Toyota Pallet Trucks 6HBC40 : Scheduled Maintenance Every Two Months or 250 Operating Hours

Daily Checklist

• Perform Daily Checklist.

Battery

• Check cleanliness and exterior condition. See “Battery Exterior Cleaning” on page 6-9.

• Check the charge.

• Check the weight.

• Make sure there are solid electrical connections and no damage.

• Check the connector. Make sure all powered functions are shut down when disconnected.

• Make sure battery is properly installed.

• Check the battery gates (if so equipped) for bending or cracks. Replace if necessary.

• Check the “free play” of the battery. Make sure the battery does not move more than 1/2 in. (13mm).

Brake

• Check that the control handle returns to the vertical position when released.

• Check that travel is cut out and the brake is applied when the control handle is within 10° of the fully raised or lowered position.

• Check for satisfactory brake operation.

• Check the brake actuation and deadman switch adjustment.

Forks

• Inspect for damage, bending, cracking, or signs of unauthorized modification.

• Check for minimum thickness.

Hydraulic System

• Check hydraulic connections and hoses for leaks.

• Inspect hydraulic connections and mountings.

• Inspect hoses, tubes and fittings for leaks.

• Check for correct fluid level in hydraulic reservoir.

• Clean the hydraulic fluid breather cap.

Lift Items

• Inspect lift cylinders for damage or leaks.

• Check lift cylinder yokes and lift stop bolts.

Switches

• Check that each switch controls the assigned function.

• Check for intermittent switch operation.

Wheels

• Inspect the condition of the drive wheel and load wheels.

• Remove any steel chips and foreign material to prevent damage to the wheels.

• Check for gouging and chunking of the surface.

• Check the tightness of the drive wheel mounting cap screws.

• Check and lubricate the load wheel bearings and fork trails.

General Operation

• Check that the horn operates when you press the horn button. (Battery must be connected.)

• Check the speed and directional controls.

• Check the hour meter (optional). It must operate when the key is turned ON and the handle is in the operating position.

• Check the steering operation.

• Check the lift/lower functions.

• Check all other components and hardware, inspecting for looseness as necessary.

• Check the operation of the emergency reverse switch.

NOTE: List repairs and report any damage to the supervisor or maintenance personnel.

Contactor Tips

• Check the contactor tips. Replace if: - they are burned or worn - the silver facings are almost worn through or the copper is showing in the contact area - there is a curved surface between the mating tips

Drive Unit

• Check the oil level of the drive housing.

• Check and clean the drive housing breather.

• Lubricate the steering bearing through grease fittings.

Electrical System

• Visually inspect all cables for damage and poor connections.

• Check for battery leakage to truck frame.

• Check for shorts to truck frame.

• Check for dielectric grease when cold storage.

• Check for correct cable tie installation.

• Check the condition of cables and hoses.

• Check for looseness of all mounting bolts and nuts.

Motor Brushes

• Check the condition of brushes, springs and holders.

• Check that the brush length exceeds the minimum length: Drive motor - 9/16 in. (14.3 mm) Lift/Aux. motor - 1/2 in. (13 mm)

Lift Linkage

• Inspect, lubricate, and adjust linkage.

• Examine for wear.

Stabilizer Pads

• Check that stabilizer pads are still at the required length.

Caster Assembly

• Check operation, adjustment, grease.

NOTE: List repairs and report any damage to the supervisor or maintenance personnel.