Toyota Pallet Truck 8HBE30

Remove the lower control handle back cover

Remove the trigger mounting screw [42]

Remove the trigger [43] and spring [41]

Upload a photo of the removed parts

Sign off on the jog trigger and spring change

Warning: Ensure the truck is OFF and the battery connector is disconnected before starting the procedure.

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

Is the mechanical actuator within 5/16 in. (8 mm) of the switch?

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

Does the amber LED remain ON when the mechanical actuator gap exceeds 3/8 in. (9.6 mm)?

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

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

Is the switch adjusted so that power is disconnected (amber LED OFF) when the parking brake is ON?

Did the truck operate correctly during the test?

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

- Check the lift-limit switch for lift motor cut-out. Adjust if necessary. Check wear on pull rod bushings.

- Check the fork height adjustment:

1. Remove the hex head bolt that captivates the fork height adjustment eccentric pin. See Figure 6-100.

2. Use a slide hammer and slide the eccentric pin out 1/2 in. (13 mm).

3. Rotate the eccentric pin to adjust the fork height. The indicator mark on the pin is the standard setting for the pin.

4. Make sure the flats of the pin and the cavity are correctly aligned before reinstalling. Slide in the eccentric pin and replace the hex head retaining bolt.

5. Raise and lower the forks a few times, then measure the fork height at the battery compartment and load wheels.

Continue to adjust the eccentric pins until the fork height measurements are correct.;

Warning: This procedure requires trained personnel with PPE!

Handle in full vertical position?

Measure the handle return spring dimension

Make sure that the handle returns quickly to the vertical position when the handle is released from the normal operating range with Jog Pick disengaged (where applicable).

Does the handle return to the vertical position?

If the handle does not return to the vertical position, turn the adjusting nut down to tighten the spring. The compressed length of the spring must never be less than 8.25 in. (209.5 mm) or more than 8.88 in. (225.5 mm) with the handle in the starting (full upright) position.

Further tightening will cause interference with the handle return mechanism at the lowest position and will not allow the brake to be applied.

Tighten the jam (top) nut into position after the handle return spring is adjusted.

Control head assembly removed successfully

Upload a photo of the removed control head assembly

Wiring disconnected and jam nut on the switch loosened

Upload a photo of the jog trigger [44]

Jog trigger replaced and wiring reconnected

Lower control housing and lower control handle cover reinstalled

CAUTION: Verify that all control handle functions operate correctly before placing truck back in service.

Sign off on the jog pick change