CATERPILLAR CAT EP45 FORKLIFT LIFT TRUCKS CHASSIS AND MAST Service Repair Manual

Service Manual Chassis & Mast EP40 EP45 EP50

99759-66110

CHAPTER OVERVIEW Technical Description of Components

1

General Truck Data Test and Setting Values

2

Truck Maintenance

3

Service Manual Items

4

Control System

5

Electrical wiring diagrams

6

Hydraulic diagrams

7

0-1

Technical Description of Components Component Arrangement ...................................... 1-3

Steering system .................................................... 1-12 Steering column .....................................................................1-12

Drive ........................................................................ 1-4 Drive system components .......................................................1-4

Steering axle ..........................................................................1-13 Design ...............................................................................1-13

Traction motor ..........................................................................1-4 Temperature gauge and speed sensor ...............................1-4 Asynchronous motor direction of turn ..................................1-4

Power steering pump .............................................................1-14 Design ...............................................................................1-14 Function .............................................................................1-14

Wheels/Axles .......................................................... 1-5

Steering system block diagram ..............................................1-15

Chassis / load section connection ...................... 1-16

Travel switch/Accelerator pedal ........................... 1-6

Tilt cylinder .............................................................................1-16 Design ...............................................................................1-16

Design .................................................................................1-6 Function ...............................................................................1-6

Hydraulic system .................................................. 1-17

Brake system .......................................................... 1-7

Control panel ..........................................................................1-17 Design ...............................................................................1-17 Manual Control ..................................................................1-17 Joystick Control .................................................................1-17

Service brake ...........................................................................1-7 Spring-loaded parking brake ....................................................1-8 Design .................................................................................1-8 Function ...............................................................................1-8

Control valve ..........................................................................1-18 Manual Control ..................................................................1-18 Joystick Control – Standard version ..................................1-19 Joystick Control: Optional version for large auxiliary consumers ..................................................1-20

Disc Brake ...............................................................................1-9 Position ................................................................................1-9 Design .................................................................................1-9

Pump motor / pump / pressure filter .......................................1-22 Design ...............................................................................1-22 1-1

Electrical System .................................................. 1-23 Design ....................................................................................1-23 Electrical fuses .......................................................................1-24 Charging contactor function ...............................................1-24 Block diagram ........................................................................1-25

Z M

Used before explanations.

Used before notices which must be observed to avoid material damage.

before safety instructions which must be observed to avoid F Used danger to personnel.

1-2

Component Arrangement

Item 1

Mast

2

Overhead guard

3

Driver’s seat

4

Steering column

5

Steering axle

6

Counterweight

7

Drive unit

8

Hydraulic reservoir

9

Hydraulic unit

10

Fork carriage

11

Spring-loaded accumulator cylinder

12

Electrical system

13

Steering unit

13

1-3

Description

Drive Drive system components

Traction motor

The drive system consists of a compact drive unit in which the following components form a functional unit: •

Traction motor

•

Transmission

•

Multi-plate brake

•

Spring-loaded brake

Temperature gauge and speed sensor

Z

The temperature gauge for temperature control is located in the stator coil, the speed sensor in the right sided transmission housing .

Motor overtemperature is shown by an indicator in the multifunction display.

Asynchronous motor direction of turn The direction of turn of a threephase asynchronous motor is determined by the rotary field of the 3 phases. If 2 phases are swapped, the motor will turn in the opposite direction. This assumes that tracks A and B of the sensor bearing have also been turned.

If the direction of turn of the 3 phases does not match the sensor signal when the accelerator is pressed, the controller will try to increase the motor speed. However, as the sensor feedback signal does not match the direction of turn applied, the motor remains at its lowest speed.

Z Z

The complete drive unit is connected to the chassis with 16 industrial grade bolts.

1-4

If the phases are wrongly connected, the error message appears.

Wheels/Axles Design

3

Item

Z

2

1n

Description

1

Wheel nut

2

Load wheel

3

Drive

n For torques, see chapter 2 1-5

Travel switch/Accelerator pedal Design 2

Function

3

The mircroswitch releases the travel impulse if the seat switch is also applied at the same time.

The potentiometer controls the travel speed. The further the pedal is depressed, the less the resistance and the greater the speed.

