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Caterpillar EP18CPN Lift Truck Service, Operation & Maintenance Manuals – PDF DOWNLOAD
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Caterpillar EP18CPN Lift Truck Service, Operation & Maintenance Manuals – PDF DOWNLOAD
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Description
Caterpillar EP18CPN Lift Truck Service, Operation & Maintenance Manuals – PDF DOWNLOAD
DESCRIPTION:
Caterpillar EP18CPN Lift Truck Service, Operation & Maintenance Manuals – PDF DOWNLOAD
FOREWORD
The Occupational Safety and Health Administration (OSHA) prohibits employees under the age of 18 years old from operating
lift trucks, and is now mandating operator training for all lift truck operators.
SAFE and EFFICIENT OPERATION of a lift truck depends to a great extent on the skill and alertness of the operator. To develop
the skill, the operator should read this manual to understand the following points:
(1) Working capabilities and limitations of the lift truck
(2) Make-up of the lift truck
(3) Safe driving and load handling procedures
It is the employer’s responsibility to make sure the operator can see, hear, and has the physical and mental ability to operate
the lift truck safely.
It is also important that a qualified person experienced in lift truck operation should guide new operators through several
driving and load handling operations before they attempt to operate the lift truck on their own.
Note:
– This manual contains information necessary for the operation and maintenance of standard lift trucks.
– This manual contains information necessary for the operation and maintenance of standard lift trucks.
– Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a lift truck, make sure the necessary instructions are available and understood.
– Forklift truck operator training is provided through your authorized Cat lift truck dealer. They will be glad to help you and answer any questions you may have about operating your new lift truck. Forklift trucks are NOT intended for use on public roads.
– If you resell a lift truck, be sure to attach the original Operation & Maintenance Manual to the lift truck. In some countries, strict regulations do not allow imported lift trucks for resale. For resale information, contact your authorized Cat lift truck dealer.
– If a lift truck is resold from another country, an Operation & Maintenance Manual attached to the lift truck may not meet your country’s rules and regulations. For manual information, contact your authorized Cat lift truck dealer.
TABLE OF CONTENTS:
Caterpillar EP18CPN Lift Truck Service, Operation & Maintenance Manuals – PDF DOWNLOAD
99750-6M120-00_FOREWORD.................................................................................. 1 99750-6M120-01_SAFETY_RULES_FOR_LIFT_TRUCK_OPERATORS..................................................... 11 99750-6M120-02_KNOW_YOUR_LIFT_TRUCK...................................................................... 39 99750-6M120-03_HOW_TO_AVOID_A_TIPOVER.................................................................... 101 99750-6M120-04_OPERATION................................................................................. 109 99750-6M120-05_OPERATING_TECHNIQUES...................................................................... 131 99750-6M120-06_STORING_THE_LIFT_TRUCK.................................................................... 143 99750-6M120-07_TRANSPORTATION_HINTS...................................................................... 145 99750-6M120-08_SPECIAL_SITUATIONS........................................................................ 151 99750-6M120-09_TROUBLESHOOTING........................................................................... 153 99750-6M120-10_MAINTENANCE............................................................................... 167 99750-6M120-11_SERVICE_DATA.............................................................................. 211 99750-6M120-12_TO_THE_CAT_LIFT_TRUCK_OWNER............................................................... 215 99750-6M120-13_APPENDIX.................................................................................. 219 FOREWORD............................................................................................. 0 FOREWORD......................................................................................... 0 How to Use This Manual........................................................................... 0 Lift Truck Models Covered in This Manual..................................................... 0 SAFETY RULES FOR LIFT TRUCK OPERATORS................................................................ 0 General.......................................................................................... 0 Warning Decals, Location......................................................................... 0 Warning Decals and Description................................................................... 0 No Riders Decal.............................................................................. 0 Fasten Seat Belt Decal....................................................................... 0 Capacity Plate............................................................................... 0 No One under / on Forks Decal................................................................ 0 Pinch Point Decal (Mast)..................................................................... 0 Overhead Guard Decal......................................................................... 0 Load Backrest Extension Decal................................................................ 0 Safety Rules..................................................................................... 0 Operating Precautions............................................................................ 0 Working Precautions.............................................................................. 0 KNOW YOUR LIFT TRUCK................................................................................. 0 Serial Number and Capacity Plate................................................................. 0 3 Wheel Model................................................................................ 0 4 Wheel Model................................................................................ 0 Electrical Components............................................................................ 0 Controller................................................................................... 0 Motor........................................................................................ 0 Model View....................................................................................... 0 3 Wheel Model................................................................................ 0 4 Wheel Model................................................................................ 0 MC Model..................................................................................... 0 FC Model..................................................................................... 0 Driving Switches and Controls.................................................................... 0 Key Switch................................................................................... 0 Direction Lever.............................................................................. 0 Foot Direction Control (Option).............................................................. 0 Dual Pedal (Option).......................................................................... 0 Armrest FNR Switch (FC Model Option)......................................................... 0 Battery Disconnect Switch.................................................................... 0 Turn Signal / Light Switch................................................................... 0 Steering Column Tilt Lever................................................................... 0 Meter Panel...................................................................................... 0 Configuration of Meter Panel................................................................. 0 Basic Screen Display......................................................................... 0 Battery Low Warning.......................................................................... 0 Warning icons................................................................................ 0 Setting and Adjustment....................................................................... 0 Display When Error Occurs.................................................................... 