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Taylor TX180S, Maintenance Manual

The Taylor TX180S Maintenance Manual is essential for keeping your equipment running smoothly. Download this free manual from our website to ensure proper care and maintenance of your Taylor TX180S. Get all the information you need to maximize the lifespan and performance of your equipment.

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Contents

Contents

Maintenance Manual

Maintenance Manual

Section

Section

Introduction

Introduction

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 Air Intake System

 Air Intake System

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B

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W

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S

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C

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C

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0

0

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https://www.forkliftpdfmanuals.com/

Summary of Contents for TX180S

Page 1: ...Maintenance Manual Maintenance Manual TX180S 360L TX180S 360L TXH300L TXH350L TXH400L TXH300L TXH350L TXH400L TXB180S 300L TXB180S 300L https www forkliftpdfmanuals com...

Page 2: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 https www forkliftpdfmanuals com...

Page 3: ...hen climb mb ing ramps ing ramps 6 6 Do no Do not st t stand o and or wor r work und k under an e er an elev levate ated loa d load d 7 7 T Tran ranspo sport t rt the lo he load lo ad low and t w and...

Page 4: ...res and fittin fittings aft gs after one hu er one hundred ndred 100 ho 100 hours of op urs of operati eration on 3 3 Norma Normal deterio l deterioratio ration of appear n of appearance due to u ance...

Page 5: ...https www forkliftpdfmanuals com...

Page 6: ...ervice will be performed cannot be performed cannot be anticipated be anticipated Do not Do not perform any service if you are unsure that it can perform any service if you are unsure that it can be d...

Page 7: ...n OSHA operating rules found in 29 CFR 1910 178 Appendix A in Safety Check 2nd Edition ANSI B56 1 rules ANSI B56 1 rules for operating a for operating a powered industrial truck powered industrial tru...

Page 8: ...ss ses es 4 4 He Heav avy y Gl Glov oves es 5 5 He Hear arin ing Pro g Prote tect ctio ion n 6 6 Re Refl flec ecti tive ve Cl Clot othin hing g Failure to follow the safety precautions outlined in Fai...

Page 9: ...being inadvertently started before performing maint performing maintenance or enance or repairs repairs The battery The battery should be locked out tagged out to prevent acci should be locked out tag...

Page 10: ...ment equipment Under Under no circumstances should any attempt be made no circumstances should any attempt be made to disconnect or in any way render any of to disconnect or in any way render any of t...

Page 11: ...the energy source s electrical mechanical hydraulic etc is dis electrical mechanical hydraulic etc is dis connected or isolated from the equipment connected or isolated from the equipment Stored ener...

Page 12: ...S TILT CYINDERS Section 22 Section 22 CARRIAGE CARRIAGE Section 28 Section 28 DRIVE AXLE DRIVE AXLE Section 14 Section 14 DRIVE SHAFT DRIVE SHAFT Section 11 Section 11 TRANSMISSION TRANSMISSION Sectio...

Page 13: ...1 2 1 2 Rev 11 94 Rev 11 94 https www forkliftpdfmanuals com...

Page 14: ...or rs s 6 6A A T Tr ra an ns sm mi is ss si io on n 9 9 T Tr ra an ns sm mi is ss si io on n C Co oo ol le er r 9 9A A T Tr ra an ns sm mi is ss si io on n C Co on nt tr ro ol ls s 9 9C C D Dr ri iv v...

Page 15: ...https www forkliftpdfmanuals com...

Page 16: ...a at ti in ng g S Sy ys st te em m 2 20 0H H H Hy yd dr ra au ul li ic c S Sy ys st te em m 2 22 2 Accumulator Accumulator 22E 22E M Ma as st t A As ss se em mb bl ly y 2 27 7 C Ca ar rr ri ia ag ge e...

Page 17: ...https www forkliftpdfmanuals com...

Page 18: ...1 1 Illustration 1 1 The engine lubricating oil should be checked daily The engine lubricating oil should be checked daily on the oil dipstick to ensure that the engine has on the oil dipstick to ensu...

Page 19: ...il filter tact the gasket on the new oil filter 6 6 Fill Fill the the new f new filter ilter with with clean clean engine engine oil b oil before efore installation installation 7 7 Appl Apply a lig y...

Page 20: ...e bolt re install the bolt and locknut and locknut T Torque the locknuts orque the locknuts on the Cummins engine mounting bolts to 200 on the Cummins engine mounting bolts to 200 220 ft lbs 270 300 N...

Page 21: ...stic Icons Engine Diagnostic Icons Illustration 1 4 Illustration 1 4 The The engine diagnostic icons displayed by the Taylor engine diagnostic icons displayed by the Taylor Integrated Control System T...

Page 22: ...s the he F1 button Engine to view the Engine Infor F1 button Engine to view the Engine Infor mation screen mation screen 4 4 At the E At the Engin ngine Inf e Inform ormati ation sc on scree reen dep...

Page 23: ...el lo ow w N No or rm ma al l O Op pe er ra at ti io on na al l Range Moderately Severe Level Range Moderately Severe Level 1 14 44 4 Y Ye el ll lo ow w C Co oo ol la an nt t T Te em mp pe er ra at t...

Page 24: ...Severe Level Range Most Severe Level 2 23 35 5 R Re ed d C Co oo ol la an nt t L Le ev ve el l L Lo ow w D Da at ta a V Va al li id d b bu ut t B Be el lo ow w N No or rm ma al l O Op pe er ra at ti...