Z 1 4

6 5

Item

Description

1

Microswitch

2

Coupler plug

3

Seal

4

Pedal/Pedal support

5

Potentiometer

6

Spring 1-6

When the default settings have been made or the potentiometer replaced, check the “MIN” and “MAX” potentiometer voltage with the service program.

Brake system Service brake

Service note:

M

2

1 3 4

5

Item

Description

1

Brake pedal

2

Compensator reservoir

3

Main brake cylinder

4

Pressure switch

5

Drive unit 1-7

Do not add brake fluid!

Fill the brake system with RENOLIN 22 hydraulic oil.

Spring-loaded parking brake Item

Design

Description

1

Parking brake switch

2

Spring-loaded accumulator block

3

Spring-loaded accumulator cylinder

Function

1

Z

For functional test see Service Manual page 4-17

Service note:

M 2

3 1-8

Do not add brake fluid!

Disc Brake

.

Item

Position

Description

1

RH reducing gear housing (transmission housing)

2

Disc brake housing (cylinder bell)

3

Brake lining Design

1

2

The disc brake is located in the right-hand bell of the drive unit (seen in the direction of travel).

3

1-9

9

10

9

8

7 3

6

Item

1

2 3 4

5

1-10

Description

1

O ring (2 off)

2

Pressure plate and brake piston

3

Brake lining (2 off)

4

Self adjust kit complete with clamping sleeve (3 off)

5

Brake disc with internal toothing

6

Pressure plate

7

Moment support (3 off)

8

Brake disc

9

Pressure plate (2 off)

10

Brake lining with internal toothing

2

11 12

5 13

9

10

9

Item

3

8

3 14

Description

2

Pressure plate and brake piston

3

Brake lining (2 off)

5

Brake disc with internal toothing

8

Brake disc

9

Pressure plate (2 off)

10

Brake lining with internal toothing

11

Differential

12

Pinion

13

Carrier (4 off)

14

Two-stage planetary gear

Service note: See service manual B 1003

1-11

Steering system Steering column

Design 1

All truck models are fitted as standard with a hydraulic steering system with emergency steering.

The steering electronics are incorporated in the steering motor.

The system is controlled by a steering wheel sensor (Hall sensor) on the steering column.

Function When the steering wheel is turned the rotary movement is converted into an electric signal. The servostat controls the volume of oil in proportion to the speed of the steering wheel turn and directs it to the required side of the steering cylinder.

2

After turning, the servostat automatically reverts to neutral.

If the hydraulic pump fails, emergency steering is provided at all times by the emergency pump in the servostat.

Item

Description

1

Servostat

2

Steering wheel sensor / Hall sensor 1-12

Steering axle

The steering axle with its integrated steering cylinder forms a complete unit with the steering wheels. It is located elastically and vibration-proof in the counterbalance surrounded by two rubber layers to compensate for uneven ground.

Design 1

The steering cylinder transmits the steering movement to the king pin via two connecting units.

The steering angle sensor transmits the current actual value of the wheel position to the drive controller and thereby controls the travel speed as a function of the steering angle.

Service note: After replacing the steering angle sensor see service manual B 6001: “Steering angle sensor replacement / adjustment – Assembly�.

2

3

Item

4

Description

1

Full floating axle

2

Steering cylinder

3

Steering angle sensor (Hall sensor)

4

Magnet support

1-13

Power steering pump

Function The steering motor turns at a standardspeed of approx. 750 rpm provided the main and seat switches are closed.

Design

The steering motor is controlled (higher speed) by a steering wheel sensor (Hall sensor) via the control electronics on the motor housing.

The motor r.p.m. is governed by the steering wheel speed.

Z

If the hydraulic pump fails, emergency steering is provided at all times by the emergency pump in the servostat.

This requires greater steering effort!

1-14

Steering system block diagram Signal from spring-loaded brake / travel switch 1S2 / hydrostatic switch 7S21

Steering wheel

Sensor

Steering motor

Spring-loaded brake released

1-15

Servostat

Steering cylinder

Chassis / load section connection Tilt cylinder

M

Design

n

1)

Service note:

Z

n Sealed with Loctite n1) When adjusting the tilt cylinder you should still be able to feel the piston rod thread in the check bore hole.

1-16

When adjusting, ensure the tilt cylinders are synchronised.

Hydraulic system

Design

Control panel

A control block is used as standard with lifting/lowering, tilt and aux. hydraulics (ZH1).