0 Presence Detection System........................................................................ 0 Mast Interlock System (MC Model)............................................................. 0 Mast Interlock System (FC Model)............................................................. 0 Mast Interlock System Functions.............................................................. 0 Driving Interlock System..................................................................... 0 Driving Interlock System Functions........................................................... 0 Neutral Interlock System..................................................................... 0 Seat Belt Warning............................................................................ 0 Parking Brake Warning Alarm and Warning Icon................................................. 0 Parking Brake Protection......................................................................... 0 Operating Levers and Controls (MC Model)......................................................... 0 Lift Lever................................................................................... 0 Tilt Lever................................................................................... 0 Mast Height Sensor (Option).................................................................. 0 Attachment Lever............................................................................. 0 Operating Switches and Controls (FC Model)....................................................... 0 Lift Switch.................................................................................. 0 Tilt Switch.................................................................................. 0 Armrest FNR Switch (FC Model Option)......................................................... 0 Mast Height Sensor (Option).................................................................. 0 Forward and Backward Adjustment.............................................................. 0 Up and Down Adjustment....................................................................... 0 Operator Seat.................................................................................... 0 Seat Adjustment.............................................................................. 0 Forward and Back Adjustment.................................................................. 0 Adjustment of Suspension..................................................................... 0 Backrest Angle Adjustment.................................................................... 0 Pocket for the Manual........................................................................ 0 Operator Presence Switch and Alarm........................................................... 0 Seat Belt........................................................................................ 0 Fork Locking Pins................................................................................ 0 Replacing Forks.................................................................................. 0 Drawbar Pin...................................................................................... 0 Assist Grip...................................................................................... 0 Battery Cover.................................................................................... 0 Cover Latch.................................................................................. 0 Battery Replacement and Charging............................................................. 0 Battery Removal and Installation............................................................. 0 Charging the Battery on the Lift Truck....................................................... 0 Hydraulic Tank Oil Filler Hole................................................................... 0 Rear View Mirror (Option)........................................................................ 0 Brake Fluid Reserve Tank......................................................................... 0 PS Pump Reserve Oil Tank (4 Wheel Model)......................................................... 0 Parking Brake Check Mode......................................................................... 0 Integrated Side Sifter (Option).................................................................. 0 Fork Positioner (Option)......................................................................... 0 HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE........................................................... 0 Know What Lift Truck Stability Is................................................................ 0 Center of Gravity (CG)........................................................................... 0 Stability and Center of Gravity (Top View)....................................................... 0 Stability and Center of Gravity (Side View)...................................................... 0 Lift Truck Stability Base........................................................................ 0 Capacity (Weight and Load Center)................................................................ 0 Capacity Plate................................................................................... 0 Sample....................................................................................... 0 Do’s and Don’ts to Avoid Tipover................................................................. 0 How to Survive in a Tipover...................................................................... 0 OPERATION............................................................................................ 0 New Lift Truck Break-in.......................................................................... 0 Before Starting.................................................................................. 0 Starting..................................................................................... 0 Mast Interlock System........................................................................ 0 Driving Interlock System..................................................................... 0 Seat Adjustment.............................................................................. 0 Check Central Vehicle Monitoring System.......................................................... 0 Before Moving Lift Truck......................................................................... 0 Lift Truck Operation............................................................................. 0 Changing Speed............................................................................... 0 Changing Direction........................................................................... 0 Plugging Mode................................................................................ 0 Operating Techniques......................................................................... 0 Steering (Turning)........................................................................... 0 Stopping Lift Truck.............................................................................. 0 Parking Lift Truck (After Stopping).............................................................. 0 Leaving Lift Truck............................................................................... 0 OPERATING TECHNIQUES................................................................................. 0 Stacking Methods................................................................................. 0 Stacking Different Loads in Size............................................................. 0 Stacking Small Identical Loads............................................................... 0 Stacking Large Identical Loads............................................................... 0 Handling Loads Safely............................................................................ 0 Correct Operating Steps.......................................................................... 0 Incorrect Operating Steps........................................................................ 0 Lifting the Load................................................................................. 0 Traveling with the Load.......................................................................... 0 Unloading........................................................................................ 0 Working on Grades................................................................................ 0 Normal Travel Position....................................................................... 0 Traveling on a Grade......................................................................... 