………………………………………………………….. 178
Inspection ……………………………………………………………………………………………… 179
Assembly ……………………………………………………………………………………………… 180
Installation …………………………………………………………………………………………….. 181
Steering Arm/Wheel, Tiller Arm ………………………………………………………………….. 183
Removal ……………………………………………………………………………………………….. 184
Inspection ……………………………………………………………………………………………… 185
Installation …………………………………………………………………………………………….. 186
Steering Arm/Wheel, Head …………………………………………………………………………. 187
Control Handle Head ……………………………………………………………………………… 188
Removal ……………………………………………………………………………………….. 188
Installation …………………………………………………………………………………….. 188
Direction Control Switches ………………………………………………………………………. 189
Raise, Lower, and Horn Switches …………………………………………………………….. 191
Potentiometer ………………………………………………………………………………………… 194
Removal ……………………………………………………………………………………….. 194
Installation …………………………………………………………………………………….. 195
Reverser Assembly Replacement …………………………………………………………….. 199
Electrical Functions …………………………………………………………………………………… 201
General ………………………………………………………………………………………………… 201
Adjustable Settings ………………………………………………………………………… 201
References ……………………………………………………………………………………. 201
Key Switch S17 in ON Position ………………………………………………………… 202
Operating Arm in Drive Position, S10, Brake Switch Closed ………………… 202
Travel Request, Forks First ……………………………………………………………… 202
Travel Request, Forks Trailing …………………………………………………………. 202
Reversing/Motor Brake Forks First to Forks Trailing Direction ………………. 203
Reversing/Motor Brake Forks Trailing to Forks First Direction ………………. 203
Reverser switch ……………………………………………………………………………… 203
Lifting Forks …………………………………………………………………………………… 203
Lowering Forks ………………………………………………………………………………. 204
Horn …………………………………………………………………………………………….. 204
Options …………………………………………………………………………………………………. 204
Lifting Forks (Manual Valve) ……………………………………………………………. 204
Tilting Forks …………………………………………………………………………………… 204
Side Shifting Forks …………………………………………………………………………. 204
Extend/Retract Forks ……………………………………………………………………… 205
Electrical Symbols …………………………………………………………………………………….. 207
Electrical Schematics ………………………………………………………………………………… 213
Battery ………………………………………………………………………………………………………. 219
Removal ……………………………………………………………………………………………….. 219
Installation …………………………………………………………………………………………….. 220
Battery Maintenance ………………………………………………………………………………. 221
Battery Inspection and Care …………………………………………………………….. 221
Battery Exterior Cleaning ………………………………………………………………… 222
Charging ……………………………………………………………………………………….. 222
Storage ………………………………………………………………………………………………… 223
Battery History Record ……………………………………………………………………………. 223
Battery Connector ……………………………………………………………………………………… 225
Location ……………………………………………………………………………………………….. 225
Inspection ……………………………………………………………………………………………… 226
Installation …………………………………………………………………………………………….. 226
200 Amp System Line Contactor ……………………………………………………………….. 229
Replacement …………………………………………………………………………………………. 229
Removal ……………………………………………………………………………………….. 229
Installation …………………………………………………………………………………….. 229
300 Amp System Line Contactor (6BWC15/20 only) …………………………………… 231
Maintenance …………………………………………………………………………………………. 231
Removal/Replacement of Contact Tips ……………………………………………… 232
200/300 Amp System “EE” Line Contactor ………………………………………………… 233
Maintenance …………………………………………………………………………………………. 233
Removal/Replacement of Contact Tips ……………………………………………… 234
Battery Controller/Hourmeter/Lift Interrupt …………………………………………………. 237
General Information ……………………………………………………………………………….. 237
Electrical ………………………………………………………………………………………………. 238
Voltage …………………………………………………………………………………………. 238
Battery Controller (BC) ……………………………………………………………………………. 239
General Information ……………………………………………………………………….. 239
Reset ……………………………………………………………………………………………. 241
Key Switch ……………………………………………………………………………………. 241
Hourmeter …………………………………………………………………………………….. 242
Troubleshooting …………………………………………………………………………………….. 242
Battery Discharge Indicator (BDI) …………………………………………………….. 242
Hourmeter …………………………………………………………………………………….. 245
Start/Stop Switches …………………………………………………………………………………… 247
General ………………………………………………………………………………………………… 247
Test/Inspection ………………………………………………………………………………. 247
Master Control On/Off Switch (S21) ………………………………………………………….. 249
Inspection ……………………………………………………………………………………… 249
Removal ……………………………………………………………………………………….. 249
Installation …………………………………………………………………………………….. 249
Light Assemblies ………………………………………………………………………………………. 251
Warning Lights (Option) ………………………………………………………………………….. 251
Removal ……………………………………………………………………………………….. 253
Installation …………………………………………………………………………………….. 253
Travel/Back-up Alarm (Option) …………………………………………………………………. 254