Manual Control

Joystick Control

If an additional function is required, a control valve (ZH2) and a Joystick Control PCB can be added.

Manual Control The travel direction switch and the horn switch are contained in the lift/lower lever.

Joystick Control All hydraulic functions are controlled by the Joystick Control. The horn switch and the travel direction switch are contained in the Joystick Control.

Z

1-17

The dual pedal version does not have a travel direction switch. (Option)

Control valve Item

Manual Control

Description

Function

electrical 1

2 3

4

5

9

Z

8

7

6

The integrated load hold valve prevents accidental forward tilting when the electrical system is switched off.

The valve is factory pre-set.

refitting / installation, the lowering speed, forward and F After reverse tilt must be checked.

See section 2.

1-18

1

Lowering brake

2

Pressure relief valve

3

Reservoir return connection

4

Pressure port

5

Lift port

6

2R3/XB 29

Lift potentiometer

7

2S73/XB 75

Fwd/rev tilt switch

8

2S57/XB 76

ZH1 valve switch

9

2S76/XB 77

ZH2 valve switch

Joystick Control – Standard version 1 2

3

4

5

6

7

Item 1

Description hydraulic m1/2Y1 m2/2Y5

Lifting XB 29

2 3

PRV

Pressure relief valve Volume adjustment, forward tilt

5

m6/2Y47

XB 47

Rev. tilt

6

m3/2Y65

XB 49

Sideshift left

7

m7/2Y66

XB 51

ZH2 left

8

m8/2Y67

XB 50

ZH2 right

9

m4/2Y64

XB 48

Sideshift right

10 11

Z

12

11

10

9

8

The integrated load hold valve prevents accidental forward tilting when the electrical system is switched off.

The valve is factory pre-set.

refitting / installation, the lowering speed, forward and F After reverse tilt must be checked.

See section 2.

1-19

Lowering, volume control Emergency drain

4

13

Function

electrical

Volume adjustment, rev. tilt m5//2Y46

XB 46

Fwd. tilt

12

Measurement connection

13

Lowering speed

Joystick Control: Optional version for large auxiliary consumers Front view 1

Item 3

5

6

Description hydraulic

1

electrical

m1/2Y1 m2/2Y5

Lifting XB 29

2 3

Z

12

11

9

7,8

PRV

Pressure relief valve Volume adjustment, forward tilt

5

m6/2Y47

XB 47

Rev. tilt

6

m3/2Y65

XB 49

Sideshift left (back of hydraulic connection)

7

m7/2Y66

XB 50

ZH2 left (option) (back of hydraulic connection)

8

m8/2Y67

XB 50

ZH2 right (option) (back of hydraulic connection)

9

m4/2Y64

XB 48

Sideshift right (back of hydraulic connection)

10

The integrated load hold valve prevents accidental forward tilting when the electrical system is switched off.

11

The valve is factory pre-set.

1-20

Lowering, volume control Emergency drain

4

13

Function

Volume adjustment, rev. tilt m5//2Y46

XB 46

Fwd. tilt

12

Measurement connection

13

Lowering speed

Rear view 4

3

1

Item

Description hydraulic

1 2

electrical

m1/2Y1 m2/2Y5

Lifting XB 29

2 7

3

10

13

refitting / installation, the lowering speed, forward and F After reverse tilt must be checked.

PRV

Pressure relief valve Volume adjustment, forward tilt

5

m6/2Y47

XB 47

Rev. tilt

6

m3/2Y65

XB 49

Sideshift left (back of hydraulic connection)

7

m7/2Y66

XB 50

ZH2 left (option) (back of hydraulic connection)

8

m8/2Y67

XB 50

ZH2 right (option) (back of hydraulic connection)

9

m4/2Y64

XB 48

Sideshift right (back of hydraulic connection)

10

See section 2.

11

1-21

Lowering, volume control Emergency drain

4

8

Function

Volume adjustment, rev. tilt m5//2Y46

XB 46

Fwd. tilt

12

Measurement connection

13

Lowering speed

Pump motor / pump / pressure filter

Design A threephase motor @ 80V/23.5 kW is used to drive the pump.

7

6

1

5

4

2 3

Z Item

Description

Item

Motor overtemperature is shown by an indicator in the multifunction display.

Description

1

Pump motor

5

Measurement connection

2

Exposure valve

6

Pressure filter

3

Hydraulic pump

7

4

Hydraulic reservoir

Sensor bearing and temperature gauge connector

The thermal gauge for temperature control runs down into a field coil, the speed sensor is located in the sensor bearing.