0 Stopping on a Grade.......................................................................... 0 STORING THE LIFT TRUCK............................................................................... 0 End of Each Shift Storage........................................................................ 0 Long Term Storage................................................................................ 0 Hydraulic System............................................................................. 0 Battery...................................................................................... 0 Controller................................................................................... 0 Other........................................................................................ 0 TRANSPORTATIONS HINTS................................................................................ 0 Lifting Positions................................................................................ 0 Loading Instructions............................................................................. 0 Lift Truck Loading and Shipping.................................................................. 0 Lift Truck Lifting and Tiedown Information....................................................... 0 Operating the Lift Truck Without Power Supply.................................................... 0 SPECIAL SITUATIONS................................................................................... 0 Care in Cold Weather............................................................................. 0 Battery...................................................................................... 0 Care in Hot Weather.............................................................................. 0 Battery...................................................................................... 0 TROUBLESHOOTING...................................................................................... 0 If the Lift Truck Shuts Down Suddenly............................................................ 0 Fuses Replacement............................................................................ 0 If Central Vehicle Monitoring System Does Not Turn On............................................ 0 If Abnormal Noise Sounds From Electromagnetic Brake.............................................. 0 If Lights Won't Glow............................................................................. 0 Light Bulb Replacement....................................................................... 0 If Diagnostic Code Blinks or Glows and the Lift Truck Stop Moving................................ 0 If the Mast and Attachments Malfunction.......................................................... 0 Replacing Tires.................................................................................. 0 Before Replacing Tires........................................................................... 0 To Remove Wheel.............................................................................. 0 To Raise Front Wheel......................................................................... 0 To Raise Rear Wheel.......................................................................... 0 To Install Wheel............................................................................. 0 Manually Releasing Magnet Brakes................................................................. 0 Manual release of magnet brake............................................................... 0 Diagnostic Code List............................................................................. 0 MAINTENANCE.......................................................................................... 0 General.......................................................................................... 0 Inspection Precautions........................................................................... 0 LOCKOUT/TAGOUT................................................................................... 0 Maintenance Schedule............................................................................. 0 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First........................... 0 Every 50 Service Hours or Weekly, Whichever Comes First...................................... 0 Every 1000 Service Hours or 6 Months, Whichever Comes First.................................. 0 Every 2000 Service Hours or 1 year, Whichever Comes First.................................... 0 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First............................... 0 Faulty Operation Found the Day Before........................................................ 0 Oil or Battery Electrolyte Leaks............................................................. 0 Tires and Rims............................................................................... 0 Wheel Nuts................................................................................... 0 Head Light and Rear Light.................................................................... 0 Hydraulic Hoses, Pipes, and Joints........................................................... 0 Load Backrest Extension and Lift Bracket..................................................... 0 Lift Cylinder and Tilt Cylinder.............................................................. 0 Tilt Cylinder Socket Bolts................................................................... 0 Forks........................................................................................ 0 Overhead Guard............................................................................... 0 Assist Grip.................................................................................. 0 Brake Fluid Level............................................................................ 0 Hydraulic Oil Level.......................................................................... 0 Battery Electrolyte.......................................................................... 0 PS Pump Brake Fluid Tank (4 Wheel Model)..................................................... 0 Operator Seat................................................................................ 0 Seat Belt.................................................................................... 0 Accelerator Pedal............................................................................ 0 Brake Pedal.................................................................................. 0 Horn......................................................................................... 0 Parking Brake Switch......................................................................... 0 Key Switch and Meter Panel................................................................... 0 Battery Charge Level......................................................................... 0 Steering Wheel and Column.................................................................... 0 Lift Chains.................................................................................. 0 Mast......................................................................................... 0 Mast Interlock System........................................................................ 0 Driving Interlock System..................................................................... 0 Parking Brake Warning Alarm.................................................................. 0 Driving Control System (Traction Motors, Steering System, and Brake System).................. 0 Rear Axle Steering Gear (3 Wheel Model)...................................................... 0 Parking Brake (PKB) Check Mode............................................................... 0 Every 50 Service Hours or Weekly, Whichever Comes First.......................................... 0 Bolts and Nuts............................................................................... 0 Battery Electrolyte Specific Gravity......................................................... 0 One Month (30 days) or 200 Service Hours After Delivery of a New Truck, Whichever Comes First.... 0 Electrical Wires............................................................................. 0 Contactors and Fuses......................................................................... 0 Microswitches and Steering Sensor............................................................ 0 Chain Wheel.................................................................................. 0 Every 1000 Service Hours or 6 Months, Whichever Comes First...................................... 