Toyota Pallet Truck 8HBC30

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips may prevent the contactor from opening or closing causing unscheduled downtime. With the truck OFF and the battery disconnected, check the plunger for smooth operation with no binding.

If binding occurs, the pallet truck may malfunction or exhibit intermittent fault codes. See "Contactors" on page 6-30. Note: For EE trucks, remove cover to inspect tips.

Contactor tips have special textured tips that provide mechanical self-cleaning when the contactor opens or closes. When you inspect contactor tips, obey these guidelines:

- Do not file, use sandpaper or emery cloth on the contact points to remove discoloration or minor irregularities. This practice produces a surface more susceptible to sticking.

- Darkened points do not indicate burning.

- Burning indicates a loss of contact point material.

- Replace the contact points if there is not sufficient contact point material to last until the next regular inspection.

- The silver alloy part of the point is usable contact material; the copper backing is not usable contact material.

Warning: Ensure the brake adjusting rod and adjusting screw are correctly adjusted before the brake switch is adjusted.

Turn the truck OFF and disconnect the battery connector.

Connect the battery connector and turn the truck ON.

Verify correct brake switch adjustment: With the mechanical actuator within 5/16 in. (8 mm), the amber LED on the switch should be ON.

If the mechanical actuator gap exceeds 3/8 in. (9.6 mm) and the amber LED remains ON, replace the switch.

Using the nuts on the barrel of the brake (deadman) switch, adjust the switch so that power is disconnected (amber LED OFF) when: For 8HBC30 and 8HBE30 or 8HB40, the handle is approximately 10 degrees from fully raised or fully lowered. For 8HBC30/40 and 8TB50 with fixed-position handle, the parking brake is ON.

Test the operation of the truck.

Turn the truck OFF and disconnect the battery connector.

Remove the lower control handle back cover

Remove the trigger mounting screw [42]

Remove the trigger [43] and spring [41]

Sign off on the jog trigger and spring change

Warning: Ensure to wear safety gloves and goggles before starting the procedure

Clean the pinion and spiral gear

Upload a photo of the pinion gear with red lead applied

Rotate the gear several times to the right and left

Check the tooth contact pattern on the spiral and pinion gear

Upload a photo of the tooth contact pattern

Refer to “Tooth Pattern of Drive Unit” on page 6-56 for correct pattern

Mount the gear sets as per the instructions

Warning: Store and handle the hydraulic fluid with extreme care to prevent moisture and foreign matter from entering the hydraulic system.

Warning: Contaminated hydraulic fluid is the major cause of hydraulic system failures. Any service equipment, such as containers, funnels, and hand pumps, must be kept clean at all times. Cover them when not in use.

Turn the truck OFF and disconnect the battery connector.

Remove the lift cylinder hoses from the fitting at the hydraulic pump.

Connect a drain hose (high pressure) to the open fitting on the pump and tighten.

Warning: Fluid will be under pressure and may spray or splash. Point hose away from your body and hold firmly in the waste fluid container.

Connect the battery connector and turn the truck ON.