Page 25: ...Pr re es ss su ur re e S Se en ns so or r I In np pu ut t 2 2 C Ci ir rc cu ui it t V Vo ol lt ta ag ge e B Be el lo ow w N No or rm ma al l o or r S Sh ho or rt te ed d t to o L Lo ow w Source Sourc...

Page 26: ...re ec ct t 4 44 41 1 Y Ye el ll lo ow w B Ba at tt te er ry y 1 1 V Vo ol lt ta ag ge e L Lo ow w D Da at ta a V Va al li id d b bu ut t B Be el lo ow w N No or rm ma al l O Op pe er ra at ti io on na...

Page 27: ...t 6 69 91 1 Y Ye el ll lo ow w T Tu ur rb bo oc ch ha ar rg ge er r 1 1 C Co om mp pr re es ss so or r I In nl le et t T Te em mp pe er ra a ture Sensor Circuit ture Sensor Circuit Voltage Above Norm...

Page 28: ...l lt ta ag ge e A Ab bo ov ve e N No or rm ma al l o or r S Sh ho or rt te ed d t to o H Hi ig gh h Source Source 2 21 11 12 2 Y Ye el ll lo ow w C Co oo ol la an nt t T Te em mp pe er ra at tu ur re...

Page 29: ...rt te ed d t to o L Lo ow w Source Source 2 23 36 63 3 Y Ye el ll lo ow w E En ng gi in ne e B Br ra ak ke e A Ac ct tu ua at to or r C Ci ir rc cu ui it t 2 2 V Vo ol lt ta ag ge e B Be el lo ow w N...

Page 30: ...t a definite rule or test that will positive ly determine the source of a noise complaint ly determine the source of a noise complaint Engine driven components and accessories such Engine driven compo...

Page 31: ...y hydra ency hydraulic ulic movement stop has been movement stop has been depressed to disable certain depressed to disable certain functions functions 1 1 T Turn ba urn batte ttery di ry disco sconne...

Page 32: ...tery ery vo volt ltag age is l e is low ow 3 3 Eng Engine c ine cran rankin king sp g speed i eed is to s too sl o slow ow 4 4 Sta Starti rting ai ng aid ne d needed eded for for col cold we d weath a...

Page 33: ...too l too low f ow for ac or acces ces sories sories 4 4 Ai Air is r is in t in the f he fue uel sy l syst stem em 5 5 Fu Fuel s el sup uppl ply is r y is res estr tric icte ted d 6 6 En Engi gine m...

Page 34: ...oble oblem 10 m 10 in in thi this tr s trou ou bleshooting chart bleshooting chart 5 5 Ins Inspec pect th t the en e engin gine fo e for ex r exter ternal nal oil oil leaks leaks Tighten Tighten the c...

Page 35: ...oning is malfunctioning 15 15 Water Water pump is pump is malfunctioning malfunctioning 1 1 Ins Inspec pect the ch t the charg arge air co e air coole oler r rad radia ia tor and air conditioner conde...

Page 36: ...trols trols 3 3 Che Check b ck belt elt ten tensio sion and n and tig tighte hten if n if necessary necessary Replace driv Replace drive belt e belt if if necessary necessary 4 4 Re Repl plac ace ra...

Page 37: ...leaking or misassembled plugs leaking or misassembled 2 2 Cyl Cylind inder h er head ead gas gasket ket is l is leak eaking ing 3 3 Cyl Cylind inder h er head i ead is cr s crack acked or ed or poro...

Page 38: ...ot reach rated speed reach rated speed rpm rpm 1 1 Ele Electr ctronic onic fau fault c lt code odes are s are act active ive 2 2 T Truc ruck pa k paras rasiti itics a cs are ex re exces cessiv sive e...

Page 39: ...em m 2 in this troubleshooting chart 2 in this troubleshooting chart 3 3 Che Check t ck the fu he fuel li el lines nes fu fuel c el conne onnec c tions and fuel filters for leaks tions and fuel filter...

Page 40: ...troubleshooting chart 23 23 Altern Alternator i ator is not s not charging or insuffi charging or insuffi ciently charging ciently charging 1 1 Alt Altern ernato ator pul r pulley ley is l is loos oos...

Page 41: ...acti ctive ve 2 2 Air Air int intake ake sys system tem is r is rest estric ricted ted 3 3 Air Air int intake ake or or exh exhaus aust l t leak eaks s 4 4 Cha Charge rge air air coo cooler ler is r...

Page 42: ...ing ing har harnes ness s connectors connectors 5 5 Ai Air is r is in t in the f he fuel uel sy syst stem em 1 1 F Fil ill f l fue uel t l tan ank k 2 2 Ref Refer t er to Co o Corre rrecti ction 2 on...

Page 43: ...s dama amaged ged or m or miss issing ing or the air recirculation baffles are or the air recirculation baffles are damaged or missing damaged or missing 4 4 T Tru ruck s ck spe peed i ed is to s too...

Page 44: ...e Check ck and and cle clean an the the ven vent t t tube ube 2 2 Ref Refer t er to Co o Corre rrecti ction 2 on 2 of of Pro Proble blem m 8 in this troubleshooting chart 8 in this troubleshooting cha...

Page 45: ...5 i 5 in th n this t is trou rou bleshooting chart bleshooting chart 39 39 Engine Engine noise noise is is excessive excessive Connecting Rod Connecting Rod continued continued 1 1 Eng Engine ine oil...

Page 46: ...e torq rque o ue on th n the ma e main in bearing bearing capscrews capscrews Inspect Inspect the the capscrews for capscrews for wear wear Tighten caps Tighten caps crews to the correct torque value...