0 Wheel Bearings............................................................................... 0 Drift Lowering Distance of Lift Cylinders.................................................... 0 Drift Forward Tilting Distance of Tilt Cylinders............................................. 0 Hydraulic Tank Filters....................................................................... 0 Transfer Oil................................................................................. 0 Mast Supports................................................................................ 0 Tilt Sockets................................................................................. 0 Lift Chains.................................................................................. 0 Mast Strips and Roller Surfaces.............................................................. 0 Every 2000 Service Hours or 1 Year, Whichever Comes First........................................ 0 Hydraulic Oil................................................................................ 0 Brake Fluid.................................................................................. 0 PS Pump Oil (4 Wheel Model).................................................................. 0 Parts to Be Changed Periodically................................................................. 0 SERVICE DATA......................................................................................... 0 Recommended Oils and Greases..................................................................... 0 Specifications (Standard Models)................................................................. 0 3 Wheel Model................................................................................ 0 4 Wheel Model................................................................................ 0 Capacities and Lift Truck Weight (Standard Models)............................................... 0 3 Wheel Model................................................................................ 0 4 Wheel Model................................................................................ 0 TO THE CAT LIFT TRUCK OWNER.......................................................................... 0 The Importance of Genuine Parts.................................................................. 0 Proper Disposal of Your Lift Truck............................................................... 0 Instructions for Ordering Parts.................................................................. 0 Service Registration............................................................................. 0 APPENDIX............................................................................................. 219 Noise Level...................................................................................... 219 Vibration Level.................................................................................. 219 Climate Conditions............................................................................... 219 Specifications................................................................................... 220 3 Wheel Model................................................................................ 220 4 Wheel Model................................................................................ 221 Dimensions, Performance, Electric motors..................................................... 222 Mast Performance and Capacity................................................................ 226 Capacities at Various Load Centers........................................................... 230 Panel cabin...................................................................................... 231 Battery exchange or battery charging......................................................... 231 Driving...................................................................................... 231 Cleaning Top Roof............................................................................ 231 Maintenance.................................................................................. 232 INDEX................................................................................................ 233 SPINE................................................................................................ 235 BACK COVER........................................................................................... 236 FOREWORD_CAT.pdf..................................................................................... 0 FOREWORD......................................................................................... 0 FOREWORD..................................................................................... 0 How to Use This Manual....................................................................... 0 Lift Truck Models Covered in This Manual................................................. 0 99750-6M130_00_FOREWORD.................................................................................. 237 空白ページ................................................................................................ 238 空白ページ................................................................................................ 246 99750-6M130_01_SAFETY_RULES_FOR_LIFT_TRUCK_OPERATORS..................................................... 247 99750-6M130_02_KNOW_YOUR_LIFT_TRUCK...................................................................... 275 99750-6M130_03_HOW_TO_AVOID_A_TIPOVER_HOW_TO_SURVIVE_ONE................................................. 337 99750-6M130_04_OPERATION................................................................................. 345 99750-6M130_05_OPERATING_TECHNIQUES...................................................................... 367 99750-6M130_06_STORING_THE_LIFT_TRUCK.................................................................... 379 99750-6M130_07_TRANSPORTATIONS_HINTS..................................................................... 381 99750-6M130_08_SPECIAL_SITUATIONS........................................................................ 387 99750-6M130_09_TROUBLESHOOTING........................................................................... 389 99750-6M130_10_MAINTENANCE............................................................................... 403 99750-6M130_11_SERVICE_DATA.............................................................................. 447 99750-6M130_12_TO_THE_CAT_LIFT_TRUCK_OWNER............................................................... 451 99750-6M130_13_APPENDIX.................................................................................. 455 99759-6M100-00........................................................................................... 456 99759-6M100-01........................................................................................... 470 99759-6M100-02........................................................................................... 476 99759-6M100-03........................................................................................... 512 99759-6M100-04........................................................................................... 518 99759-6M100-05........................................................................................... 538 99759-6M100-06........................................................................................... 566 99759-6M100-07........................................................................................... 584 99759-6M100-08........................................................................................... 600 99759-6M100-09........................................................................................... 704 99759-6M100-10........................................................................................... 752 99759-6M100-11........................................................................................... 768 99759-6M120-00_FOREWORD.................................................................................. 772 99759-6M120-01........................................................................................... 788 99759-6M120-01_GENERAL_INFORMATION....................................................................... 804 99759-6M120-02_ELECTRICAL_COMPONENTS..................................................................... 810 99759-6M120-03_POWER_TRAIN............................................................................... 850 99759-6M120-04_TRANSFER_UNITS............................................................................ 