Removal ……………………………………………………………………………………….. 254
Installation …………………………………………………………………………………….. 254
Transistor Controller …………………………………………………………………………………. 255
Basics Of Circuit Operation ……………………………………………………………………… 255
Control Features ……………………………………………………………………………. 257
Maintenance …………………………………………………………………………………………. 258
Safety …………………………………………………………………………………………… 258
Cleaning ……………………………………………………………………………………….. 258
Motor Circuit ………………………………………………………………………………………….. 259
Control Circuit ……………………………………………………………………………………….. 260
Troubleshooting Guidelines …………………………………………………………………….. 261
General ………………………………………………………………………………………… 263
Shorts to Frame Test ……………………………………………………………………………… 264
Definitions …………………………………………………………………………………………….. 268
Diagnostics and Troubleshooting ……………………………………………………………… 269
Handset Diagnostics ………………………………………………………………………. 269
Troubleshooting …………………………………………………………………………….. 269
Troubleshooting Chart …………………………………………………………………….. 271
Technical Specification …………………………………………………………………… 276
Troubleshooting Chart Using Handset ………………………………………………. 277
Transistor Controller Troubleshooting ……………………………………………………….. 279
Troubleshooting Chart Index ……………………………………………………………………. 279
Troubleshooting Charts …………………………………………………………………………… 280
Hydraulic System ………………………………………………………………………………………. 299
General ………………………………………………………………………………………………… 299
Description of Function …………………………………………………………………………… 299
Main Components ………………………………………………………………………………….. 300
Lift (Solenoid valve) ………………………………………………………………………… 300
Lift (Mechanical Valve) ……………………………………………………………………. 300
Lower (Solenoid Valve) …………………………………………………………………… 300
Lower (Mechanical Valve) ……………………………………………………………….. 300
Relief Pressure ………………………………………………………………………………. 300
Compensating Cylinder …………………………………………………………………… 301
Reach (Solenoid valve) …………………………………………………………………… 301
Tilt (Solenoid valve) ………………………………………………………………………… 301
Sideshift (Solenoid valve) ………………………………………………………………… 301
Maintenance …………………………………………………………………………………………. 302
Adjustments ………………………………………………………………………………………….. 303
Troubleshooting …………………………………………………………………………………….. 304
Primary Malfunctions ………………………………………………………………………. 305
Definitions …………………………………………………………………………………………….. 306
Removal ……………………………………………………………………………………………….. 307
Installation …………………………………………………………………………………………….. 309
Hydraulic Schematics ………………………………………………………………………………… 311
Hydraulic Fluid ………………………………………………………………………………………….. 315
Hydraulic Fluid Selection …………………………………………………………………………. 315
Changing Hydraulic System Fluid …………………………………………………………….. 315
System Draining …………………………………………………………………………………….. 316
Refilling System …………………………………………………………………………………….. 317
Bleeding Hydraulic System ……………………………………………………………………… 318
Hydraulic Tank ………………………………………………………………………………………….. 319
Removal ……………………………………………………………………………………………….. 320
Installation …………………………………………………………………………………………….. 320
Hydraulic Pump Assembly …………………………………………………………………………. 321
Disassembly ………………………………………………………………………………………….. 323
Inspection ……………………………………………………………………………………………… 324
Assembly ……………………………………………………………………………………………… 325
One Spool Control Valve ……………………………………………………………………………. 327
Operators Controls Removal ……………………………………………………………………. 328
Control Valve Disassembly and Inspection ………………………………………………… 328
Operators Controls Installation …………………………………………………………………. 329
Two Spool Control Valve ……………………………………………………………………………. 330
Operators Controls Removal ……………………………………………………………………. 331
Control Valve Disassembly and Inspection ………………………………………………… 331
Operators Controls Installation …………………………………………………………………. 332
Lift Cylinder, Two Stage Mast ………………………………………………………………….. 337
Removal ……………………………………………………………………………………….. 337
Disassembly ………………………………………………………………………………….. 338
Assembly ………………………………………………………………………………………. 338
Installation …………………………………………………………………………………….. 338
Two Stage Full Freelift Mast Cylinder Repair ……………………………………………… 339
Removal ……………………………………………………………………………………….. 339
Disassembly ………………………………………………………………………………….. 340
Assembly ………………………………………………………………………………………. 340
Installation …………………………………………………………………………………….. 340
Two Stage Full Freelift Mast Staging Cylinder Repair …………………………………. 341
Removal ……………………………………………………………………………………….. 341
Disassembly ………………………………………………………………………………….. 342
Assembly ………………………………………………………………………………………. 342
Installation …………………………………………………………………………………….. 342
Lift Cylinder, Three Stage Mast …………………………………………………………………. 343
Repair ………………………………………………………………………………………………….. 346
Removal ……………………………………………………………………………………….. 346
Disassembly ………………………………………………………………………………….. 347
Assembly ………………………………………………………………………………………. 347