Page 47: ...em tem is r is rest estric ricted ted 3 3 Air i Air inta ntake or ke or exh exhaus aust sy t syste stem lea m leaks ks 4 4 Exh Exhaus aust s t syst ystem em is is res restri tricte cted d 5 5 T Turb u...

Page 48: ...s troubleshooting chart 43 in this troubleshooting chart 3 3 Ref Refer t er to Co o Corre rrecti ction 3 on 3 of of Pro Proble blem m 43 in this troubleshooting chart 43 in this troubleshooting chart...

Page 49: ...47 Air com Air compress pressor will or will not maintain ade not maintain ade quate air pressure quate air pressure not pumping con not pumping con tinuously tinuously 1 1 Ai Air s r sys yste tem l...

Page 50: ...A N NA A C Cl le ea an n f fu ue el l f fi il lt te er r i in n H Hg g k kP Pa a 6 6 2 20 0 Ma Maxi ximu mum fu m fuel dr el drain r ain res estr tric icti tion b on bef efor ore o e or wi r with tho...

Page 51: ...1 33 1 33 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 52: ...NG ILLUSTRATIONS IN PLACE THE FOLLOWING ILLUSTRATIONS IN FOLDER ENVELOPES FOLDER ENVELOPES Illustration 1 6 06B 2234 Engine Electrical ANSI Illustration 1 6 06B 2234 Engine Electrical ANSI Illustratio...

Page 53: ...1 35 1 35 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 https www forkliftpdfmanuals com...

Page 54: ...Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 55: ...ace the fuel water separator and fuel filter separator and fuel filter They should They should be replaced be replaced periodically or more often if conditions warrant periodically or more often if co...

Page 56: ...of drained fuel in Dispose of drained fuel in accordance to federal and local regulations accordance to federal and local regulations Do not overtighten the drain Do not overtighten the drain valve va...

Page 57: ...d level s vel surf urface ace app apply ly the parking brake and block the wheels in both the parking brake and block the wheels in both directions to prevent movement of the truck directions to prev...

Page 58: ...2 3 2 3 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 FUEL LEVEL FUEL LEVEL SENDING UNIT SENDING UNIT FILLER FILLER CAP CAP FILLER FILLER NECK NECK https www forkliftpdfmanuals com...

Page 59: ...stra Illustration tion 2 3 2 3 Fuel Fuel T Tank ank Section 3 Section 3 Air Intake System Air Intake System PRECLEANER CAP PRECLEANER CAP VACUATOR VACUATOR AIR CLEANER AIR CLEANER HOUSING HOUSING PRIM...

Page 60: ...ock the wheels in both directions to prevent block the wheels in both directions to prevent movement of the truck and Lock O movement of the truck and Lock Out Tag Out ut Tag Out the truck the truck R...

Page 61: ...Ca au us se e C Co or rr re ec ct ti io on n 1 1 Sh Shor ort f t fil ilte ter l r lif ife e primary filter primary filter 1 1 Imp Imprope roper as r assem sembly bly whe when pri n prior f or filt ilt...

Page 62: ...w etween t een the he air restriction indicator and the air restriction indicator and the safety fitting safety fitting 2 2 Air Air lea leak in k in air air hos hose be e betwe tween t en the a he air...

Page 63: ...exhaust exhaust puri puri fier converts up to 90 of the harmful diesel fier converts up to 90 of the harmful diesel exhaust gases such as carbon monoxide and exhaust gases such as carbon monoxide and...

Page 64: ...or high pressure water not greater than 100 psi high pressure water not greater than 100 psi 7 bar keeping the tip of the nozzle at least 2 7 bar keeping the tip of the nozzle at least 2 inches away i...

Page 65: ...thermostat will C at which point the thermostat will start to open start to open This will allow This will allow coolant flow back coolant flow back into into the top of the radiator core the top of t...

Page 66: ...ntain pres in prescri cribed inh bed inhibi ibitor st tor stren rength gth 3 3 Use lo Use low sili w silicat cate anti e antifre freeze wi eze with an eth th an ethyle ylene ne glycol base glycol bas...

Page 67: ...at approximately 190 start to open at approximately 190 F 88 F 88 C and C and Belt Tension Belt Tension in in Section 1 Section 1 for the proper tension for the proper tension values values Fan Ring P...

Page 68: ...Fan Ring Ring Positioning Positioning DEAERATION DEAERATION 16 PSI 110 kPa 16 PSI 110 kPa PRESSURE CAP PRESSURE CAP HYDRAULIC HYDRAULIC SYSTEM SYSTEM COOLER COOLER CHARGE AIR CHARGE AIR COOLER COOLER...

Page 69: ...ponents I ponents Identification dentification Illustration 5 4 Illustration 5 4 Engine C Engine Coolant C oolant Circuit ircuit UPPER UPPER RADIATOR HOSE RADIATOR HOSE DEAERATION DEAERATION LINE LINE...

Page 70: ...OLANT FLOW MAIN FLOW THERMOSTAT OPEN MAIN FLOW THERMOSTAT OPEN DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT DEAERATION REMOVES UNWANTED AIR FROM COOLING CIRCUIT 05 2374 05 2374 CUMMINS QSB6 7...

Page 71: ...ce of the electrical system can result in electrical shorts electrical system can result in electrical shorts which may which may cause fires cause fires Regularly i Regularly inspect and nspect and m...

Page 72: ...eversing the battery connections must be dentally reversing the battery connections must be avoided avoided If a boost If a booster battery is er battery is to be used to be used first first connect t...

