Toyota Pallet Truck SLL12.5, SLL12.5F, 13.5S Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Toyota Pallet Truck Models SLL12.5, SLL12.5F, 13.5S, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Toyota SLL12.5, SLL12.5F, 13.5S workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 134 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
207717-040 (2001-05) - Toyota SLL12.5, SLL12.5F, 13.5S Master Service Manual (Valid from serial number 270001AT-)
MAIN SECTIONS
Contents Master Service Manual (MSM).....3
Valid from serial number:.....3
T-code.....3
Model.....3
Serial No.....3
Notes.....3
1. Document list.....3
Section.....3
C-code.....3
T-code.....3
Document.....3
Issued.....3
Introduction to TOYOTA’s Master Service Manual.....5
Contents, M.....7
1. Truck information.....7
Technical data.....9
Valid from serial number:.....9
T-code.....9
Model.....9
Serial number.....9
Notes.....9
MODEL.....9
SLL12.5.....9
SLL13.5S.....9
SLL12.5F.....9
Drive motor.....9
Transmission/drive gear.....9
Wheels.....9
Hydraulic system.....10
Fuses.....12
Batteries.....12
Driving speeds.....12
Lifting/lowering times.....12
Power consumption.....12
Contents, P.....13
1. Preventive Maintenance.....13
Introduction, maintenance.....15
1. Safety regulations with maintenance work.....15
WARNING!.....15
WARNING!.....16
WARNING!.....16
NOTE!.....16
CAUTION!.....16
2. Cleaning and washing.....16
NOTE!.....17
2.1. External cleaning.....17
NOTE!.....17
2.2. Cleaning the motor compartment.....17
NOTE!.....17
2.3. Electrical components.....18
NOTE!.....18
3. Safe lifting.....18
WARNING!.....18
Preventive maintenance.....19
Valid from serial number:.....19
T-code.....19
Model.....19
Serial No.....19
Notes.....19
1. Maintenance schedule.....19
Pos. no.....19
Work to carry out.....19
Intervals in hours.....19
5.....19
20.....19
80.....19
250.....19
500.....19
1000.....19
3000.....19
Intervals in Days/Weeks/Months.....19
1 D.....19
1 W.....19
1 M.....19
3 M.....19
6 M.....19
12 M.....19
36 M.....19
0000.....19
Chassis.....19
1700.....19
Motors.....19
2550.....19
Drive unit.....19
3370.....20
Brakes.....20
3500.....20
Wheels.....20
4110.....20
Tiller arm.....20
4380.....20
Steering bearings.....20
5000.....21
Electrical operations.....21
5110.....21
Battery.....21
5400.....21
Power system driving.....21
5700.....21
Electronic Card.....21
6000.....22
Hydraulic system.....22
6600.....22
Cylinders.....22
7000.....22
Mast.....22
2. Lubrication chart.....24
Pos no.....24
Service point.....24
Interval/Running hours.....24
Lubricant.....24
500h.....24
1000h.....24
3000h.....24
Oil and grease specification.....25
Valid from serial number:.....25
T-code.....25
Model.....25
Serial No.....25
Notes.....25
1. Approved oil’s and grease.....25
Lubticant.....25
Specification.....25
Application area.....25
> - 15C.....25
< - 15C.....25
Contents, S.....27
1. Service instructions.....27
Support arms, stabilizators.....29
Valid from serial number:.....29
1. Welding of support arms on SLL13.5S.....29
2. Adjustment of rated lift capacity.....30
Electric pump motor.....31
Valid from serial number:.....31
T-code.....31
Model.....31
Serial number.....31
Notes.....31
1. General.....31
1.1. Mechanical construction.....31
1.2. Special tools.....32
Tool.....32
2. Removal/Refitting.....33
2.1. Removing the motor from the truck.....33
2.2. Refitting.....33
3. Service/Repairs.....33
3.1. Cleaning.....33
3.2. Dismantling.....34
3.3. Re-assembling.....35
3.4. Armature bearings.....35
3.4.1. Changing bearings.....36
3.5. Carbon brushes and brush holder.....36
3.5.1. Changing carbon brushes.....36
3.6. Commutator.....37
3.6.1. Machining the commutator.....37
4. Storage/Transport.....38
4.1. Storage.....38
5. Data.....38
Torque.....38
Nm.....38
Component.....39
Item.....39