856 99759-6M120-05_REAR_AXLE................................................................................. 874 99759-6M120-06_BRAKE_SYSTEM.............................................................................. 902 99759-6M120-07_STEERING_SYSTEM........................................................................... 920 99759-6M120-08_HYDRAULIC_SYSTEM.......................................................................... 936 99759-6M120-09_MAST_AND_FORKS............................................................................1042 99759-6M120-10_SERVICE_DATA..............................................................................1098 99759-6M120-11_PANEL_CABIN...............................................................................1114 FOREWORD............................................................................................. 0 1. Safety........................................................................................ 0 2. LOCKOUT/TAGOUT................................................................................ 0 3. How to Use This Manual........................................................................ 0 3.1 Forklift Model........................................................................... 0 4. Symbols and Abbreviations..................................................................... 0 5. Units......................................................................................... 0 Chapter 1 GENERAL INFORMATION........................................................................ 0 1. Model View.................................................................................... 0 2. Lift Truck Models Covered..................................................................... 0 3. Serial Number Locations....................................................................... 0 4. Specifications................................................................................ 0 Chapter 2 ELECTRICAL COMPONENTS...................................................................... 0 1. Console....................................................................................... 0 1.1 MC Model................................................................................. 0 1.2 FC Model................................................................................. 0 2. Disassembling Console......................................................................... 0 2.1 Disassembling Sequence................................................................... 0 2.2 Suggestions for Disassembly.............................................................. 0 3. Assembling Console............................................................................ 0 4. Meter panel................................................................................... 0 4.1 Functions of Meter panel................................................................. 0 4.2 Adjusting and Setting of Meter panel..................................................... 0 4.3 Diagnostic Code List..................................................................... 0 5. Key Switch.................................................................................... 0 6. Lighting Switch (Rear Working Light).......................................................... 0 6.1 Lights................................................................................... 0 6.2 Specification Chart...................................................................... 0 7. Horn Switch and Battery Disconnect Switch..................................................... 0 7.1 MC Model................................................................................. 0 7.2 FC Model................................................................................. 0 8. Troubleshooting of Lighting and Horn Systems.................................................. 0 9. Parking Brake Switch.......................................................................... 0 10. Combination Switch........................................................................... 0 10.1 Direction lever......................................................................... 0 10.2 Light Switch, Turn Signal Switch (option)............................................... 0 11. Disassembling Accelerator Control............................................................ 0 11.1 Disassembling Sequence.................................................................. 0 11.2 Adjusting............................................................................... 0 12. FC Armrest................................................................................... 0 12.1 Lift Switch............................................................................. 0 12.2 Tilt Switch............................................................................. 0 12.3 Armrest FNR Switch (FC Model Option).................................................... 0 12.4 Forward and Backward Adjustment......................................................... 0 12.5 Up and Down Adjustment.................................................................. 0 13. Foot Direction Control (Option).............................................................. 0 14. Dual Pedal (Option).......................................................................... 0 15. Fuses........................................................................................ 0 Chapter 3 POWER TRAIN................................................................................ 0 1. Removing Battery.............................................................................. 0 2. Removing Front Wheels......................................................................... 0 3. Removing Transfer Assemblies, Traction Motors................................................. 0 4. Installing Transfer Assemblies, Traction Motors and Calipers.................................. 0 5. Service Data.................................................................................. 0 Chapter 4 TRANSFER UNITS............................................................................. 0 1. Specifications................................................................................ 0 2. Structure..................................................................................... 0 2.1 External View............................................................................ 0 2.2 Structure................................................................................ 0 3. Disassembling Transfer Units.................................................................. 0 3.1 Preparation.............................................................................. 0 3.2 Disassembly Sequence..................................................................... 0 4. Inspecting Transfer Units..................................................................... 0 5. Assembling Transfer Units..................................................................... 0 5.1 Assembly Sequence........................................................................ 0 6. Service Data.................................................................................. 0 Chapter 5 REAR AXLE.................................................................................. 0 1. Structure..................................................................................... 0 1.1 Rear Axle................................................................................ 0 1.2 Steering Cylinder........................................................................ 0 2. Removing Rear Wheels.......................................................................... 0 2.1 Earth wire............................................................................... 0 2.2 Preparation.............................................................................. 0 2.3 Removing Wheels.......................................................................... 0 3. Installing Rear Wheel......................................................................... 0 4. Removing Rear Axle Assembly................................................................... 0 4.1 Preparation.............................................................................. 0 4.2 Removal Sequence......................................................................... 0 4.3 Suggestions for Removal.................................................................. 0 5. Installing Rear Axle Assembly................................................................. 0 6. Disassembling Rear Axle Assembly.............................................................. 