Page 73: ...er it is recommended that extreme caution be used extreme caution be used Never disconnect the battery while the alternator Never disconnect the battery while the alternator is in is in operation oper...

Page 74: ...N SWITCH IGNITION SWITCH TICS D TICS DISPLA ISPLAY Y MODULE LIGHT MODULE LIGHT SWITCHES SWITCHES CB13 CB13 15 AMP 15 AMP ACCESSORY ACCESSORY CB11 CB11 30 AMP 30 AMP DEFROSTERS DEFROSTERS HIGH SPEED HI...

Page 75: ...PERS CB20 CB20 10 AMP 10 AMP FUEL GAUGE FUEL GAUGE HORN HORN PARKING PARKING BRAKE SWITCH BRAKE SWITCH Illustration Illustration 6 2 6 2 Dash Dash Circuit Circuit Breakers Breakers CB21 CB21 30 AMP 30...

Page 76: ...d bat tery tery Repair Repair if if required required 6 6 With With all a all access ccessories ories turne turned of d off c f connect onnect a vol a volt t meter across meter across the battery the...

Page 77: ...y Closed Normally Closed Contact when relay Contact when relay is de energized is de energized Normally Open Normally Open Contact when relay Contact when relay is de energized is de energized Common...

Page 78: ...lose spools of spools of valves valves The The readings should indicate a higher ohm resistance readings should indicate a higher ohm resistance in one direction opposed to the other direction in one...

Page 79: ...es not close accessory posi tion tion 2 2 Ign Igniti ition sw on switc itch S1 I h S1 Illu llustr strati ation 6 6 on 6 6 does not close start position does not close start position 1 1 On t On the ba...

Page 80: ...nal terminal Turn Turn the ignition the ignition switch switch S1 to the start position and S1 to the start position and recheck for 12 VDC at the S termi recheck for 12 VDC at the S termi nal nal If...

Page 81: ...FOLDER ENVELOPES Illustration 6 6 06 2485 SHT 2 Panel ANSI Illustration 6 6 06 2485 SHT 2 Panel ANSI Illustration 6 7 06 2485 SHT 3 Bottom Cab ANSI Illustration 6 7 06 2485 SHT 3 Bottom Cab ANSI Illu...

Page 82: ...Electrical Box Illustration 6 10 06 2485 SHT 6 Truck Electrical Box ANSI ANSI Illustration 6 11 06 2485 SHT 7 Top Cab and Illustration 6 11 06 2485 SHT 7 Top Cab and A Frame ANS A Frame ANSI I Illustr...

Page 83: ...https www forkliftpdfmanuals com...

Page 84: ...https www forkliftpdfmanuals com...

Page 85: ...https www forkliftpdfmanuals com...

Page 86: ...https www forkliftpdfmanuals com...

Page 87: ...XH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 6 12 6 12 T Taylor Integrated aylor Integrated Control System TICS Control System TICS Components Components https www forkliftpdfmanuals...

Page 88: ...odule is mounted is mounted on the right side of the dash on the right side of the dash The TICS system display modules should not be exchanged between trucks The TICS system display modules should no...

Page 89: ...f Indicates that the forward alarm is disabled while in the Operator Con alarm is disabled while in the Operator Con trolled mode trolled mode of operation of operation This message This message will...

Page 90: ...e engine ECM shuts down the truck due to high transmission temperature high transmission temperature 12 12 F1 Depress this F1 Depress this button to view t button to view the Diagnos he Diagnos tics S...

Page 91: ...w Secondary Flash yellow Error description Error description 1 1 n n S Se ee e n no ot te e a a 2 2 n n S Se ee e n no ot te e a a 3 3 1 1 C CA AN N e er rr ro or r 3 3 2 2 A Ad dd dr re es ss s e er...

Page 92: ...DDRESS TAG AG PROTECTIVE PROTECTIVE COVER COVER TICS Module Wire Harness Plug TICS Module Wire Harness Plug PIN 14 PIN 14 PIN 28 PIN 28 PIN 42 PIN 42 PIN 1 PIN 1 PIN 15 PIN 15 PIN 29 PIN 29 TICS Modul...

Page 93: ...mploys XA2 modules XA2 modules Always replace each module with the Always replace each module with the correct module correct module Refer to the following illustration for truck control module locati...

Page 94: ...program Function groups are primarily used by Function groups are primarily used by TMW personnel during truck set TMW personnel during truck set up and troubleshooting up and troubleshooting The The...

Page 95: ...ay Screen Main Display Screen 1 1 From th From the Main Dis e Main Display sc play screen de reen depress t press the Meas he Measure Adjus ure Adjust Groups b t Groups button utton This This will dis...

Page 96: ...below T To exit out of the selected group values o exit out of the selected group values depress the depress the button to return to the Measure Groups list display button to return to the Measure Gro...

Page 97: ...4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 6 22 6 22 THESE WILL VARY BASED THESE WILL VARY BASED ON THE NUMBER OF ACCESSORY ON THE NUMBER OF ACCESSORY FUNCTIONS FUNCTIONS ACTIVA ACTIVATED TED https www...

Page 98: ...ure Groups Maintenance and Measure Groups DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES SENSOR SENSOR STATUS STATUS COMMUNICATION COMMUNICATION STATUS...

Page 99: ...23 07 TX TXH TXB 180S 400L Rev 4 23 07 6 24 6 24 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Engine Maintenance Group Engine Maintenance Group https...

Page 100: ...EPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Cab Maintenance Group Cab Maintenance Group DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALE...

