Toyota Pallet Truck 8HBC40

Remove the lower control handle back cover

Remove the trigger mounting screw [42]

Remove the trigger [43] and spring [41]

Warning: Handle wiring harnesses with care. Do not pull on wires or pry apart connectors with unspecified tools.

All connectors carefully connected and disconnected?

All added materials used to dress or protect the wire examined and maintained?

Harness wires checked for abrasions, scrapes, nicks, overheating damage, burns, or other general insulation damage?

All terminations with exposed wire visible at the connectors replaced?

Note: Damaged terminations, exposed wires, or damaged connectors can cause operational failure of the truck.

All protective and/or securing hardware returned or replaced to its original condition after repair?

Wire marker present at each termination? If missing or not readable, has the wire been remarked for easier identification?

Note: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness.

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

Is the brake switch installed within 5/16 in. (8 mm) of the adjusting rod?

Turn the truck OFF and disconnect the battery connector.

Connect the battery connector and turn the truck ON.

With the mechanical actuator within 5/16 in. (8 mm), is the amber LED on the switch ON?

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

Adjust the switch so that power is disconnected (amber LED OFF) when the handle is approximately 10 degrees from fully raised or fully lowered.

For 8HBC30/40 and 8TB50 with fixed-position handle, is the parking brake ON?

Remove the fill level dipstick. See Figure 6-71.

Check the oil level. When the truck is level, the oil must be within the operating range indicated on the dipstick.

If necessary, add the specified oil through the fill plug opening, but do not overfill.

Install the fill plug securely.

Turn the truck OFF and disconnect the battery connector.

Measure the resistance to an unpainted, grounded surface on the frame at B+, B–, and all fuses.

If resistance reading is less than 1000 ohms, find the source of low resistance or short to frame.

Disconnect the power cables from each motor or major sub-assembly to determine if that item is causing the low resistance.

Do not continue until this condition is corrected.

Remove the battery from the pallet truck: Lift the damaged roller from its slot and replace with a new one.

Connect the battery lead to the truck.

Use an ammeter to measure the leakage current to an unpainted, grounded surface on the frame at B+, B–, all fuses, and all motors.

If the current is less than 0.001 ampere (1 mA), the truck system passes. If the current exceeds 1 mA, go to step 6.