Service note:

Z 1-22

Note the position of the exposure valve!

Groove depth (pump side): 6.5 mm – motor side: 9.5 mm

Electrical System Design Item

Description

1

Fan

2

Traction controller

3

Steering unit

4

Lift controller

5

Transformer

6

Fuses

Service note:

M

When testing for earth contact, remove connector XB 18/19 (sensor bearing) from the traction and hydraulic motors beforehand!

Observe ESD requirements. (Electro Static Discharge)

1-23

Electrical fuses

Charging contactor function The voltage application contactor for the charging connection and for options is controlled directly via the key switch. The charging contactor closes and applies voltage to the charging switch. The charging switch has a current limit to charge the capacitors in the controllers.

Drawing needs to be updated!

4

The main contactor is only controlled when the capacitors have been charged and the controllers have successfully completed a self-test. All other consumers (e.g. transformer for options, cabin heating) are switched on via the charging contactor.

Item 9

8

7

6

5

2

10

3

1-24

Description

2

Charging contactor K6

3

Charging switch

4

F1 overall fuse

5

1F9 electronics F/H control fuse

6

F2.1 fuse

7

F1.2 control fuse

8

F4 control fuse main contactor

9

F3.1 fuse

10

3F1 steering power motor fuse

Block diagram

MultiFunctional Display

Digital Input/Output Analog Input/ Power Output CANION Master

1M1 Traction controller CAN-OPEN

Sensor bearing

Manual operation of: Forward / reverse travel Lift / Lower Fwd./Rev. tilt Option ZH1/ZH2

2M1

Lift controller Sensor bearing

3M1

Service PC

1-25

General Truck Data / Test and Setting Values

General Truck Data ................................................ 2-2 Test and Setting Values ......................................... 2-5 Tightening torques ................................................. 2-8

Z M

Used before explanations.

Used before notices which must be observed to avoid material damage.

before safety instructions which must be observed to avoid F Used danger to personnel.

2-1

General Truck Data EP40 A

Chassis/Superstructure: Capacity

B

EP45

t

Load centre of gravity

mm

Load distance (DZ mast +32mm)

mm

Wheelbase

mm

Turning radius

mm

Net weight incl. battery

kg

Axle load, laden (front/rear)

kg

Axle load, unladen (front/rear)

kg

See operating instructions and data plate

Drive Traction controller type

Type

Rated tow force w / w.o. load S2 / 60 min.

N

Max. tow force w / w.o. load S2 / 5 min.

N

Gradeability w / w.o. load S2 / 30 min.

%

See operating instructions

2-2

EP50

EP40 Max. gradeability w / w.o. load S2 / 5 min.

%

Acceleration time w. / w.o. load to 10 m

s

Sound level, driver’s ear

db(A)

Travel speed w / w.o. load

km/h

G

EP45

EP50

See operating instructions

Mast / Load section Mast height retracted

mm

Mast height extended

mm

Height above overhead guard (cabin + 15mm)

mm

Free lift

mm

Lift

mm

Fork dimensions s/e/l

mm

Fork carriage DIN 15173, class / type A, B Fork carriage width

See operating instructions

50 x 125 x 1150

50 x 150 x 1150

p

ISO 3A

p

p

mm

See operating instructions

2-3

G1

EP50

DIN 15170-H

p

p

23.5

p

p

43 536 A

p

p

Hydraulics Pump motor Capacity at S3 15%

K

EP45

Attachments Attachment coupling type / DIN

I

EP40

kW

Battery Battery in accordance with DIN

2-4

Test and Setting Values

B

EP40

EP45

EP50

18

p

p

Hydraulic

p

p

Drive Traction motor output (S2 = 60 min)

kW

Current consumption

D

Brakes Service brake

E

Service brake pressure

bar

90

p

p

Spring-loaded accumulator cylinder spring pre-tension (lift)

mm

20+5

p

p

Wheels/Axles Full rubber tyres

See operating instructions

Front tyre size Rear tyre size Track width, front

mm

Track width, rear

mm

2-5

F

G

G1

EP45

EP50

Steering system Steering motor

kW

2

p

p

Pressure relief valve (not adjustable)

bar

90

p

p

Impact valve (not adjustable)

