Toyota SLL12.5 SLL12.5F 13.5S Pallet Truck Workshop Repair Service Manual PDF - MTOINSLL207717.zip

This is a full factory-level service and repair guide, complete with Electrical Wiring Diagrams, covering Toyota Pallet Truck models SLL12.5, SLL12.5F, and 13.5S. It supplies every technical detail you need to service, troubleshoot, fix, and rebuild these trucks to the standard of professional technicians.

The Toyota SLL12.5, SLL12.5F, and 13.5S workshop service repair manual contains:

* 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