Page 101: ...EPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Brake Maintenance Group Brake Maintenance Group DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND S...

Page 102: ...nal accessory hy Additional accessory hydraulic maintenance groups ACC draulic maintenance groups ACC2 ACC3 etc 2 ACC3 etc have the typic have the typical values al values as those listed in the ACC1...

Page 103: ...80S 400L Rev 4 23 07 6 28 6 28 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Joystick Measure Group Joystick Measure Group Continu...

Page 104: ...400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Joystick Measure Group Joystick Measure Group https w...

Page 105: ...180S 400L Rev 4 23 07 6 30 6 30 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Engine Measure Group Engine Measure Group Continued...

Page 106: ...0S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Engine Measure Group Engine Measure Group https www...

Page 107: ...Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 6 32 6 32 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Cab Measure Group Cab Measure Group https www fo...

Page 108: ...TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Transmission Measure Group Transmission Measure Group Con...

Page 109: ...400L Rev 4 23 07 6 34 6 34 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Transmission Measure Group Transmission Measure Group Con...

Page 110: ...TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Transmission Measure Group Transmission Measure Group Con...

Page 111: ...07 TX TXH TXB 180S 400L Rev 4 23 07 6 36 6 36 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Transmission Measure Group Transmission Measure Group htt...

Page 112: ...TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Display Data Measure Group Display Data Measure Group Con...

Page 113: ...07 TX TXH TXB 180S 400L Rev 4 23 07 6 38 6 38 DEPRESS TO TOGGLE BETWEEN DEPRESS TO TOGGLE BETWEEN RAW AND SCALED VALUES RAW AND SCALED VALUES Display Data Measure Group Display Data Measure Group htt...

Page 114: ...TXB 180S 400L Rev 4 23 07 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued APC Interface APC Interface Measure Group Measure Group Co...

Page 115: ...07 TX TXH TXB 180S 400L Rev 4 23 07 6 40 6 40 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES APC Interface APC Interface Measure Group Measure Group ht...

Page 116: ...180S 400L Rev 4 23 07 DEPRESS TO TOGGLE DEPRESS TO TOGGLE BETWEEN RAW AND BETWEEN RAW AND SCALED VALUES SCALED VALUES Continued Continued Engine Fault Code Measure Group Engine Fault Code Measure Grou...

Page 117: ...n and the range of values allowed is controlled by the soft ware ware These parameters minimum current m These parameters minimum current maximum current start ramp t aximum current start ramp time an...

Page 118: ...ll display display the the Main Measure Adjust screen Main Measure Adjust screen ADJUST ADJUST Main Select Screen Main Select Screen 2 2 A At t t th he e Main Measure Adjust screen Main Measure Adjust...

Page 119: ...DEPRESS UP OR DEPRESS UP OR DOWN BUTTON DOWN BUTTON TO CHANGE DIGIT TO CHANGE DIGIT DEPRESS OK BUT DEPRESS OK BUT TON TO ENTER TON TO ENTER DIGIT DIGIT PIN Code Screen PIN Code Screen 4 4 From the PI...

Page 120: ...r DOWN Slowly depress the UP or DOWN button until the mast just button until the mast just begins to lift the carriage begins to lift the carriage Observe the value underneath the Min v Observe the va...

Page 121: ...screen button back to go back to the Adjust Groups screen 8 8 Repeat t Repeat these proc hese procedures f edures for adjust or adjusting the set ing the setting s ting s of the other TI of the other...

Page 122: ...ps button on as indicated by arrow above to access the Main Measure Adjust screen as indicated by arrow above to access the Main Measure Adjust screen Adjust Adjust Button Button 2 2 A At t t th he e...

Page 123: ...the UP or Down button as indi ton as indicated by t cated by the arrows ab he arrows above unti ove until the firs l the first numeric di t numeric digit appea git appears rs in the first field in th...

Page 124: ...ton Reset may be depressed to reset the Allowed be depressed to reset the Allowed Ground Speed percent Ground Speed percent age back to 100 if necessary age back to 100 if necessary Measure Adjust Mea...

Page 125: ...e Select Diagnost gnostic Option sc ic Option screen reen 8 8 Depres Depress the F2 butt s the F2 button as indic on as indicated by arro ated by arrow above to ac w above to access the T cess the Tr...

Page 126: ...n to return to the Main Display screen Resetting The Service Timer Resetting The Service Timer The Service T The Service Timer should be reset after scheduled maintenance has imer should be reset afte...

Page 127: ...en depr een depress the ess the F1 button Diagnostics to access the Diagnostics Select screen F1 button Diagnostics to access the Diagnostics Select screen ENGINE ENGINE BUTTON BUTTON Diagnostics Sele...

Page 128: ...Ti ce Timer to acc mer to access the Ma ess the Mainte inte nance Timer Reset screen nance Timer Reset screen Maintenance Timer Reset Screen Maintenance Timer Reset Screen 4 4 At the Mainte At the Mai...

Page 129: ...d depress th ress the Down Butt e Down Button to reset t on to reset the Mainte he Maintenance nance Timer Timer Depress the OK button to exit the Maintenance T Depress the OK button to exit the Maint...

Page 130: ...m m e e r r a a s s a a n n d d M M o o n n i i t t o o r r s s https www forkliftpdfmanuals com...

Page 131: ...ional requirements 4 4 Volu Volume Buttons me Buttons Depress Depress the the upper butt upper button on to increase the volume of the monitor depress to increase the volume of the monitor depress the...