bar

180

p

p

bar

200

p

p

l / min

30

p

p

α°/β°

6/8

p

p

Mast / Load section Mast lift cylinder line break safety device LB3C 0.8-70 (s=)

mm

Line break safety device / Lowering brake valve LB4C 0.8-110 Free lift cylinder (s=)

mm

Attachments Max. operating pressure Oil volume for attachments

H

EP40

Chassis / load section connection Mast / fork carriage fwd./rev. tilt

2-6

EP40

I

EP45

Hydraulics Lift speed w / w.o. load

m/s

Lowering speed w / w.o. load

m/s

K

See operating instructions

Battery Battery Battery weight

V / Ah

See operating instructions and data plate

kg

2-7

EP50

Tightening torques EP40 A

B

Chassis/Superstructure: Counterweight / Chassis

Nm

M24 x 1.5 x 60 - 8.8 = 600

Counterweight, top

Nm

M16 x 70 - 8.8 = 210

Overhead guard / rubber mounting

Nm

M16 x 80 - 8.8 = 210

Nm

M24 x 50 - 12.9 = 700

Wheels / drive axle 10 hole rim

Nm

Spherical collar nut M22 x 1.5 - 10.9 = 430

Wheels / steering axle 5 hole rim

Nm

Spherical collar screw M14 x 1.5 - 10.9 = 220

Motor / pump

Nm

M8 x 75 - 8.8 = 25+5

Steering axle on counterweight

Nm

M20 x 45 - 8.8 = 430

Steering cylinder / steering axle

Nm

M16 x 40 - 10.9 ratchet = 250+10

Drive Drive / truck chassis

E

F

EP45

Wheels/Axles

Steering

2-8

EP50

EP40 G

Mast / Load section Mast support / chassis

H

Nm

M20 x 60 - 12.9 = 700

Nm

M32 x 1.5 = 200

Nm

M8 x 115 = 25+5

Controller / truck

Nm

M8 = 25

Traction motor connections

Nm

M12 = 50

Lift motor connections

Nm

M10 = 40

Terminal socket X1.1 / X1.2

Nm

M10 = 40

Chassis / load section connection Tilt cylinder / jam nut

I

Hydraulics Motor / pump

J

EP45

Electrical System

2-9

EP50

Maintenance of Cat Products 1.2 Maintenance Interval Definition

Cat products are serviced on the basis of standard maintenance checklists. The following (enclosures) are applied: • Maintenance checklist, • Additional service items for system trucks, • Additional inspection items for UVV(*) testing where servicing and UVV test are combined.

Z

1

Preparation time:

Net servicing time:

see also UVV test instructions.

The enclosed lists are for sample purposes.

The maintenance checklists are issued by the persons in charge.

Maintenance intervals and instructions are issued by the VZ / AF customer service managers.

Total servicing time: Total time:

The maintenance checklist is a working guideline for customer service technicians to help them perform maintenance work. Any other type of work not mentioned here is repair or other test work, e.g. UVV test.

Terminology Definition

1.1 Maintenance Definition Maintenance: Inspection: Repair:

Maintaining the rated condition.

Determining and assessing the actual condition.

Restoring the rated condition (error diagnostics / error rectification, parts replacement etc.).

(*) UVV = Unfall VerHütungsvorschriften (German Safety Regulations)

Time required to expose the components, e.g. disassembly and assembly of brush covers.

Time spent on servicing the components, e.g. visual inspection of carbon brushes and determining the wear level.

Sum of preparation and net servicing time.

Overall time between arrival at and departure from customer.

In the framework of maintenance, an operational test is performed and where possible the brake lining wear level assessed via a peep hole. A thorough inspection of the brakes is carried out at least 1 x year or every 1000 service hours. To do this, the brakes, e.g. load wheel brakes, must be opened.

The time required for this is stipulated in the UVV test overtime specifications.

3-1

2

Points covered under maintenance

3

2.1 Test items • • • • • •

Summary • Maintenance is a planned preventative strategy designed to maintain the truck’s rated condition.

• It is condition and time-oriented.

• It extends the working life of the product and increases its uptime.

• It provides security to the user of the product.

Operation Correct levels (e.g. oil level) Secure attachments Damage / wear Settings (e.g. play / paralletity) Sealing / leakages

Maintenance and repair work is extended after 1000 service hours or at least 1 x annually.

