Powertrain:
Engine, transmission, drivetrain, hydraulics.
Chassis:
Steering, braking, suspension, lifting mechanism.
Electrical:
Wiring diagrams, charging system, starting system, lighting, instrumentation.
Hydraulics:
Mast operation, hydraulic circuits, cylinders, pumps, valves, filters.
Operator Controls:
Description and function of all levers, pedals, and switches.
Cooling System:
Radiator, fan, water pump, thermostat, and coolant circuit maintenance and repair.
Fuel System:
Fuel tank, lines, filters, injection pump, injectors, and troubleshooting.
Mast And Forks:
Inspection, maintenance, and repair of mast channels, rollers, lift chains, and fork carriage.
Safety Devices:
Operation, testing, and adjustment of safety features like parking brake, seat switch, and lift interlocks.
Drive Axle And Differential:
Maintenance and repair of the drive axle assembly and differential.
Steering Axle:
Maintenance and repair of the steering axle, linkage, and components.
Operator Compartment:
Removal and installation of interior panels, seat, and controls for access.
Frame And Chassis:
Inspection and repair of the main frame and chassis structure.
Attachment Systems:
Information on the hydraulic and mechanical systems for operating attachments like side shifters.
Maintenance:
Scheduled maintenance, lubrication, fluid changes, filter replacements.
Repair:
Component removal, disassembly, inspection, repair, reassembly, and installation procedures.
Troubleshooting:
Diagnostic charts, fault finding procedures, common issues and their solutions.
Diagnostics:
Testing procedures for all major systems, including electrical and hydraulic diagnostics.
Installation:
Procedures for installing common attachments or replacement parts.
Calibration:
Procedures for calibrating sensors or control systems if applicable.
Engine Overhaul:
Detailed steps for complete engine disassembly, inspection, and rebuild.
Transmission Overhaul:
Detailed steps for transmission disassembly, inspection, and rebuild.
Hydraulic Component Repair:
Repair procedures for hydraulic pumps, motors, cylinders, and valves.
Depth:
In-depth technical information suitable for professional technicians, covering everything from basic adjustments to major overhauls.
Torque Specifications:
Detailed torque values for critical fasteners across all systems.
Electrical Schematics:
Complete and detailed electrical wiring diagrams for troubleshooting and repair.
Hydraulic Schematics:
Detailed hydraulic circuit diagrams illustrating flow and component relationships.
Special Tools:
Identification and usage of specialized tools required for specific repair tasks.
Tolerances And Clearances:
Precise specifications for critical component clearances and wear limits.
Part Identification:
Illustrations and part numbers for component identification and ordering.
Engine Oil Change:
Typically every 250-500 operating hours, depending on operating conditions.
Transmission Fluid Change:
Typically every 1000-2000 operating hours.
Hydraulic Fluid Change:
Typically every 1000-2000 operating hours.
Engine Oil:
API CD or CE class diesel engine oil, SAE 15W-40 recommended for most ambient temperatures.
Hydraulic Oil:
ISO VG 32 or ISO VG 46 hydraulic oil, consult manual for precise viscosity and additive package.
Coolant:
Ethylene glycol-based antifreeze/coolant with a 50/50 mix of water.
Common Problems:
Potential wear in mast channels, hydraulic cylinder seal leaks, transmission shifting issues, and electrical connection corrosion are common in older units.
Tasks:
Regular inspection of tires, forks, mast chains, hydraulic hoses, and all safety devices.
