Toyota 6BWC10/15/20, 6BWS11/15/20, 6BWR15 Forklift Service Manual


Covers: Toyota 6BWC10/15/20, 6BWS11/15/20, 6BWR15 Electric Forklift
Pages: 468
Format: PDF file
File size: 15mb
Compatibility: Windows/Mac/Tablet
Notes: Instant digital download only – no printed copy or CD-ROM media.

This service manual contains maintenance, specifications and repair procedures for the Toyota 6BWC10/15/20, 6BWS11/15/20, 6BWR15 Forklift. View the repair manual on your computer or print off detailed specifications, service and maintenance instructions, including illustrations, as needed. Inside this manual you will find all the detailed information needed to correctly perform maintenance and repairs.

Topics in the Toyota 6BWC10/15/20, 6BWS11/15/20, 6BWR15 Forklift Service Manual:

General Product Information
Presentation of Walkie Trucks
Truck Side Views
Intended Truck Application
Prohibited Truck Application
Truck Data
6BWC10 Dimensions
6BWC15 Dimensions
6BWC20 Dimensions
6BWS11 Dimensions
6BWS15 Dimensions
6BWS20 Dimensions
6BWR15 Dimensions
Data Plate
Main Components
Inch (SAE) and Metric Fasteners
Nomenclature, Threads
Strength Identification
Conversion of Metric and English Units
Technical Service Data
Ordering Spare Parts
Planned Maintenance
Introduction, Maintenance
Jacking Truck Off The Floor
Elevate Rear of Truck
Elevate Either Side of Truck
Cold Storage
Service Schedule
Planned Maintenance Schedule
Planned Maintenance Procedures
Services Performed Daily or Every 8 Operating Hours
Services Performed Monthly or Every 120 Operating Hours
Services Performed Every 480 or 960 Operating Hours
Services Performed Annually or Every 1400 Operating Hours
Lubrication Chart
Oil and Grease Specifications
Approved Oils and Grease
6BWC Grease & Mast Adjustment Points Location
6BWS Grease & Mast Adjustment Points Location
6BWR Grease & Mast Adjustment Points Location
Contents, Section S
Service Instructions
Main Components
Inspection Covers
Battery Roller (Optional)
Battery Cover, Optional (6BWS11 “EE” Trucks Only)
Battery Rollers
Driver Controls, One Spool
Driver Controls, Two Spool
Motor Maintenance
General Information
Operating Conditions
Motor Repair
Pump Motor
Drive Motor
Brush Replacement
Drive Motor Removal
Drive Motor Installation
Component Repair
Drive End head
Commutator End Head
Brush and Commutator
Frame and Field Assembly
Kick Panel
Axle Seal
Parking Brake System
Brake Theory of Operation
Brake Adjustment
Brake Shoe Removal / Installation
Drive Wheel
Tire Pressing Procedure
Support/Swivel Wheel
Maintenance and Adjustments
Caster Adjustment
Stabilizing Caster
Load Wheels
Caster Assembly
Steering Arm/Wheel, Tiller Arm
Steering Arm/Wheel, Head
Control Handle Head
Direction Control Switches
Raise, Lower, and Horn Switches
Reverser Assembly Replacement
Electrical Functions
Adjustable Settings
Key Switch S17 in ON Position
Operating Arm in Drive Position, S10, Brake Switch Closed
Travel Request, Forks First
Travel Request, Forks Trailing
Reversing/Motor Brake Forks First to Forks Trailing Direction
Reversing/Motor Brake Forks Trailing to Forks First Direction
Reverser switch
Lifting Forks
Lowering Forks
Lifting Forks (Manual Valve)
Tilting Forks
Side Shifting Forks
Extend/Retract Forks
Electrical Schematics
Battery History Record
Battery Connector
200 Amp System Line Contactor
300 Amp System Line Contactor (6BWC15/20 only)
200/300 Amp System “EE” Line Contactor
Removal/Replacement of Contact Tips
Battery Controller/Hourmeter/Lift Interrupt
General Information
Battery Controller (BC)
Key Switch
Battery Discharge Indicator (BDI)
Start/Stop Switches
Master Control On/Off Switch (S21)
Light Assemblies
Warning Lights (Option)
Travel/Back-up Alarm (Option)
Transistor Controller
Basics Of Circuit Operation
Control Features
Motor Circuit
Control Circuit
Troubleshooting Guidelines
Shorts to Frame Test
Diagnostics and Troubleshooting
Handset Diagnostics
Troubleshooting Chart Using Handset
Transistor Controller Troubleshooting
Troubleshooting Chart Index
Troubleshooting Charts
Hydraulic System
Main Components
Lift (Solenoid valve)
Lift (Mechanical Valve)
Lower (Solenoid Valve)
Lower (Mechanical Valve)
Relief Pressure
Compensating Cylinder
Reach (Solenoid valve)
Tilt (Solenoid valve)
Sideshift (Solenoid valve)
Primary Malfunctions
Hydraulic Schematics
Hydraulic Fluid
Hydraulic Fluid Selection
Changing Hydraulic System Fluid
System Draining
Refilling System
Bleeding Hydraulic System
Hydraulic Tank
Hydraulic Pump Assembly
One Spool Control Valve
Operators Controls Removal
Control Valve Disassembly and Inspection
Operators Controls Installation
Two Spool Control Valve
Operators Controls Removal
Control Valve Disassembly and Inspection
Operators Controls Installation
Lift Cylinder, Two Stage Mast
Two Stage Full Freelift Mast Cylinder Repair
Two Stage Full Freelift Mast Staging Cylinder Repair
Lift Cylinder, Three Stage Mast
Reach Cylinder, 6BWR15
Tilt Cylinder
Shimming Carriage with Mast on Truck
Lift Chain
Mast, Three Stage
Shimming Carriage with Mast on Truck
Lift Chain
Mounting Instructions
Carriage Removal
Upper Pad Replacement
Lower Pad Replacement
No Sideshifting
Very Slow Sideshifting
Irregular Sideshifting
Single Reach, 6BWR
Carriage Bumpers
Reach Adjustment
Fork Carriage Pivot Pins
Carriage Roller Bearings
Load Backrest
Handset Operation
Operating Modes
Revert to Previous Settings
Handset Self Test
Electrical Controllers (Handset)
Interface Protocols and Backward Compatibility
Parameter Changing
Real-Time Monitoring
Reading Faults and Diagnostic History File
Cloning and Restoring the Previous Programming
Information Displays
Programmer Set Up

Example content (actual manual may vary): Manual Sample

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