2.2 Maintenance items • Cleaning (removal of contamination caused through normal use, e.g. brake lining dust) • Grease, oil, lubricants • Bleeding • Adjusting • Tightening

3-2

Maintenance checklist Customer:

Place: Type: Serial no.: Year of manufacture:

Service hours:

Complaints Yes No 001

Brakes Brake force of operating and parking brakes Brake lining wear Brake fluid level (oil level) Lines and connections

Complaints Yes No 003

o

o

o

o

o

o

o

o

004 002

Electrics Instruments and operating switches Testing the signal system Fuses and wiring Lighting Travel direction switches Microswitch settings Contactors and relays Safety switches Electrical steering Carbon brush wear Cable and motor attachments Electronics check Check / delete error log book Check parameters, adjust if necessary

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

Energy supply Battery Battery plug Gas system Travel Valve setting Ignition and spark plugs Distributors Replace air, oil and fuel filters Check engine oil V-belt Exhaust system Coolant level Anti-freeze inspection Engine suspension Test transmission for noises Hydrostat Check oil or grease filling Wheel bearings and wheel attachments Tyre wear Tyre aire pressure

3-3

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

Customer:

Place: Type: Serial no.: Year of manufacture:

Service hours:

Complaints Yes No 005

Structure of truck Battery trolley Mast attachment Doors and covers Counterweight bolts Overhead guard Slide rails Driver’s seat Support systems Labels

006

Hydraulic movement Roller bearings and stops Mast section play and parallelity Lift chains Pull rod Forks Tilt angle Connections and lines Cylinders and piston rods Cylinders and piston rod attachments Check oil level, replenish if necessary Replace hydraulic oil filter Hydraulic system operation Attachments and auxiliary equipment

Complaints Yes No Operator platform

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

007

008

009

3-4

Agreed work Fully lubricate the truck in accordance with lubrication schedule When maintenance is completed, present the truck to the responsible person.

Steering Steering play and steering chain Hydraulic steering Steering axle Steering housing oil level Emergency recovery test System components Mast Bracing Lift cutouts Diagonal travel switch Slack chain switch Chain settings Potentiometers, index switches, sensor bearings Slide pieces

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

Customer:

Place: Type: Serial no.: Year of manufacture:

Service hours:

Complaints Yes No Aux. lift and attachment Gear wheels and toothed racks Creep distances and limit positions Chain settings Bearings and stops Traverse and lift speeds Swivel Telescopic forks Synchronised Transmission switches Overpressure Cabin Cabinets Safety switches and panels Abseil device Hydraulics Pump speed Wheels Drive wheel position and forward travel Catches Starting rollers Hicont Sensor system

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

Complaints Yes No Wire guidance system Hydraulic cylinder brake Stopping distances and end of aisle safety device Sensors Electrics Personal safety system Operational test

3-5

o

o

o

o

o

o

o

o

o

o

Additional test items for UVV test Where maintenance and UVV test work are combined, the following work must also be carried out.

1.

Chassis

• Crack inspection on load-bearing parts and weld seams.

• Check decals for completion and legibility. (opposite steering, hooks, capacity diagram etc.).

2.

Mast

• Check load forks for cracks and deformation. (also welding seams if necessary).

• Measure lift chain, elongation under max. load with chain wear ruler no. 3 (1/2“ - 11/4“) 4.

Brakes

• Measure brake retardation.

• Visually inspect all brake components.

• Measure brake lining thickness and air gap.

11. Hydraulic system • Check operation of pressure relief valves.

• Assess leaked oil rate for lowering and tilting.

14. Special accessories • Check operating stage works safely.

3-6

Service Manual Items File no.

Title

B 1003

Drive unit

B 6001

Steering angle sensor replacement / adjustment

D 3002

Checking and Removing the Spring-Loaded Brake

D 4002

Main brake cylinder (single stage)

D 6360.03

Braking distances, minimum braking ratio

D 6360.16

Guidelines for brake line installation

D 6360.21

Parking brakes

F 4001 G 6355.01

Steering aux. motor connection diagram Load chain elongation testing

G1 6401.01 Forks I 5012

Control valve standard setting

J 5003

Information and Service Display

J 6900.09

Notes on how to avoid accidents and material damage during maintenance, test and repair work on industrial trucks with electronic components

Z 0000.15

Notes on how to avoid malfunctions and material damage when cleaning an industrial truck

4-1

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