Page 132: ...ton to view the video from camera 2 CA2 camera 2 CA2 3 3 Menu Button Menu Button Depress this button to display Depress this button to display the main menu of the monit the main menu of the monitor o...

Page 133: ...ev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 6A 2 6A 2 06C 0108 06C 0108 Section 9 Section 9 Transmission Transmission CHARGING CHARGING PUMP PUMP BRAKE BRAKE PUMP PUMP FILLER FILLER CAP CAP https www...

Page 134: ...the converter blade cavity and exits in the passage between the tur cavity and exits in the passage between the tur bine shaft bine shaft and converter and converter support support The oil then The o...

Page 135: ...h or serious injury could result from a r result from a runaway truck unaway truck Park truck on Park truck on a a hard level surface apply parking brake block hard level surface apply parking brake b...

Page 136: ...check and add oil to bring the oil level to the FULL mark on the dipstick to the FULL mark on the dipstick Filling The Transmission Filling The Transmission Illustration 9 1 Illustration 9 1 Perform...

Page 137: ...INSTALL PRESSURE GAUGE IN THIS LINE GAUGE IN THIS LINE FOR CONVERTER OUT FOR CONVERTER OUT PRESSURE CHECK PRESSURE CHECK CLUTCH PRESSURE CHECK CLUTCH PRESSURE CHECK POINT 240 PSI 16 6 bar LOW IDLE PO...

Page 138: ...RTER OUT TO CONVERTER OUT TO COOLER 25 PSI 1 7 bar MIN COOLER 25 PSI 1 7 bar MIN 70 PSI 4 8 bar 70 PSI 4 8 bar MAX AT MAX AT RATED RPM RATED RPM Illustration 9 4 Illustration 9 4 Transmiss Transmissio...

Page 139: ...require removal to detect a magnetic field will require removal to detect a magnetic field An effective way to accomplish this is with a An effective way to accomplish this is with a metal wrench met...

Page 140: ...psi 16 6 20 7 bar normal operating pressure operating pressure 4 4 Bro Broken ken or or wor worn c n clut lutch ch sha shaft ft or or piston sealing rings piston sealing rings 5 5 Clu Clutch tch pis p...

Page 141: ...smis missio sion tem n temper peratu ature re transducer transducer 5 5 La Lac ck k of of po powe wer r 1 1 Low Low en engi gine R ne RPM a PM at co t conv nver erte ter r stall stall 2 2 Wo Worn o rn...

Page 142: ...change replace t replace the defect he defective solenoid ive solenoid If If fault did not change replace fault did not change replace cartridge cartridge 2 2 Pl Plac ace the t e the tra rans nsmi mis...

Page 143: ...Tr Transmis ansmission is sion is overhe overheating ating 16 16 Drive a Drive axle is l xle is loose oose 17 17 Tr Tread patter ead pattern on tires n on tires 1 1 Re Repa pair ir di diff ffer erent...

Page 144: ...o o l l e e r r https www forkliftpdfmanuals com...

Page 145: ...Section 9A Section 9A Transmi Transmission ssion Cooler Cooler CHARGE AIR CHARGE AIR COOLER COOLER https www forkliftpdfmanuals com...

Page 146: ...be valid the transmis in order for warranty to be valid the transmis sion oil cooler transmission filter and hoses sion oil cooler transmission filter and hoses from the transmission to the transmissi...

Page 147: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 9A 2 9A 2 https www forkliftpdfmanuals com...

Page 148: ...9 9 C C T T r r a a n n s s m m i i s s s s i i o o n n C C o o n n t t r r o o l l s s https www forkliftpdfmanuals com...

Page 149: ...n ically shift the transmission Before servicing truck park Before servicing truck park the truck on level ground apply parking brake the truck on level ground apply parking brake and block the wheels...

Page 150: ...on selecting the transmis OG160 for information on selecting the transmis sion shift mode sion shift mode T To select the mode of o select the mode of transmis transmis sion shifting from within the T...

Page 151: ...PRESS UP OR DOWN BUTTON DOWN BUTTON TO SELECT THE TO SELECT THE NUMERIC DIGITS NUMERIC DIGITS OF THE PIN CODE OF THE PIN CODE DEPRESS OK BUT DEPRESS OK BUT TON AFTER EACH TON AFTER EACH DIGIT IS ENTER...

Page 152: ...ed range of the transmission is manually shifted or automatically shifted Operator Controlled Mode refer range of the transmission is manually shifted or automatically shifted Operator Controlled Mode...

Page 153: ...the e Diagnostics Select screen Diagnostics Select screen DIAGNOSTICS DIAGNOSTICS BUTTON BUTTON Illustration Illustration 9C 7 9C 7 Main Dis Main Display Screen play Screen 2 2 At the Diagnos At the...

Page 154: ...smission Information Screen ion Information Screen 4 4 Once t Once the des he desired m ired mode ha ode has bee s been sele n selected cted depres depress the s the button once to return to the Main...

Page 155: ...tic Mode operator operator cannot choose when cannot choose when to use forward to use forward alarm alarm Selecting Operator Controlled Selecting Operator Controlled activates the forw activates the...

Page 156: ...on er is placed in its Forward position FORWARD ALARM OFF FORWARD ALARM OFF FORWARD ALARM ON FORWARD ALARM ON Illustration 9C 12 Illustration 9C 12 Main Display Main Display Screen Forward Screen Forw...

Page 157: ...e APC is in the reset condition due to the bootstrap or bootstrap or F Fault mode ault mode After power up the After power up the display defaults to the display defaults to the last display mode if l...

