1998 Toyota 6BRU18/6BRU23/6BDRU15/6BSU20/6BSU25 Forklift Service Manual (P/N 00700-CL220)

This service manual covers the 1998 Toyota 6BRU18, 6BRU23, 6BDRU15, 6BSU20, and 6BSU25 electric lift trucks. Document 00700-CL220, issued October 1, 1998, covers single-deep reach, double-deep reach, and straddle configurations within the serial ranges listed above.

• Electrical diagnosis: Decision-tree troubleshooting flowcharts, wiring diagrams, connector locator charts and photos, shorts-to-frame testing, and electrical fault-code explanations.

• Controls and calibration: Analyzer, Calibrate, Configure, Tuning, and Self-diagnosis modes, plus password access, brush wear warnings, and control-input tests.

• Steering and braking: Steer tach and motor replacement, steer-controller adjustment, deadman pedal service, electromagnetic brake inspection, and caster assemblies with or without brakes.

• Motor and drive-unit service: Drive and lift motor removal, brush and commutator inspection, contactor-tip checks, axle-seal replacement, and steering-bearing service.

• Hydraulic repair: Lift pump removal, control-valve and solenoid service, hydraulic bleeding, and freelift, staging, reach, and tilt cylinder repair.

• Mast and carriage: Mast disassembly, roller-bearing shimming, lift-chain adjustment and replacement, reach-carriage repair, hose routing, fork inspection, and load-wheel replacement.

This manual is suited to trained lift-truck service technicians with electrical diagnostic skills and the lifting equipment required for mast and carriage work.

Electrical Fault Isolation and Control Modes

Troubleshooting segments use decision trees for travel, lift-pump, and reach/retract faults. The Electrical Connector Locator Chart and component location photos connect the test instructions to the Tractor Interface card, Display card, power amplifiers, and motor connections. This helps your shop trace a reported fault to its circuit before replacing a control board.

Analyzer mode links fault history to switch, analog-input, output, and software-version tests. Calibrate mode addresses the traction, lift/lower, and deadman potentiometers, plus the optional weight pressure transducer. The system overview explains how pulsed coil drivers let the higher-voltage trucks use the same lift/lower coils.

Electronic component limits: The steer controller and traction and lift power amplifiers have no user-serviceable internal parts; their procedures address external servicing, replacement, and controller settings where applicable. The control handle is also replaced as a unit.

The steering-sensor instructions identify incorrect drive-unit positioning during adjustment as a cause of sensor shearing.

Hydraulic, Mast, and Drive Repairs

The system overview maps the tractor section, mast assembly, and reach mechanism. Hydraulic procedures cover separation of the lift pump and motor, cylinder disassembly and resealing, and the reach/tilt/sideshift manifold.

Variant-specific tilt-cylinder and scissor-arm procedures distinguish different reach assemblies. A leaking or defective sideshift cylinder is treated as a replacement component.

Mast work includes telescopic disassembly, chain anchors, and carriage roller bearings. The hose-routing instructions identify an assembly error that can shear a hydraulic hose as the mast rises.

Drive-unit procedures include axle-seal replacement and gear-tooth contact-pattern guidance. Motor sections cover open-circuit and grounded-motor tests; shorted-winding diagnosis calls for equipment at a motor rebuilding facility.

Scheduled Maintenance and Circuit References

Scheduled maintenance runs from daily checks through annual service, with operating-hour alternatives and guidance for severe use. It identifies lubricants and inspection points for the drive unit, hydraulic system, and overhead guard mounting.

Cold Storage Conditioning distinguishes Classes I, II, and III and specifies hydraulic and drive-unit oil selection by operating environment. The appendix provides lubrication equivalency charts, standard and metric torque charts, decimal equivalents, and standard/metric conversions.

Diagram coverage includes the two-part Electrical Schematic and separate Hydraulic Schematics for single-deep reach, double-deep reach, and straddle trucks. These complement the Shorts to Frame Test chart and connector-location material.

Follow the manual's battery-isolation, static-discharge, mast-support, and jacking precautions; mast replacement is reserved for authorized personnel in an equipped service shop.

Brake Adjustment and Wear-Limit Examples

The brake chapter offers a small sample of the manual's component-specific service data. It specifies an electromagnetic-brake air gap of 0.008-0.014 in., with no more than 0.003 in. variation around the circumference.

The brake friction plate replacement threshold is 15/64 in. (6 mm) or less. These are separate adjustment and wear limits, supported by brake component views and inspection procedures.

PDF Navigation, Diagram Detail, and Page Count

Search and schematic detail: The PDF has no searchable text layer. Embedded bookmarks cover the main chapters and selected subsections. Some small electrical labels remain difficult to read when enlarged, and the hydraulic schematics have faint or broken linework.

Supplied as one printable, 513-page PDF in English. The total includes one cover page and seven intentionally blank pages; there are no separate supplements.