OM Series 4169, 4170 XD15, XD18, XD20, XD25, XD30 workshop Manual – PDF DOWNLOAD

Description

OM Series 4169, 4170 XD15, XD18, XD20, XD25, XD30 workshop Manual – PDF DOWNLOAD

FILE DETAILS:

OM Series 4169, 4170 XD15, XD18, XD20, XD25, XD30 workshop Manual – PDF DOWNLOAD

Language : English
Pages : 456
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

OM Series 4169, 4170 XD15, XD18, XD20, XD25, XD30 workshop Manual – PDF DOWNLOAD

Product information
Instruction and maintenance manual

This chapter gives information taken from the instruction and maintenance manual, considered as of interest for the assistance technician

General Forklift Description

The forklift is diesel motor driven with seated operator and counterbalanced forks. This model can be equipped with the following main equipment:

? side shifts
? positioners
? grippers with jaws or forks
? tilting
? load arms

TABLE OF CONTENTS:

OM Series 4169, 4170 XD15, XD18, XD20, XD25, XD30 workshop Manual – PDF DOWNLOAD

00 General information
Product information
Instruction and maintenance manual
General Forklift Description
Technical information XD 15-18-20
General front view -2
Overall dimensions -3
Technical data -4
Abbreviations key -6
Alternative lift characteristics -7
Fork lift truck capacities – Model 1500 kg – Masts vertical with fork arms = 1400 mm
max -9
Fork lift truck capacities – Model 1800 kg – Masts vertical with fork arms = 1400 mm
max -12
Fork lift truck capacities – Model 2000 kg – Masts vertical with fork arms = 1400 mm
max -15
Tyre characteristics -17
Tyre inflation pressure -17
-18
General front view -18
Overall dimensions -19
Technical data -20
Abbreviations key -22
Alternative lift characteristics -23
Fork lift truck capacities – Model 2500 kg – Masts vertical with fork arms = 1400 mm max
– pneumatic tyres -24
Fork lift truck capacities – Model 2500 kg – Masts vertical with fork arms = 1400 mm max
– superelastic tyres -26
Forklift capacities – Model 3000 kg – Masts vertical with forks = 1400 mm max – (Narrrow
track= 965 mm) -28
Forklift capacities – Model 3000 kg – Masts vertical with forks = 1400 mm max – pneumatic
tyres -30
Forklift capacities – Model 3000 kg – Masts verticalwith forks = 1400 mm max – superelastic
tyres -32
Tyre characteristics -34
Tyre inflation pressure -34
-34
-35
-36
Loading and unloading the truck -36
-38
Loading and unloading the truck -38
-39
-40
Internal accessibility -40
Internal accessibility XD 25-30
Safety precautions
Description of safety symbols
Operations Preliminary to Maintenance
To avoid accidents
General safety Regulations
Safety Regulations Relative to Operating Materials
01 Service
Maintenance
Synoptic table of general maintenance operations on the truck
Synoptic table of maintenance operations to be performed on the engine
Supply table XD 15-18-20
Supply table XD 25-30
12 Engine models 4TNE92 and 4TNE98
General service information
Component identification
Engine family
Functions of the main engine components
Diesel fuel specifications
Priming the fuel supply system
Specifications
Main engine specifications
Engine processing
Tightening torques for standard bolts and nuts
Fuel system
Removal of the fuel injection pump
Installation of the fuel injection pump
Checking/adjusting the fuel injection timing
Maintenance of the fuel injectors
Fuel injectors inspection and testing
Maintenance
Standard torques table
Engine oil level checking procedure
Workshop literature ? 41698042301 EN ? 07/2008 III
Table of contents
Checking/ replacing the feed pipes and cooling hoses 12
Checking and adjusting the V-belt of the cooling fan 12
Changing the engine oil and oil filter 12
Checking and adjusting the regulator lever and engine speed control 12
Checking and adjusting the valve clearance 12
Changing the fuel filter 12
Troubleshooting 12
Troubleshooting information 12
Quick reference table for troubleshooting solutions 12
Troubleshooting solutions 12
13 Engine accessory parts
Equipment 13
Engine setup replacements 13
Engine attachment XD 15-18-20 13
Engine 13
Engine reassembly 13
Engine attachment XD 25-30 13
Reinstalling the engine 13
Air intake 13
Air filter 13
Cleaning the air filter 13
Cooling system 13
Radiator 13
Engine coolant level check XD 15-18-20 13
Table of contents @)
20 Transmission
Technical data for the TXL25 20
General transmission views 20
Transmission technical data 20
General transmission description 20
Transmission sections 20
Transmission wiring diagram 20
Distributor technical data 20
Transmission hydraulic circuit 20
Technical data for the TXL30 20
General transmission views (TXL30) 20
Transmission technical data (TXL30) 20
General transmission description (TXL 30) 20
Transmission sectional views for the TXL30 20
Transmission wiring diagram 20
Distributor technical data (TXL30) 20
Description of the hydraulic circuit 20
Transmission fastening for the TXL25 20
Transmission 20
Engine/transmission coupling 20
Checking the engine-transmission coupling 20
Inching cable 20
Transmission fastening for the TXL30 20
Engine-transmission coupling 20
Checking the engine-gearbox coupling 20
Maintenance for the TXL25 20
Transmission oil level inspection procedure 20
Check axle oil level 20
Maintenance for the TXL30 20