Min.....39
Max.....39
Unit.....39
Electric drive motor.....41
Valid from serial number:.....41
T-code.....41
Model.....41
Serial number.....41
Notes.....41
1. General.....41
1.1. Mechanical contruction.....41
1.2. Special tools.....43
Tool.....43
2. Removal/Refitting.....43
2.1. Removing the motor from the truck.....43
2.2. Reassembly.....44
3. Service/Repairs.....45
3.1. Cleaning.....45
3.2. Removal of motor.....46
3.3. Refitting of motor.....47
3.4. Armature bearings.....48
3.4.1. Changing the drive end bearing.....48
3.4.2. Changing the commutator end bearing.....48
3.5. Carbon brushes and brush holder.....48
3.5.1. Changing carbon brushes.....49
3.6. Commutator.....50
3.6.1. Turning the commutator.....50
4. Storage/Transport.....51
4.1. Storage.....51
5. Data.....52
Torque.....52
Nm.....52
Grease specification.....52
Component.....52
Item.....52
Min.....52
Max.....52
Unit.....52
Mechanical drive gear unit.....53
Valid from serial number:.....53
T-code.....53
Model.....53
Serial No.....53
Notes.....53
1. General technical description.....53
1.1. Technical data.....54
Data.....54
Description.....54
1.2. Gear components.....55
Pos No.....55
Component.....55
1.3. Special tools.....56
Pos No.....56
Tool.....56
2. Removing the gear from the truck.....56
3. Change of seal on the drive shaft.....58
4. Reconditioning of the gear.....60
Electric parking brake, magnetic brake.....65
Valid from serial number:.....65
T-code.....65
Model.....65
Serial no.....65
Note.....65
1. General.....65
2. Function.....66
2.1. Releasing the brake.....66
2.2. Braking.....67
3. Maintenance.....68
3.1. Adjustment of gap.....68
3.1.1. Adjustment procedure.....68
3.2. Exchange of brake disc/magnetic coil.....69
3.2.1. Exchange procedure.....69
3.3. Check/adjustment of the braking force.....70
WARNING!.....70
Electrical system.....71
Valid from serial number:.....71
T-code.....71
Model.....71
Serial number.....71
Notes.....71
1. Electrical panel, components.....71
2. List of symbols and electrical diagrams.....72
2.1. List of symbols.....72
Symbol.....72
Description.....72
Function.....72
Notes.....72
2.2. Electrical diagram 1(5).....74
2.3. Electrical diagram 2(5).....75
2.4. Electrical diagram 3(5).....76
2.5. Electrical diagram 4(5).....77
2.6. Electrical diagram 5(5).....78
3. Functional description.....79
3.1. General.....79
3.2. Description.....79
3.3. Ignition key switch S17 in ON position.....80
3.4. Tiller arm in drive position, S10.....81
3.5. Driving in direction of forks.....82
Driving permitted Speed.....82
Yes 6km/h.....82
No.....82
Yes 6 km/h.....82
Yes 8km/h.....82
No.....82
Yes 6 km/h.....82
NOTE.....83
3.6. Driving in steer wheel direction.....84
Driving permitted Speed.....84
Yes 6km/h.....84
No.....84
Yes 6 km/h.....84
Yes 8km/h.....84
No.....84
Yes 6 km/h.....84
NOTE.....85
3.7. Load dependent current limits.....86
3.7.1. S59 Activation area.....86
S59.....86
Min. (kg).....86
Max. (kg).....86
3.8. Reversing/motor brakes, fork direction to steer wheel direction.....87
3.9. Reversing/motor brakes, steer wheel direction to fork direction.....87
3.10. Safety reversing.....88
3.11. Support arm lifting.....89
3.12. Support arm lower.....89
3.13. Fork lift.....90
3.14. Horn.....90
3.15. Breaker function for platform and gates.....91
1. Driving with platform up and without gates being used.....91
2. Driving with the platform down and without using the gates.....91
3. Driving with platform up and without gates being used.....91
4. Brake function when leaving platform.....92
3.16. Lifting and driving limits.....92
1. Lifting forks with platform down and with gates being used.....92
2. When the forks are over 1.8m and an attempt is made to drive the truck with the platform down......93
Voltage/battery indicator/ control.....95
