Toyota Forklift PP13 Service Manual SN 914369 – PDF DOWNLOAD

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Toyota Forklift PP13 Service Manual SN 914369 – PDF DOWNLOAD

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Toyota Forklift PP13 Service Manual SN 914369 – PDF DOWNLOAD

Language : English
Pages : 100
Downloadable : Yes
File Type : PDF

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Toyota Forklift PP13 Service Manual SN 914369 – PDF DOWNLOAD

Introduction Maintenance – P1:

• All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with TOYOTA’s minimum requirements.
• The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations.

The following running times have been used when calculating the intervals:
-Day time:08.00-17.00 (20 hr./week)
-2-shifts:06.00-14.00, 14.00-22.00 (40 hr./week)
-3-shifts:06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work are carried out.

Safety regulations with maintenance work:
Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.
•Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so.
•Keep the area where you carry out the service clean. Oil or water makes the floor slippery.
•Never wear loose objects or jewellery when working on the truck.
•Always disconnect the battery by pulling out the battery isolator when carrying out maintenance work on the truck unless otherwise stated in this Service Manual.
•Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system.
•Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

TABLE OF CONTENTS:

Toyota Forklift PP13 Service Manual SN 914369 – PDF DOWNLOAD

1- Table of contents........................................................ 3
2- Technical data - M4...................................................... 9
	2.1 Tightening torque...................................................11
3- Introduction Maintenance - P1............................................13
	3.1 Safety regulations with maintenance work............................13
	3.2 Cleaning and washing................................................14
		3.2.1 External cleaning.............................................15
		3.2.2 Cleaning the motor compartment................................15
		3.2.3 Electrical components.........................................15
	3.3 Safe lifting........................................................15
	3.4 Lifting points......................................................16
		3.4.1 Using a lifting device........................................16
		3.4.2 Lifting points, using another fork lift truck.................17
4- Maintenance, Lubrication schedule - P2...................................19
	4.1 Maintenance schedule................................................19
	4.2 Lubrication schedule................................................23
5- Oil and grease specification - P3........................................25
6- Tools - P4...............................................................27
	6.1 Super Seal connectors...............................................27
	6.2 AMP connectors......................................................28
		6.2.1 AMP Connectors, 040 series....................................29
	6.3 Molex connectors....................................................30
	6.4 Grease guns.........................................................31
	6.5 Other tools.........................................................32
7- Drive unit/drive gear - 2000.............................................35
	7.1 Component parts.....................................................35
	7.2 Service and repairs.................................................36
		7.2.1 Dismantling the motor from the truck..........................36
		7.2.2 Inspection/replacement of the carbon brushes..................36
		7.2.3 Replacing the drive gear......................................37
		7.2.4 Cleaning......................................................37
		7.2.5 Brakes, Maintenance...........................................38
		7.2.6 Replacing the brake disc......................................38
8- Steering system - 4000...................................................39
	8.1 Components..........................................................39
9- Electrical system - 5000.................................................41
	9.1 General.............................................................41
		9.1.1 Firmware (truck control software).............................41
	9.2 Nomenclature........................................................41
	9.3 Electrical equipment overview.......................................42
		9.3.1 Electric component overview...................................44
	9.4 Accessing main electrical panel.....................................46
	9.5 Electrical circuit overview.........................................47
	9.6 Symbol list.........................................................48
	9.7 Electrical wiring diagram...........................................49
	9.8 Functional description..............................................54
		9.8.1 Theory of operation...........................................54
		9.8.2 Transistor regulator..........................................58
			General.........................................................58
			Safety..........................................................58
		9.8.3 On-board battery charger......................................60
			General.........................................................60
			Charging........................................................60
		9.8.4 Battery charge status.........................................61
			Battery display (option)........................................61
		9.8.5 Built-in battery charger for charging on trucks...............62
			General.........................................................62
			Installation recommendations for ‘connection point’ on truck....62
			Installation in truck...........................................63
			Charging........................................................65
			Troubleshooting.................................................65
			Technical data..................................................65
		9.8.6 Speed limitation..............................................66
		9.8.7 Hour meter....................................................66
		9.8.8 Hand terminal.................................................67
			General.........................................................67
			Connecting the hand terminal....................................67
			Hand terminal overview..........................................68
			Hand terminal menus.............................................69
	9.9 Diagnostic and troubleshooting......................................70
		9.9.1 General.......................................................70
		9.9.2 Display of error codes........................................70
			Direct display of error codes...................................70
			Hand terminal display of error codes............................70
			Error code history..............................................71
		9.9.3 List of error codes...........................................72
		9.9.4 TESTER function...............................................75
	9.10 Parameters & adjustments...........................................77
		9.10.1 General......................................................77
		9.10.2 Adjusting parameters.........................................77
		9.10.3 List of parameters...........................................78
		9.10.4 Description of parameters....................................79
			Acceleration ramp time (ACC.DELAY)..............................79
			Deceleration ramp time (DECELER.DELAY)..........................79
			Neutral braking intensity (RELEASE BRAKING).....................79
			Reverse braking intensity (INVERSION BRAKING)...................79
			Maximum travel speed (CUTBACK SPEED 3)..........................79
			Reset service counter (CHECK UP DONE)...........................79
			Select service warning type (CHECK UP TYPE).....................79
			“Time to next service” (CHECK UP HOURS).........................80
		9.10.5 Transferring parameter sets..................................80
			General.........................................................80
			From the truck to the hand terminal.............................81
			From the hand terminal to the truck.............................82
		9.10.6 Calibrating the speed potentiometer..........................83
			General.........................................................83
			Procedure.......................................................83
	9.11 Technical specifications...........................................84
		9.11.1 Transistor regulator SEM-X...................................84
10- Hydraulic system - 6000.................................................85
	10.1 Hydraulic chart and list of symbols................................85
	10.2 Description........................................................86
		Lift................................................................86
		Lower...............................................................86
		Operating pressure..................................................86
		Pressure limit valve................................................86
	10.3 Adjustments........................................................86
		Adjustment of the pressure limit valve..............................86
	10.4 Tools..............................................................87
11- Destruction instructions................................................89
	11.1 General............................................................89
	11.2 Procedure..........................................................89
	11.3 Abbreviations......................................................90
	11.4 Sorting............................................................90
	11.5 Chassis (0300).....................................................91
		Disassembly.........................................................91
		Material handling...................................................91
	11.6 Hoods, hatches (0340)..............................................91
		Disassembly.........................................................91
		Material handling...................................................91
	11.7 Electric Pump Motor (1710).........................................91
		Disassembly.........................................................91
		Material handling...................................................91
	11.8 Drive assembly/drive motor (1760/ 2550)............................92
		Disassembly.........................................................92
		Material handling...................................................92
	11.9 Wheels (3500)......................................................93
		Disassembly.........................................................93
		Material handling...................................................93
	11.10 Tiller arm (4110).................................................94
		Disassembly.........................................................94
		Material handling...................................................94
	11.11 General electrical equipment (5100)...............................95
		Disassembly.........................................................95
		Material handling...................................................95
	11.12 Hydraulic unit (6100).............................................96
		Disassembly.........................................................96
		Material handling...................................................96
	11.13 Hydraulic cables/cylinders (6230/ 6610)...........................97
		Disassembly.........................................................97
		Material handling...................................................97

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