Transmission oil level inspection procedure 20
Check axle oil level 20
Troubleshooting 20
Troubleshooting 20
Counterweight
Reinstalling the counterweight XD 15-18-20
Counterweight reassembly
Reinstalling the counterweight XD 25-30
Reinstalling the counterweight
34 Driver’s compartment
Driver’s compartment
Driver’s compartment central cross traverse
Driver’s compartment
Driver’s compartment reassembly
Driver’s compartment spring supports
Covers
Driver’s compartment covers and panelling
42 Steering
Hydraulically assisted steering
Hydraulically assisted steering technical data
Hydraulically assisted steering column unit
Steering axle XD 15-18-20
Steering axle
Reinstalling the steering axle
Steering axle XD 25-30
Reinstalling the steering axle
46 Wheels and tyres
General information
Safety regulations for wheels and rims
General information for changing tyres
Tyrewear check
Changing a wheel XD 15-18-20
Wheel replacement procedure
Table of contents
Changing a wheel XD 25-30 46
Wheel replacement procedure 46
Disassembling a wheel 46
Disassembly/assembly of tyres on rims with movable flange 46
Quick tyres assembly/disassembly 46
Tightening torques XO 15-18-20 46
Wheel Tightening Check 46
Tightening torques XD 25-30 46
Wheel Tightening Check 46
49 Braking/inching system
Braking system operating characteristics 49
Braking system technical data 49
Braking system reassembly 49
Service brake 49
Brake pump 49
Brake shoes 49
Stop lights microswitch 49
Parking brake 49
Parking brake lever 49
Parking brake microswitch 49
Parking brake cables 49
Maintenance 49
Brake fluid level check 49
Air bleeding from the brake pipes 49
50 Controls
Twin pedal 50
Accelerator pedal 50
Accelerator cable 50
56 Instruments
Instrument panel 56
Instrument panel 56
60 Electrical and electronic system
Battery
Battery carrier
Checking the battery
Fuses
Fuse and relay location
Fuse replacement
71 Working hydraulic system
Service and lifting pump XD 15-18-20
Service and lifting pump technical data
Service and lifting pump XD 25-30
Service and lifting pump technical data
71 Hydraulic components
Service and lifting pump
Service and lifting pump
Tank
Hydraulic oil tank technical data
Oil tank
Oil filter unit
Hydraulic tank oil level check procedure
76 Valves
Shut-off valves
Safety valve (load lowering block) (VBDC)
Safety valve
Safety valve
Safety valve technicaldata
Safety valve layout XD 15-18-20
Safety valve layout
Safety valve layout XD 25-30
Safety valve positioningon the simplex lift mast
Safety valve positioningon the duplex lift mast
Safety valve positioning on the triplex lift mast
Simplex lift mast functional description -4
Hydraulic circuit for supplying the simplex lift mast cylinders -5
Registrazione della catena di carico sollevatore Simplex -6
Simplex lifting diagram -7
Duplex lift mast functional description -9
Hydraulic circuit for supplying the duplex lift mast cylinders -10
Adjusting the load chains of the duplex lift mast -12
Duplex lifting diagram -13
Triplex lift mast functional description -16
Hydraulic circuit for supplying the triplex lift cylinders -17
Adjusting the lift chains on the triplex lift mast -19
Triplex lifting diagram -20
Description of the simplex lift mast -44
Hydraulic circuit for supplying the simplex lift mast cylinders -45
Adjusting the simplex lift mast load chain -46
-47
Description of the duplex lift mast -47
VIII Workshop literature ? 41698042301 EN ? 07/2008
Table of contents
Distributor valves 76
Lifting distributor technical data 76
80 Lifting
Lift mast XD 15-18-20 80
Lift typologies 80
Simplex lift mast 80
Load chain locking device 80
Fork carriage retaining device 80
Assembly of the mast/ carriage support rollers 80
Check 80
Disassembly of the Simplex lift cylinder 80
Disassembly of the side cylinders of the Duplex lift 80
Disassembly of the side cylinders of the Triplex lift 80
Duplex/ Triplex central cylinder 80
Limit stop dampers 80
Disassembly of the fork carriage 80
Lift 80
Lift reassembly 80
Lift mast XD 25-30 80
Lift typologies 80
Simplex lift mast 80
Duplex lift mast 80
Hydraulic circuit for supplying the duplex lift mast cylinders -48
Adjusting the load chains of the duplex lift mast -49
Triplex lift mast functional description -50
Hydraulic circuit for supplying the triplex lift mast cylinders -51
Adjusting the lift chains on the triplex lift mast -52
Hydraulic diagram -7
Workshop literature ? 41698042301 EN ? 07/2008 IX
Triplex lift mast
Load chain locking device
Fork carriage retaining device
Assembly of the mast/ carriage support rollers
Check
Removing the cylinder of the simplex lift mast
Removing the side cylinders of the duplex lift mast
Removing the side cylinders of the triplex lift mast
Removing the duplex/triplex central cylinder
Limit stop dampers (duplex and triplex)
Removing the fork carriage
Reinstalling the lift mast
Tilt cylinders XD 15-18-20
Tilt cylinder
Tilt cylinder
Tilt cylinders XD 25-30
Tilt cylinder
Cylinders
Lift cylinders
Air bleeding of the lift cylinders
Bleeding the tilt cylinders of air
Annex
A Diagrams
Wiring diagrams
Truck functional diagram
Lights functional diagram
Hydraulic diagrams
Diagram XD25-30
Diagram XD15-20

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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