Toyota Pallet Truck 8HBE40

Drive Unit: Change fluid. See “Drive Housing Lubrication” on page 6-58.

Remove the drain plug from the bottom of the gear housing cover and let the oil drain. See Figure 6-72.

After the oil has drained completely, flush the housing with a suitable solvent and permit it to drain.

Install the drain plug. See Figure 6-72.

Fill the drive housing with the specified gear oil through the fill plug opening in the top cover of the drive unit. The drive housing will hold 2.9 quarts (2.75 liters) of gear oil. Do not overfill.

Sign off on the oil change procedure

Warning: Ensure the machine is powered off before starting the procedure

Lower control handle back cover removed

Trigger mounting screw [42] removed

Trigger [43] and spring [41] removed

Upload a photo of the machine after removing the parts

Sign off on the jog trigger and spring change

Handle returns to full vertical position when released from any 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)

Handle returns to the vertical position

Measure the compressed length of the spring

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

NOTE: The return spring can also be adjusted with the handle in the lowered position. Adjust the initial return spring length to 7.5 in. (190.5 mm). Do not readjust the spring length to less than 6.75 in. (171 mm)

Pallet Entry Wheels/Sliders: Check and replace damaged wheels/sliders as necessary.

WARNING: Use extreme care when the truck is jacked up. Keep hands and feet clear from the vehicle while jacking the truck. After the truck is jacked, put solid blocks beneath it to hold it. Do not rely on the jack alone to hold the truck.

6000 lb. Models (Single Pallet)

- Raise the forks and block them in the raised position. See “Jacking Safety” on page 2-9.

- Remove the two lock nuts and bolts from the bottom of the entry slider bracket. See Figure 6-99.

- Insert the two 1/4-20 bolts through the slider bracket and slider. Secure with a lock nut. See Figure 6-99.;

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.