0 6.1 Disassembly Sequence..................................................................... 0 6.2 Suggestions for Disassembly.............................................................. 0 7. Inspection Rear Axle Assembly................................................................. 0 8. Installing Steering Cylinder and Hydraulic Pipe............................................... 0 8.1 Installation Sequence.................................................................... 0 9. Assembling Knuckle and Kingpin................................................................ 0 9.1 Assembly Sequence........................................................................ 0 9.2 Suggestions for Assembly................................................................. 0 10. Assembling Rear Axle Hub..................................................................... 0 10.1 Assembly Sequence....................................................................... 0 10.2 Suggestions for Assembly................................................................ 0 11. Removing Steering Sensor..................................................................... 0 12. Installing Steering Sensor Assembly.......................................................... 0 13. Disassembling Steering Cylinder.............................................................. 0 13.1 Disassembly Sequence.................................................................... 0 13.2 Suggestions for Disassembly............................................................. 0 14. Inspecting Steering Cylinder................................................................. 0 15. Assembling Steering Cylinder................................................................. 0 15.1 Assembly Sequence....................................................................... 0 15.2 Suggestions for Assembly................................................................ 0 16. Adjustment................................................................................... 0 16.1 Adjusting of Steering Sensor............................................................ 0 16.2 Adjusting of Minimum Turning Radius..................................................... 0 17. Troubleshooting.............................................................................. 0 18. Service Data................................................................................. 0 18.1 Rear axle............................................................................... 0 18.2 Steering cylinder....................................................................... 0 Chapter 6 BRAKE SYSTEM............................................................................... 0 1. Specifications................................................................................ 0 2. Structure..................................................................................... 0 2.1 Outline of Brake System.................................................................. 0 2.2 Brake Pedal Assembly..................................................................... 0 2.3 Electro-magnetic Brake Assembly.......................................................... 0 3. Removing Master Cylinder...................................................................... 0 3.1 Removal Sequence......................................................................... 0 4. Disassembling Master Cylinder................................................................. 0 4.1 Disassembly Sequence..................................................................... 0 5. Inspecting and Adjusting Master Cylinder...................................................... 0 6. Assembling Master Cylinder.................................................................... 0 7. Inspecting and Adjusting Brake Pedal Assembly................................................. 0 8. Adjusting and Manual Release of Electro-Magnetic Brake........................................ 0 9. Troubleshooting............................................................................... 0 9.1 Brake Pedal Assembly..................................................................... 0 9.2 Parking Brake............................................................................ 0 10. Service Data................................................................................. 0 10.1 Brake Pedal............................................................................. 0 10.2 Master Cylinder......................................................................... 0 Chapter 7 STEERING SYSTEM............................................................................ 0 1. Specifications................................................................................ 0 2. Structure..................................................................................... 0 2.1 Outline of Steering System............................................................... 0 3. Removing Steering Linkage Assembly............................................................ 0 3.1 Removal Sequence......................................................................... 0 3.2 Suggestions for Removal.................................................................. 0 4. Inspecting Steering Linkage Assembly.......................................................... 0 5. Installing Steering Linkage Assembly.......................................................... 0 6. Removing PS Pump Assembly..................................................................... 0 6.1 Removal Sequence......................................................................... 0 6.2 Suggestions for Removal.................................................................. 0 7. Installing PS Pump Assembly................................................................... 0 8. Disassembling PS Pump Assembly................................................................ 0 8.1 Hydraulic Oil Drain Procedure............................................................ 0 8.2 Disassembly Sequence..................................................................... 0 9. Assembling PS Pump Assembly................................................................... 0 10. Inspecting PS Pump Assembly.................................................................. 0 11. Troubleshooting.............................................................................. 0 12. Service Data................................................................................. 0 12.1 PS Pump Assembly........................................................................ 0 12.2 Reserve Tank............................................................................ 0 Chapter 8 HYDRAULIC SYSTEM........................................................................... 0 1. Specifications................................................................................ 0 1.1 MC model................................................................................. 0 1.2 FC model................................................................................. 0 2. Structure..................................................................................... 0 2.1 Hydraulic Line (MC Model)................................................................ 0 2.2 Hydraulic Line (FC Model)................................................................ 0 2.3 Lift and Tilt Cylinders.................................................................. 0 2.4 Down Safety Valve........................................................................ 0 3. Removing Control Valve (MC Model)............................................................. 0 3.1 Preparation.............................................................................. 0 3.2 Suggestions for Removal.................................................................. 0 4. Installing Control Valve...................................................................... 0 5. Removing Gear Pump............................................................................ 0 5.1 Preparation.............................................................................. 0 5.2 Suggestions for Removal.................................................................. 0 6. Installing Gear Pump.......................................................................... 0 7. Removing Suction Filter and Return Filter..................................................... 0 7.1 Preparation.............................................................................. 0 7.2 Suggestions for Removal.................................................................. 