Safety Procedures:
Safe maintenance practices, lifting/jacking/blocking, towing.
Periodic Service:
Maintenance schedules, planned maintenance programs, PM inspection forms.
Electrical System:
Battery service, wiring, switches, instruments, schematic electric circuit diagrams, general electrical service tips, wiring and cables, switches and sensors, instrument panel.
Drive Motors:
Motor specifications, drive motor overhaul, pump motor overhaul.
Control Systems:
Contactors, motor controls, ZAPI handset programming and adjustments, control troubleshooting, TMX factory control settings.
Drive Axle:
Specifications, fluid check/change, troubleshooting, removal/installation, overhaul.
Wheels Tires:
Specifications, mounting, maintenance.
Brake System:
Specifications, fluid check/fill/bleed, pedal/master cylinder R&R/adjustment, caliper R&R, parking brake R&R/adjustment, brake overhaul.
Steer System:
TMX: Steering system specs, troubleshooting, column/component R&R, relief pressure check/adjustment, steer gear overhaul, steer axle service, steer cylinder overhaul. EPX: Steering axle wheel bearing maintenance/adjustment, steer axle R&R, steer cylinder R&R, steer gear overhaul, steer cylinder overhaul.
Hydraulic System Main:
Main hydraulic system specifications, fluids and filters, troubleshooting, pressure checks/adjustments, R&R, overhaul.
Hydraulic System Controls:
Hydraulic system schematic, main hydraulic control valve R&R, overhaul.
Tilt Cylinders:
Specifications, checks/adjustments, R&I, overhaul.
Uprights:
Specifications, troubleshooting, inspection, carriage/upright roller clearance checks/shim adjustment, cylinder R&I/overhaul/replacement, upright chain inspection/adjustment/replacement, fork/carriage R&R, upright R&R.
Chassis:
Counterweight specs, counterweight R&I, overhead guard R&I, floor plate/seat/seat deck R&I.
General Specs:
Nameplate and decals, general specifications, hydraulic fitting tightening procedures.
Electrical Components:
Specific coverage of contactors and ZAPI control systems.
Hydraulic Components:
Detailed procedures for hydraulic control valve, tilt cylinders, and general hydraulic system overhaul.
Control Unit:
Detailed coverage of motor controls and their programming/troubleshooting.
Repair Procedures:
Detailed step-by-step repair, assembly, and disassembly procedures for all covered systems.
Maintenance Procedures:
Comprehensive technical maintenance guidelines and planned service programs.
Troubleshooting Procedures:
Systematic troubleshooting guides for common and complex issues across all major components.
Diagnostic Procedures:
Detailed troubleshooting procedures for electrical, hydraulic, drive axle, and steer systems.
Adjustment Procedures:
Includes adjustments for steering system relief pressure, brake pedal/master cylinder, and upright roller clearance.
Overhaul Procedures:
Comprehensive overhaul procedures for drive motors, pump motors, drive axles, brake systems, steer systems, and hydraulic components.
Depth:
Complete factory-level repair and overhaul procedures, suitable for certified technicians and experienced mechanics.
Diagram Quality:
Features diagrams and actual real photo illustrations for clarity.
Interval Details:
Maintenance schedules and planned maintenance programs are thoroughly covered, providing specific interval guidance for various service tasks.
Pm Program:
Detailed Planned Maintenance (PM) program and inspection forms are included.
Fluid Types:
Information on hydraulic fluids and filters, as well as drive axle fluid, is provided. Specific fluid specifications (e.g., ISO VG ratings, OEM part numbers) are expected within the manual.
Common Issues Coverage:
Troubleshooting sections for drive axle, brake system, steer system, and hydraulic system address common issues and provide diagnostic steps.
Troubleshooting Approach:
Structured troubleshooting guides with clear steps for diagnosing problems.