Toyota Stacker Pallet LOP10 LOP20 LOP10CW LOP10CF Workshop Repair Service Manual PDF - MTOIN216867LOP.zip
A comprehensive service and repair guide featuring Electrical Wiring Diagrams for the Toyota Stacker Pallet Models LOP10, LOP20, LOP10CW and LOP10CF, providing every technical detail needed to service, troubleshoot, and rebuild these machines the way professional technicians do.
The Toyota Stacker Pallet LOP10/LOP20/LOP10CW/CF 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: 431 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
216867-040 - Toyota Stacker Pallet LOP10 Service Manual (Valid from serial number 595874-).pdf
216868-040 - Toyota Stacker Pallet LOP20 Service Manual (Valid from serial number 595874-).pdf
216869-040 - Toyota Stacker Pallet LOP10CW_CF Service Manual (Valid from serial number 595874-).pdf
MAIN SECTIONS
216867-040 - Toyota Stacker Pallet LOP10 Service Manual (Valid from serial number 595874-).....1
1- Table of contents.....3
2- Technical service data - M4.....11
3- Introduction, maintenance - P1.....15
3.1 Safety regulations with maintenance work.....15
3.2 Cleaning and washing.....17
3.2.1 External cleaning.....17
3.2.2 Cleaning the motor compartment.....17
3.2.3 Electrical components.....17
3.3 Safe lifting.....18
4- Preventive maintenance - P2.....19
4.1 Maintenance schedule.....19
4.2 Lubrication table for LOP10.....25
5- Oil and grease specification - P3.....27
5.1 Approved oil’s and grease for LOP10.....27
6- Electric drive motor - 1760.....29
6.1 General.....29
6.1.1 Mechanical structure.....30
6.1.2 Special tools.....31
6.2 Removal/assembly.....31
6.2.1 Removing the motor from the truck.....31
6.2.2 Installing the motor in the truck.....32
6.3 Service/repairs.....33
6.3.1 Cleaning.....33
6.3.2 Removing the motor.....34
6.3.3 Installing the motor.....35
6.3.4 Rotor bearing.....36
Changing the drive end bearing.....36
Changing the commutator end bearing.....37
6.3.5 Carbon brushes and brush holder.....37
Replacing carbon brushes.....37
6.3.6 Commutator.....38
Regrinding the commutator.....38
6.4 Storage/transport.....39
6.4.1 Storage.....39
6.5 Data.....40
7- Transmission, Gear - 2550.....41
7.1 General description.....41
7.1.1 Gear components.....42
7.1.2 Gear data.....43
7.2 Dismantling/fitting of gear from/in truck.....44
7.2.1 Dismantling.....44
7.2.2 Fitting.....45
7.3 Filling of oil.....45
7.4 Exchange of oil.....46
7.5 Exchange of drive shaft seal ring.....47
7.5.1 Dismantling.....47
7.5.2 Assembly.....48
7.6 Leakage from the top cover.....49
8- Electromagnetic brake - 3370.....51
8.1 General description.....51
8.1.1 Function LOP10.....51
8.2 Main brake components.....52
8.3 Maintenance.....53
8.4 Adjusting the gap.....53
8.5 Adjusting the brake force.....54
8.6 Replacing the brake disc.....54
9- Castor wheel - 3540.....55
9.1 General.....55
9.2 Main component of castor wheel.....56
9.3 Maintenance.....58
9.3.1 Checking the height of the castor wheel.....58
9.3.2 Adjusting the castor wheel height.....59
The castor wheel must be adjusted in the following circumstances:.....59
Adjustment procedure.....59
9.3.3 Replacing the castor wheel.....60
Removing the castor wheel assembly.....60
9.3.4 Changing the wheel.....60
Removal.....60
Assembly.....60
9.3.5 Changing the wheel bearing.....61
10- Tiller arm with servo - 4110.....63
10.1 General.....63
10.2 Electrical diagram.....64
10.3 Adjustment.....65
10.3.1 Instruction for adjustments.....66
11- Electric wheel/lever steering - 4310.....69
11.1 General.....69
11.2 Adjustments.....69
11.3 Electrical diagram.....70
12- Electrical system - 5000.1 Tiller arm.....71
12.1 Electrical panel, components.....71
