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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