This comprehensive workshop service repair manual provides detailed information for maintaining and repairing Toyota Electric Pallet Trucks, specifically models 6HBC30, 6HBC40, 6HBE30, 6HBE40, 6HBW30, and 6TB50 with serial numbers ranging from 10011 to 20010. The manual features high-quality images, circuit diagrams, and step-by-step instructions, ensuring clarity and ease of use. It covers a wide range of topics, including: * **Vehicle Overview and Specifications:** Provides a detailed introduction to the pallet trucks, outlining their features, dimensions, and technical specifications. * **Mechanical Components:** Explains the operation and maintenance of essential mechanical components such as the drive unit, handle assembly, coast control, drum brake, and hydraulic system. It includes detailed breakdowns of each component, including the pressure relief valve, flow control valve, lowering solenoid, lift cylinders, hydraulic reservoir, breather cap, hydraulic pump motor, hydraulic pump, check valve, and other hydraulic components. * **Electrical System:** Covers the electrical system in detail, including the battery, drive motor, contactors, lift limit switch, and advanced transistor control (motor controller). It provides specific explanations for each model variant: 6HBW30, 6HBE30 & 6HBE40, 6HBC30 & 6HBC40, and 6TB50. * **Operating Instructions:** Offers comprehensive guidance on operating the pallet truck safely and efficiently, including installation, visual inspection, battery maintenance, lubrication, hydraulic system checks, cold storage conditioning, and operational checks such as brake, fork/lift linkage, emergency reverse switch, and coast control. It also includes a section on receiving inspection and break-in period guidelines. * **Theory of Operation:** Explains the principles behind the operation of the advanced transistor control system, covering its key functions such as current limiting, low voltage cutback, thermal protection, runaway protection, static return to neutral protection, plugging, controller key switch input, controller thumbwheel throttle inputs, "Emergency Reverse" plug breaking inhibit, and control module operation. It also details the lift/lower system, covering lift and lower operations. * **Scheduled Maintenance:** Provides a detailed maintenance schedule outlining tasks to be performed at various intervals, including daily, weekly, monthly, every 500 hours, and semi-annually. It also includes a comprehensive lubrication and maintenance guide, covering hydraulic system oil and welding precautions. * **Power Section Maintenance:** Focuses on the maintenance of the drive unit, including drive unit service, drive housing lubrication, drive housing vent plug, drive housing steering bearing, drive unit assembly, drive unit tooth pattern, drive gear case data, gear checking procedure, and drive unit installation. * **Brake System Maintenance:** Covers daily inspection, after every 500 hours of operation, brake adjustment, deadman switch adjustment, handle return spring adjustment, and drive wheel maintenance. * **Wheel Maintenance:** Includes instructions for daily inspection, after every 50 hours and 200 hours of operation, cushion drive tire replacement, load wheel inspection, service, and replacement, pallet entry wheel inspection, service, and replacement, and caster daily inspection. * **Fork and Linkage Maintenance:** Provides guidance on daily inspection, after every 50 hours of operation, fork height adjustment, lowered fork height, and lift limit switch adjustment. * **Hydraulic System Maintenance:** Covers hydraulic system inspection, hydraulic reservoir inspection and adjustment, checking and adjusting hydraulic pump relief valve, relief valve setting, hydraulic reservoir inspection every 8 hours, lift cylinder service, oil leakage wiper seal inspection, cleaning breather cap, and inspection every 1,000 hours. * **Electrical System Maintenance:** Explains battery maintenance, including electrolyte level checks, specific gravity checks, battery exterior inspection, battery charging, and battery storage. It also covers motor inspection, brushing, commutator inspection, servicing, high mica, resurfacing, drive motor general data, drive motor inspection, drive motor removal, drive motor replacement, lift motor general data, inspection, removal, traction system adjustments, potentiometer adjustments, current limit setting, plug current adjustment, acceleration adjustment, potentiometer, deadman switch adjustment, contactors cleaning, inspection, tip inspection, contactor table, contactor coil replacement, replacement of contactor tips, insulation and/or core and rod assembly, contactor disassembly/reassembly, checking components, diodes, plug diode test, throttle potentiometer setting, turtle speed module (DA2) test, adjustment, and replacement, and emergency reverse module (DA1) test procedure. * **Troubleshooting:** Provides comprehensive troubleshooting guides for traction system problems, including issues with the directional contactors, high speed operation, plugging, acceleration, and emergency reverse module. It also covers lift/lower problems, such as forks not lifting or lowering. * **Appendix:** Includes helpful resources such as a lubrication equivalency chart, standard torque data for bolts, conversion table, decimal equivalency chart, schematic legend, electrical schematic, hydraulic schematic, electrical schematic (cold storage), special supplement, and alphabetical index. This manual is an invaluable resource for anyone involved in the maintenance and repair of Toyota Electric Pallet Trucks, including technicians, service personnel, and fleet managers. It provides the necessary information and guidance to ensure safe and efficient operation of these vital equipment.