12.2 List of symbols and electrical diagrams.....72
12.2.1 Electrical diagram 1 (7).....75
12.2.2 Electrical diagram 2 (7).....76
12.2.3 Electrical diagram 3 (7).....77
12.2.4 Electrical diagram 4 (7).....78
12.2.5 Electrical diagram 5 (7).....79
12.2.6 Electrical diagram 6 (7).....80
12.2.7 Electrical diagram 7 (7).....81
12.3 Description of function.....82
12.3.1 General.....82
12.3.2 Adjustable settings.....82
12.3.3 References.....82
12.3.4 Ignition lock S17 in the ON position.....83
12.3.5 Starting.....83
Starting for first time after S17 closes or the emer gency switch off is released (S21, S22).....83
Normal start with S17 closed.....83
12.3.6 Driving, steer wheel direction.....83
12.3.7 Driving, fork direction.....83
12.3.8 Braking.....84
12.3.9 Reversing/motor brake.....84
12.3.10 Auto-plug braking.....84
12.3.11 Lifting the forks.....85
12.3.12 Lowering the forks.....85
12.3.13 Lowering the forks from the side.....85
12.3.14 Horn.....85
12.4 Options.....86
12.4.1 Extra emergency switch off (electrical diagram 2).....86
12.4.2 Lifting the forks from the side.....86
12.4.3 Driving from the side of the truck.....86
Function: (electrical diagram 1-3).....86
12.4.4 Inching speed.....87
Function: (electrical diagram 3).....87
12.4.5 Operator lift platform, electrical diagram 6.....87
Lifting the platform.....87
Speed reduction at platform height 500 mm above the floor.....88
Platform lift limit switch.....88
Lowering the platform.....88
13- Electrical system - 5000.2 Steering wheel.....89
13.1 List of symbols and electrical diagrams.....89
13.1.1 List of symbols.....89
13.1.2 Electrical diagram (1/8).....92
13.1.3 Electrical diagram (2/8).....93
13.1.4 Electrical diagram (3/8).....94
13.1.5 Electrical diagram (4/8).....95
13.1.6 Electrical diagram (5/8).....96
13.1.7 Electrical diagram (6/8).....97
13.1.8 Electrical diagram (7/8).....98
13.1.9 Electrical diagram (8/8).....99
13.2 Description of function.....100
13.2.1 General.....100
13.2.2 References:.....100
13.2.3 Ignition lock S17 in the ON position.....100
13.2.4 Brake.....101
Adaption of parking brake.....101
Release of parking brake.....101
Braking during driving.....101
13.2.5 Driving, steer wheel direction.....101
13.2.6 Driving, fork direction.....102
13.2.7 Motor brake (reversing).....102
13.2.8 Auto-plug braking.....102
13.2.9 Lifting the forks.....103
13.2.10 Lowering the forks (from the platform).....103
13.2.11 Lowering the forks from the side.....103
13.2.12 Horn.....103
13.3 Options.....104
13.3.1 Extra emergency switch off (circuit diagram 2).....104
13.3.2 Lifting the forks from the side.....104
13.3.3 Push buttons for driving from the side.....104
Function: (circuit diagram 1-3).....104
13.3.4 Inching speed.....105
Function: (circuit diagram 3).....105
13.3.5 Operator lift platform, circuit diagram 6.....105
Lifting the platform.....105
Speed reduction at platform height 500 mm above the floor.....106
Platform lift limit switch.....106
Lowering the platform.....106
14- Transistor Controller, PUB 24220 CD3 - 5460.....107
14.1 Transistor controller.....107
14.2 Motor circuit.....108
14.3 Control circuit.....108
14.4 Technical specification.....109
14.5 LED indications.....110
14.6 Maintenance.....111
14.6.1 Safety.....111
14.6.2 Cleaning.....111
14.7 Test of transistor unit safety circuit.....112
15- Logic card - 5710.1 Tiller arm.....113
15.1 General description.....113
15.2 Connections and adjustments.....114
15.3 DIP-switch adjustments/settings.....115
15.4 Card pin connections and LEDs.....116
15.5 Speed limit.....120
15.5.1 LOP10.....120
15.6 Fault/error indications.....121