Installation …………………………………………………………………………………….. 347
Reach Cylinder, 6BWR15 …………………………………………………………………………… 349
Removal ……………………………………………………………………………………………….. 351
Disassembly ………………………………………………………………………………………….. 352
Inspection ……………………………………………………………………………………………… 353
Assembly ……………………………………………………………………………………………… 354
Installation …………………………………………………………………………………………….. 355
Tilt Cylinder ………………………………………………………………………………………………. 357
Removal ……………………………………………………………………………………………….. 359
Disassembly ………………………………………………………………………………………….. 360
Inspection ……………………………………………………………………………………………… 361
Assembly ……………………………………………………………………………………………… 362
Installation …………………………………………………………………………………………….. 363
Removal ……………………………………………………………………………………………….. 365
Disassembly ………………………………………………………………………………………….. 366
Inspection ……………………………………………………………………………………………… 367
Assembly ……………………………………………………………………………………………… 368
Installation …………………………………………………………………………………………….. 369
Shimming Carriage with Mast on Truck. ……………………………………………………. 377
Repair ………………………………………………………………………………………………….. 379
Removal ……………………………………………………………………………………….. 379
Disassembly ………………………………………………………………………………….. 380
Assembly ………………………………………………………………………………………. 381
Installation …………………………………………………………………………………….. 383
Lift Chain ………………………………………………………………………………………………. 384
Lift Chain Adjustment: …………………………………………………………………….. 384
Lift Chain Maintenance …………………………………………………………………… 384
Lift Chain Inspection ……………………………………………………………………….. 384
Lift Chain Replacement …………………………………………………………………… 391
Mast, Three Stage ……………………………………………………………………………………… 393
Shimming Carriage with Mast on Truck. ……………………………………………………. 399
Repair ………………………………………………………………………………………………….. 401
Removal ……………………………………………………………………………………….. 401
Disassembly ………………………………………………………………………………….. 402
Assembly ………………………………………………………………………………………. 403
Installation …………………………………………………………………………………….. 405
Lift Chain ………………………………………………………………………………………………. 406
Sideshifter ………………………………………………………………………………………………… 407
Mounting Instructions ……………………………………………………………………………… 409
Installation …………………………………………………………………………………….. 409
Operation ……………………………………………………………………………………………… 410
Maintenance …………………………………………………………………………………………. 410
Carriage Removal ………………………………………………………………………….. 411
Upper Pad Replacement …………………………………………………………………. 411
Lower Pad Replacement …………………………………………………………………. 412
Cylinder ………………………………………………………………………………………… 413
Troubleshooting …………………………………………………………………………………….. 414
No Sideshifting ………………………………………………………………………………. 414
Very Slow Sideshifting ……………………………………………………………………. 414
Irregular Sideshifting ………………………………………………………………………. 415
Single Reach, 6BWR ………………………………………………………………………………….. 417
Maintenance …………………………………………………………………………………………. 419
Inspection ……………………………………………………………………………………… 419
Adjustment ……………………………………………………………………………………. 420
Repair ………………………………………………………………………………………………….. 424
Disassembly ………………………………………………………………………………….. 424
Assembly ………………………………………………………………………………………. 426
Carriage Bumpers ………………………………………………………………………………….. 428
Reach Adjustment ………………………………………………………………………….. 428
Fork Carriage Pivot Pins …………………………………………………………………………. 430
Carriage Roller Bearings …………………………………………………………………………. 430
Removal ……………………………………………………………………………………….. 430
Installation …………………………………………………………………………………….. 430
Removal ……………………………………………………………………………………………….. 432
Inspection ……………………………………………………………………………………………… 432
Installation …………………………………………………………………………………………….. 433
Load Backrest …………………………………………………………………………………………… 435
Removal ……………………………………………………………………………………………….. 436
Installation …………………………………………………………………………………………….. 436
Handset Operation …………………………………………………………………………………….. 437
Operating Modes …………………………………………………………………………………… 440
Revert to Previous Settings ……………………………………………………………………… 443
Handset Self Test ………………………………………………………………………………….. 443
Electrical Controllers (Handset) …………………………………………………………………. 445
Display Screen ………………………………………………………………………………………. 446
Menu Navigation Key ……………………………………………………………………… 446
Data Inc/Dec Key …………………………………………………………………………… 446
Bookmark Keys ……………………………………………………………………………… 446
Operation ……………………………………………………………………………………………… 447
Menu Structure ………………………………………………………………………………. 447
Main Menu ……………………………………………………………………………………. 448
Interface Protocols and Backward Compatibility …………………………………. 449
Parameter Changing ………………………………………………………………………. 450
Real-Time Monitoring ……………………………………………………………………… 450
Reading Faults and Diagnostic History File ……………………………………….. 451
Cloning and Restoring the Previous Programming ……………………………… 451
Information Displays ……………………………………………………………………….. 452
Programmer SetUp ………………………………………………………………………… 452