0 8. Installing Suction Filter and Return Filter................................................... 0 8.1 Suggestions for Installation............................................................. 0 9. Removing Lift Cylinders (Simplex Mast)........................................................ 0 9.1 Removal Sequence......................................................................... 0 9.2 Suggestions for Removal.................................................................. 0 10. Removing Lift Cylinders (Triplex Mast and Duplex Mast)....................................... 0 10.1 Removal Sequence........................................................................ 0 10.2 Suggestions for Removal................................................................. 0 11. Installing Lift Cylinder..................................................................... 0 11.1 Suggestions for Installation............................................................ 0 12. Removing Tilt Cylinders...................................................................... 0 12.1 Preparation............................................................................. 0 12.2 Suggestions for Removal................................................................. 0 13. Disassembling Lift cylinder.................................................................. 0 13.1 Disassembly Sequence.................................................................... 0 14. Assembling Lift Cylinder..................................................................... 0 14.1 Assembly Sequence....................................................................... 0 14.2 Suggestions for Assembly................................................................ 0 15. Disassembling Tilt Cylinder.................................................................. 0 15.1 Disassembly Sequence.................................................................... 0 16. Assembling Tilt Cylinder..................................................................... 0 16.1 Assembly Sequence....................................................................... 0 17. Inspecting and Adjusting Hydraulic System.................................................... 0 17.1 Hydraulic Oil........................................................................... 0 17.2 Control Valve........................................................................... 0 17.3 Adjusting Main Relief Valve (MC model).................................................. 0 17.4 Adjusting Microswitch................................................................... 0 17.5 Adjusting Tilt Cylinder................................................................. 0 17.6 Adjusting Lift Cylinder Stroke.......................................................... 0 17.7 Inspecting Piping....................................................................... 0 18. Tests........................................................................................ 0 18.1 Vertical Drift Test..................................................................... 0 18.2 Tilt Drift Test......................................................................... 0 19. Troubleshooting.............................................................................. 0 20. Service Data................................................................................. 0 20.1 Gear Pump............................................................................... 0 20.2 Control Valve (MC)...................................................................... 0 20.3 Lift Cylinder........................................................................... 0 20.4 Tilt Cylinder........................................................................... 0 21. MC Control Valve............................................................................. 0 21.1 General Description..................................................................... 0 21.2 Hydraulic Circuit Diagram............................................................... 0 21.3 Hydraulic Circuit....................................................................... 0 21.4 Structure - Inlet Cover Section......................................................... 0 21.5 Structure - Lift Valve.................................................................. 0 21.6 Structure - Tilt Valve.................................................................. 0 22. Construction and Function of FC Control Valve................................................ 0 22.1 Outline................................................................................. 0 22.2 FC Hydraulic System Circuit............................................................. 0 22.3 Bleed-off valve......................................................................... 0 22.4 Lift Valve.............................................................................. 0 22.5 Tilt Valve.............................................................................. 0 22.6 Attachment Valve........................................................................ 0 23. Removing FC Control Valve.................................................................... 0 23.1 Preparation............................................................................. 0 23.2 Removal Sequence........................................................................ 0 23.3 Suggestions for Removal................................................................. 0 24. Installing FC Control Valve.................................................................. 0 25. Disassembly of FC Control Valve.............................................................. 0 25.1 Disassembly Sequence.................................................................... 0 25.2 Suggestions for Disassembly............................................................. 0 26. Assembly of FC Control Valve................................................................. 0 27. Valves Included in the Inlet Section......................................................... 0 28. Disassembling Inlet Section.................................................................. 0 28.1 Disassembly Sequence (Part 1)........................................................... 0 28.2 Disassembly Sequence (Part 2)........................................................... 0 28.3 Disassembly Sequence (Part 3)........................................................... 0 28.4 Disassembly Sequence (Part 4)........................................................... 0 28.5 Suggestions for Disassembly............................................................. 0 29. Valves Included in Tilt Section.............................................................. 0 30. Disassembling Tilt Section................................................................... 0 30.1 Disassembly Sequence (Part 1)........................................................... 0 30.2 Disassembly Sequence (Part 2)........................................................... 0 30.3 Suggestions for Disassembly............................................................. 0 31. Valves Incorporated in Attachment Section.................................................... 0 32. Disassembling Attachment Section............................................................. 0 32.1 Disassembly Sequence (Part 1)........................................................... 0 32.2 Disassembly Sequence (Part 2)........................................................... 0 32.3 Suggestions for Disassembly............................................................. 0 33. Disassembling End Cover Plate................................................................ 0 34. Cleaning..................................................................................... 0 35. Inspecting................................................................................... 0 36. Precautions for Assembly..................................................................... 0 37. Assembling Inlet Section..................................................................... 0 37.1 Suggestions for Assembly................................................................ 0 37.2 Disassembly Sequence.................................................................... 0 37.3 Suggestions for Assembly................................................................ 0 38. Assembling Tilt Section...................................................................... 0 38.1 Suggestions for Assembly................................................................ 