16- Logic card - 5710.2 Steering wheel.....123
16.1 General description.....123
16.2 Basic settings and adjustments.....124
16.2.1 Parameter settings:.....124
16.2.2 Setting the battery size/type.....127
16.3 Board connections and LEDs.....128
16.4 Speed limit.....132
16.4.1 LOP10.....132
16.5 Error codes.....133
16.6 Error code register.....134
17- Hydraulic system - 6000.1.....135
17.1 General.....135
17.2 Description of function.....136
17.2.1 Hydraulic diagram and components.....136
17.2.2 Main components.....137
17.2.3 Description.....137
Lifting the forks.....137
Lowering the forks.....137
Operating pressure.....137
Relief valve.....137
Pressure switch, S61.....138
Pressure switch, S62.....138
18- Hydraulic system - 6000.2 With platform lift.....139
18.1 General.....139
18.2 Description of function.....140
18.2.1 Hydraulic diagram and components.....140
18.2.2 Main components.....141
18.2.3 Description.....141
Lifting the forks.....141
Lowering the forks.....141
Lifting the platform.....141
Lowering the platform.....142
Operating pressure.....142
Relief valve.....142
Flow restrictor for the platform cylinder.....142
Pressure switch, S61.....142
Pressure switch, S62.....142
216868-040 - Toyota Stacker Pallet LOP20 Service Manual (Valid from serial number 595874-).....145
1- Table of contents.....147
2- General product information - M2.....155
2.1 General description.....155
2.1.1 Intended application of LOP20.....156
2.1.2 Forbidden application of LOP20.....156
2.2 Truck data.....157
2.3 Truck dimensions.....158
2.4 Presentation of main components.....159
2.5 Controls and instruments.....162
2.5.1 Truck with tiller arm.....162
2.5.2 Truck with electrical steering wheel.....163
2.6 Signs on the truck.....164
3- Technical service data - M4.....165
4- Introduction, maintenance - P1.....169
4.1 Safety regulations with maintenance work.....169
4.2 Cleaning and washing.....171
4.2.1 External cleaning.....171
4.2.2 Cleaning the motor compartment.....171
4.2.3 Electrical components.....171
4.3 Safe lifting.....172
5- Preventive maintenance - P2.....173
5.1 Maintenance schedule.....173
5.2 Lubrication table for LOP20.....178
6- Oil and grease specification - P3.....179
6.1 Approved oil’s and grease for LOP20.....179
7- Fork unit - 0380.....181
7.1 General description.....181
7.2 Main components of the fork unit.....182
7.3 Dismantling/fitting the fork unit from/to the chassis.....183
7.3.1 Dismantling.....184
7.3.2 Fitting.....184
7.4 Maintenance.....185
Re-assemble.....185
7.5 Exchange of push rods and bush- ings.....186
7.5.1 Dismantling.....186
7.5.2 Re-assemble.....187
8- Electric drive motor - 1760.....189
8.1 General.....189
8.1.1 Mechanical structure.....190
8.1.2 Special tools.....191
8.2 Removal/assembly.....192
8.2.1 Removing the motor from the truck.....192
8.2.2 Installing the motor in the truck.....193
8.3 Service/repairs.....194
8.3.1 Cleaning.....194
8.3.2 Removing the motor.....195
8.3.3 Installing the motor.....196
8.3.4 Rotor bearing.....197
Changing the drive end bearing.....198
Changing the commutator end bearing.....198
8.3.5 Carbon brushes and brush holder.....199
Replacing carbon brushes.....199
8.3.6 Commutator.....200
Regrinding the commutator.....200
8.4 Storage/transport.....201
8.4.1 Storage.....201
8.5 Data.....202
9- Transmission, Gear - 2550.....203
9.1 General description.....203
9.1.1 Gear components.....204
9.1.2 Gear data.....205
9.2 Dismantling/fitting of gear from/in truck.....206
9.2.1 Dismantling.....206
9.2.2 Fitting.....207
9.3 Filling of oil.....207
9.4 Exchange of oil.....208
9.5 Exchange of drive shaft seal ring.....209
9.5.1 Dismantling.....209