Planned Maintenance Toyota Pallet Truck Service Manual Every 180 Days or 500 Deadman Hours Every 180 Days or 500 Deadman Hours 4-4 00700-CL398-07, Issued: 9 August 2007 Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first. Component Task Battery Check the weight stamped on the battery in the pallet truck against the minimum and maximum allowable weights on the spec tag for the pallet truck. Report any pallet trucks that are running with batteries below the minimum or over the maximum allowable weight. Check for voltage leaks to frame. Reference shorts to frame section in maintenance manual.
If cleaning does not remove voltage to frame, install a new battery. Inspect all battery connectors and leads for damage and cuts in protective coatings. Make sure the battery gates are in position and not damaged. Make sure the battery has no more than 0.5 inch (13 mm) free play in any direction. Brakes In an open area, measure stopping distance. Traveling to 2 to 3 mph (3.2 to 4.8 km/hr) empty, apply the brake; the empty pallet truck should stop within 2 to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and traveling at top speed, the pallet truck should stop within approximately one and one-half truck lengths.
Stopping distance depends on the load, floor, and tire condition. Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake and clean the pads and rotor. Failure to keep brakes adjusted causes premature pad and rotor wear and excessive motor heat. See “Brake” on page 6-41. Contactor 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. Control Handle Assembly Make sure steering function is smooth and responsive, without binding or excess play. Verify lift/lower function is smooth and controllable. Verify travel function is smooth and responsive thru full range of acceleration and braking. Verify no codes on display. Verify function of all switches. Brake (Deadman) Switch Check the adjustment. See “Brake (Deadman) Switch (SW2)” on page 6-17. Drive Unit Inspect for leaks. Make sure O-ring is present on the dipstick. Examine for drive unit steering bearing wear. See “Drive Unit” on page 6-51. Electrical Cables Inspect all power cables for nicks or cuts.
Give special attention to those cables that are not stationary, for example, cables to the traction motor. Replace any cable that is damaged or shows signs of excessive heat. Failure to do so may cause intermittent system shutdowns and/or electronic failures. Forks Check the fork height adjustment. See “Fork Height Adjustment” on page 6-73. Check the lift-limit switch for lift motor cut-out. Adjust if necessary. Check wear on pull rod bushings. Frame and Tractor Checks General visual inspection of structural members for cracks, including but not limited to the main frame and tractor.