Valid from serial number:.....95
T-code.....95
Model.....95
Serial No.....95
Notes.....95
1. General.....95
2. Electrical.....96
2.1. Voltage.....96
2.1.1. The contact voltage and current ratings for switching resistive loads.....96
2.1.2. Memory retention.....96
3. Battery controller.....96
3.1. General.....96
3.1.1. Discharge Adjustment.....96
SETTING.....97
VPC.....97
PIN NO:.....98
FUNCTION.....98
NOTE:.....98
NOTE:.....98
3.2. Reset.....98
3.3. Keyswitch.....99
3.4. Hourmeter.....99
4. Trouble shooting.....99
4.1. Battery Discharge Indicator.....99
4.1.1. No reset.....99
4.1.2. Always resets after break in power.....100
NOTE:.....100
4.1.3. No discharge, gauge does not run down.....100
4.1.4. No lockout.....100
4.1.5. No lift.....101
4.1.6. Early lockout.....101
4.1.7. LEDs don’t light.....101
4.2. Hour meter.....102
4.2.1. No display.....102
4.2.2. Hour glass icon does not flash.....102
4.2.3. Hour meter glass icon always flashes.....102
Transistor panel.....103
Valid from serial number:.....103
T-code.....103
Model.....103
Serial number.....103
Notes.....103
1. General.....103
1.1. Characteristics and functions.....103
2. Connections.....104
Connection pin.....104
Connection.....104
2.1. Connection to the control circuits.....104
Pin No.....105
Connection.....105
Contactor driving.....105
Connections for throttle.....105
Basic control signals.....105
3. Technical specification.....105
Range.....106
Unit.....106
Description.....106
4. Parameters.....106
Parameter (1307-display).....107
Range.....107
Std. value.....107
Unit.....107
Description.....107
4.1. Mode 1 and 2.....107
5. Diagnostics and trouble shooting.....107
5.1. Trouble shooting.....108
5.2. Error codes.....109
5.2.1. LED indications.....109
LED code.....109
Programmer’s LCD- display.....109
Explanation.....109
Probable cause.....109
5.3. Testing circuits for error detection.....110
6. Maintenance.....111
WARNING!.....111
6.1. Safety.....111
WARNING.....111
6.2. Cleaning.....111
7. Curtis 1307 hand terminal.....112
Connection to Curtis 1207.....112
Connection to Curtis 1207A.....113
Pos.....114
Function.....114
Notes.....114
8. Using the hand terminal.....114
8.1. Using the PROGRAM mode, checking and adjusting parameters.....115
NOTE!.....116
8.1.1. Using the key MORE INFO in PROGRAM mode.....116
8.2. Using SPECIAL PROGRAM mode.....116
8.3. Using TEST mode.....117
Example.....117
Test value.....117
Description.....117
8.4. Using DIAGNOSTICS mode.....119
NOTE.....119
8.5. Using SPECIAL DIAGNOSTICS mode.....119
Electronic card.....121
Valid from serial number:.....121
T-code.....121
Model.....121
Serial number.....121
Notes.....121
1. General.....121
1.1. Components.....121
1.2. Connectors and adjustments.....122
Position.....122
Connectors/adjustments.....122
1.3. Connections for inputs/outputs.....123
Pin No.....123
LED No.....123
I/O.....123
SLL, Signal Name.....123
Function.....123
1.4. Adjustment of max. speed.....125
NOTE.....125
2. Cleaning/maintenance.....126
3. Changing the card.....126
Hydraulic/pneumatic system.....127
Valid from serial number:.....127
T-code.....127
Model.....127
Serial number.....127
Notes.....127
1. General.....127
2. Hydraulic diagram.....129
3. List of symbols.....130
Symbol.....130
Description.....130
Function.....130
Notes.....130
4. Functional description.....131
4.1. Lifting the forks.....131
4.2. Lowering the forks.....131
4.3. Switch, S59.....131
5. Adjustments.....131
5.1. Adjustment procedure.....132
WARNING.....132
Main valve unit lift/reach/tilt.....133
Valid from serial number:.....133
T-code.....133
Model.....133
Serial No.....133
Notes.....133
1. General description.....133
Solenoid.....133
Function.....133
Location.....133
Toyota Pallet Truck SLL12.5, SLL12.5F, 13.5S Repair Service Manual