Page 158: ...ut is used to inform you about any current or previously active errors you about any current or previously active errors The display normally shows to indic The display normally shows to indicate ther...

Page 159: ...rent shift lever direction and position ESPD ESPD Shows measured engine speed RPM Shows measured engine speed RPM TSPD TSPD Shows measured turbine speed RPM Shows measured turbine speed RPM OSPD OSPD...

Page 160: ...ate the transmission in eit an operate the transmission in either direction in 1st her direction in 1st and 2nd only and 2nd only If the fault occurs at a higher gear position If the fault occurs at a...

Page 161: ...nd Maintenance Diagnostics and Maintenance General General Principally there are no specific devices required for first level troubleshooting as the APC incorporates Principally there are no specific...

Page 162: ...d as groups of related displays The available information is organized as groups of related displays Generally each mode s start display provides an overview of the status of all members of the group...

Page 163: ...identification string e g ECON C 1 5 r6 After releasing the After releasing the S switch F4 the S switch F4 the display again illuminates all display again illuminates all segments segments Digital In...

Page 164: ...e analog inputs return high when pulled to the analog inputs return high when pulled to ground ground Pressing the S switch F4 at the last analog input brings back the overview on the display Pressing...

Page 165: ...ile pressing While pressing the the S S switch the display shows the speed channel number on the left side of the display while the switch the display shows the speed channel number on the left side o...

Page 166: ...lue or logic state and the fault specific screen the display alternates between the actual state current value or logic state and the fault type open short curr oor type open short curr oor Voltage T...

Page 167: ...e S So ol le en no oi id d A A1 16 6 A17 A17 G G2 2 D DI IG GI IN N3 3 P Pt tp p Not Used Not Used A18 A18 H H2 2 D DI IG GI IN N4 4 P Pt tp p Not Used Not Used A19 A19 J J2 2 D DI IG GI IN N5 5 P Pt...

Page 168: ...m related to the internal related to the internal RAM in CPU RAM in CPU Controller reverts to Controller reverts to a shut down mode a shut down mode and will force neutral and will force neutral 0 0...

Page 169: ...oting Voltage supply for Voltage supply for the sensors Vsense the sensors Vsense 8V is below 7 2 V 8V is below 7 2 V Check power Check power supply supply Check the controller Check the controller 3...

Page 170: ...ure and the converter out the converter out temperature sensor temperature sensor 4 43 3 0 08 8 A A T Th he e t tr ra an ns sm mi is ss si io on n converter converter out out tem tem perature sensor p...

Page 171: ...nput The analog input ANI1 is short ANI1 is shorted to ed to ground ground Check the wiring Check the wiring between the control between the control ler and the transmis ler and the transmis sion sump...

Page 172: ...to this connected to this analog analog input input Check Check this device con this device con nected nected Check if Check if the the calibration is done calibration is done correctly recalibra cor...

Page 173: ...n this device con nected nected Check if Check if the the calibration is done calibration is done correctly recalibra correctly recalibra tion of this analog tion of this analog input input 5 56 6 0 0...

Page 174: ...il channel has a fail ure and which is not ure and which is not the engine speed the engine speed channel the control channel the control ler will calculate what ler will calculate what the missing sp...

Page 175: ...re and which is not the engine speed the engine speed channel the control channel the control ler will calculate what ler will calculate what the missing speed the missing speed should be should be If...

Page 176: ...peed channel is not Speed channel is not measuring measuring Check the speed Check the speed sensor installation sensor installation Fault Fault C Co od de e T Ty yp pe e E Ex xp pl la an na at ti io...

Page 177: ...non critical f non critical feature eature output the controller output the controller will flag the fault but will flag the fault but no actions will be no actions will be taken taken limp home mode...

Page 178: ...ission valve transmission valve control the control control the control ler reverts to a limp ler reverts to a limp home mode home mode non critical f non critical feature eature output the controller...

Page 179: ...rive again Limp home mode Limp home mode will result in reduced will result in reduced driving functionality driving functionality Contact mainte Contact mainte nance for trouble nance for trouble sho...

Page 180: ...ed driving functionality driving functionality Contact mainte Contact mainte nance for trouble nance for trouble shooting shooting wires A06 wires A06 A07 A07 configured as analog configured as analog...

Page 181: ...ome mode home mode non critical f non critical feature eature output the controller output the controller will flag the fault but will flag the fault but no actions will be no actions will be taken ta...

Page 182: ...ns will be taken taken limp home mode limp home mode Stop machine and Stop machine and go to neutral to be go to neutral to be able to drive again able to drive again Limp home mode Limp home mode wil...

Page 183: ...ome mode Limp home mode will result in reduced will result in reduced driving functionality driving functionality Contact mainte Contact mainte nance for trouble nance for trouble shooting shooting wi...

Page 184: ...tions will be taken taken limp home mode limp home mode Stop machine and Stop machine and go to neutral to be go to neutral to be able to drive again able to drive again Limp home mode Limp home mode...

Page 185: ...ome mode home mode non critical f non critical feature eature output the controller output the controller will flag the fault but will flag the fault but no actions will be no actions will be taken ta...

Page 186: ...lag the fault but will flag the fault but no actions will be no actions will be taken taken limp home mode limp home mode Stop machine and Stop machine and go to neutral to be go to neutral to be able...

Page 187: ...ult but no actions will be no actions will be taken taken limp home mode limp home mode Stop machine and Stop machine and go to neutral to be go to neutral to be able to drive again able to drive agai...