0 39. Assembling Attachment Section................................................................ 0 39.1 Suggestions for Assembly................................................................ 0 40. Solenoid Control Valve....................................................................... 0 41. Service Data................................................................................. 0 Chapter 9 MAST AND FORKS............................................................................. 0 1. Mast System................................................................................... 0 1.1 Mast Model Code Stamping Position........................................................ 0 1.2 Explanation of Mast Model Code........................................................... 0 1.3 Mast Code and Type....................................................................... 0 2. Description................................................................................... 0 2.1 Simplex Mast (Dual-Stage Panoramic Mast)................................................. 0 2.2 Duplex Mast (Dual-Stage Full Free Panoramic Mast)........................................ 0 2.3 Triplex Mast (Triple-Stage Full Free Panoramic Mast)..................................... 0 2.4 Operation of Duplex Mast................................................................. 0 2.5 Operation of Triplex Mast................................................................ 0 3. Removing Simplex Mast......................................................................... 0 3.1 Removal Sequence......................................................................... 0 3.2 Suggestions for Removal.................................................................. 0 4. Installing Simplex Mast....................................................................... 0 5. Removing Triplex Mast, Duplex Mast............................................................ 0 5.1 Removal Sequence......................................................................... 0 5.2 Suggestions for Removal.................................................................. 0 6. Installing Triplex Mast, Duplex Mast.......................................................... 0 7. Disassembling Simplex Mast.................................................................... 0 7.1 Disassembly Sequence..................................................................... 0 7.2 Suggestions for Disassembly.............................................................. 0 7.3 Inspecting Simplex Mast.................................................................. 0 7.4 Assembling Simplex Mast.................................................................. 0 8. Disassembling Duplex Mast..................................................................... 0 8.1 Disassembly Sequence..................................................................... 0 8.2 Suggestions for Disassembly.............................................................. 0 8.3 Inspecting Duplex Mast................................................................... 0 8.4 Assembling Duplex Mast................................................................... 0 9. Disassembling Triplex Mast.................................................................... 0 9.1 Disassembly Sequence..................................................................... 0 9.2 Suggestions for Disassembly.............................................................. 0 10. Inspecting Triplex Mast...................................................................... 0 11. Assembling Triplex Mast...................................................................... 0 12. Mast Height Sensor (Option).................................................................. 0 12.1 Installing Mast Height Sensor........................................................... 0 13. Inspecting and Adjusting Mast and Forks...................................................... 0 13.1 Forks (All Mast Models)................................................................. 0 13.2 Chain Tension Adjustment - Simplex Mast................................................. 0 13.3 Chain Tension Adjustment - Duplex Mast.................................................. 0 13.4 Chain Tension Adjustment - Triplex Mast................................................. 0 13.5 Clearance Adjustment for Lift Bracket................................................... 0 13.6 Mast Clearance Adjustment............................................................... 0 13.7 Main Roller Shim Replacement - Simplex Mast............................................. 0 13.8 Main Roller Shim Replacement - Duplex Mast.............................................. 0 13.9 Main Roller Shim Replacement - Triplex Mast............................................. 0 13.10 Mast Strip Adjustment.................................................................. 0 13.11 Tilt Angle Adjustment.................................................................. 0 13.12 Lift Cylinder Stroke Adjustment........................................................ 0 14. Troubleshooting.............................................................................. 0 15. Service Data................................................................................. 0 15.1 Simplex Mast, Duplex Mast, Triplex Mast................................................. 0 Chapter 10 Service Data.............................................................................. 0 1. Inspection Standards.......................................................................... 0 2. Periodic Replacement of Parts................................................................. 0 2.1 Critical Safety Parts.................................................................... 0 3. Tightening Torques for Standard Bolts and Nuts................................................ 0 3.1 Metric Fine Thread....................................................................... 0 3.2 Metric Coarse Thread..................................................................... 0 4. Lubrication Instructions...................................................................... 0 4.1 Lubrication Chart........................................................................ 0 4.2 Recommended Oils and Greases............................................................. 0 4.3 Capacity................................................................................. 0 5. Weight of Major Devices....................................................................... 0 6. Special tools................................................................................. 0 Chapter 11 Panel Cabin...............................................................................1114 1. Battery Exchange or Battery Charging..........................................................1114 2. Cleaning Top Roof.............................................................................1114 3. Replacing Top Roof............................................................................1114 4. Maintenance...................................................................................1114 BACK COVER...........................................................................................1117 99759-6P100-00...........................................................................................1118 99759-6P100-01...........................................................................................1130 99759-6P100-02...........................................................................................1204 99759-6P100-03...........................................................................................1344 99759-6P100-04...........................................................................................1370 99759-6P100-05...........................................................................................1384 99759-6P110-00_FOREWORD..................................................................................1412 99759-6P110-01_CONTROLLER................................................................................1424 99759-6P110-02_TROUBLESHOOTING_FOR_CONTROL_CIRCUITS......................................................1494 99759-6P110-03_MOTOR.....................................................................................1662 99759-6P110-04_HOW_TO_READ_CIRCUIT_DIAGRAMS..............................................................1687 99759-6P110-05_CIRCUIT_DIAGRAM...........................................................................1700
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