Page 188: ...output the controller will flag the fault but will flag the fault but no actions will be no actions will be taken taken limp home mode limp home mode Stop machine and Stop machine and go to neutral to...

Page 189: ...transmission in neutral until the transmission in neutral until the vehicle speed comes below the vehicle speed comes below the direction change vehicle speed direction change vehicle speed limit lim...

Page 190: ...g brake not activated ing brake not activated The driver should take place in the The driver should take place in the operator seat and confirm his pres operator seat and confirm his pres ence cycle t...

Page 191: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 9C 42 9C 42 Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 192: ...XH TXB 180S 400L Rev 4 23 07 PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN A FOLDE A FOLDER ENVE R ENVELOPE LOPE Illustration 9C 13 09C 2343 SHIFT ANSI Illustration 9C 13 09C...

Page 193: ...https www forkliftpdfmanuals com...

Page 194: ...ection 11 Section 11 Drive Shaft Drive Shaft TRANSMISSION TRANSMISSION TO AXLE TO AXLE DRIVE SHAFT DRIVE SHAFT CROSS CROSS ASSEMBLY ASSEMBLY Illustration 1 Illustration 11 1 1 1 Transmiss Transmission...

Page 195: ...lies on the drive shaft must be align shaft must be aligned as shown ed as shown in Illustration in Illustration 11 1 11 1 If the flanges If the flanges are not aligned reposit are not aligned reposit...

Page 196: ...olts of the steer axle should be mounting bolts of the steer axle should be checked for tightness periodically refer to the checked for tightness periodically refer to the Preventive Maintenance Preve...

Page 197: ...23 07 TX TXH TXB 180S 400L Rev 4 23 07 STEER AXLE STEER AXLE MOUNTING BOLT MOUNTING BOLT STEER CYLINDER STEER CYLINDER MOUNTING BOLT MOUNTING BOLT Illustration Illustration 13 1 13 1 Steer Steer Axle...

Page 198: ...UTPUT OUTPUT PORT PORT BRAKE BRAKE APPLY APPLY PORT PORT VENT VENT PLUG PLUG POSITION PLUG POSITION PLUG HERE TO FILL OR HERE TO FILL OR CHECK LEVEL CHECK LEVEL POSITION PLUG POSITION PLUG HERE TO DRA...

Page 199: ...io tion the n the tru truck as ck as nec necess essary a ary and nd service the hub on the opposite end of the service the hub on the opposite end of the axle by repeating the above procedures axle by...

Page 200: ...ydraulic fluid 3 3 Rem Remove t ove the br he brake c ake cool ooling h ing hose oses fr s from th om the e brake housing and quickly cap hoses brake housing and quickly cap hoses 4 4 Rem Remove t ove...

Page 201: ...10 10 Re install the Re install the vent plug and vent plug and brake cooling out brake cooling out put plug put plug Tighten Tighten both to a torque v both to a torque value of alue of 60 75 ft lbs...

Page 202: ...he chec heck p k plug lug level in the differential level in the differential 2 2 Lo Loss ss of of oi oil o l out ut of of the differential the differential 1 1 Da Dama maged o ged or bad r badly w l...

Page 203: ...l driv ives o es ove ver r heat Planetary heat Planetary Axles Axles 1 1 Lo Low o w oil il le leve vel l 2 2 Inc Incorr orrect ect typ type a e and nd gra grade de of of oil oil 3 3 Inc Incorr orrect...

Page 204: ...ccumulators are are hydro pneumatic hydro pneumatic piston type and are precharged with dry nitrogen piston type and are precharged with dry nitrogen to 1 250 psi to 1 250 psi 86 bar and 86 bar and 50...

Page 205: ...ted on the instrument parking brake control is located on the instrument panel and when pushed in it energizes the park panel and when pushed in it energizes the park ing brake solenoid valve which su...

Page 206: ...tem Components Identification ponents Identification INDICATES HYDRAULIC FLUID FLOW INDICATES HYDRAULIC FLUID FLOW LH LH RH RH Illustration Illustration 15 3 15 3 Brake Brake Valves Valves Parking Bra...

Page 207: ...the parking brake in the released posi place the parking brake in the released posi tion and Lock Out Tag Out the truck tion and Lock Out Tag Out the truck 2 2 Rem Remove ove plu plug 5 g 5 an and s d...

Page 208: ...ter hex outer hex nut nut 18 and place a 0 010 0 015 inch thick shim 18 and place a 0 010 0 015 inch thick shim between the lining and the disc surface between the lining and the disc surface Adjust t...

Page 209: ...ont wheel brake housing allowing air and oil to vent into a suitable container oil to vent into a suitable container MANUAL MANUAL OVERRIDE KNOB OVERRIDE KNOB Illustration Illustration 15 7 15 7 Parki...

Page 210: ...raulic f lic flui luid d 3 3 Clo Clogge gged or dirt d or dirty hydr y hydraul aulic ret ic return fi urn filte lter with r with apparently fibrous material apparently fibrous material 4 4 Out Out of...

Page 211: ...lip in the port to remove the blockage the port to remove the blockage reassemble and perform the reassemble and perform the Wet Wet Disc Brake Bleeding Disc Brake Bleeding procedures procedures locat...

Page 212: ...to to Pro Proble blem 8 m 8 of of the the Hydraulic System Hydraulic System T Troubleshoot roubleshoot ing ing chart in chart in Section 22 Section 22 1 1 Rep Replac lace pa e parki rking ng bra brak...

Page 213: ...15 9 15 9 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 https www forkliftpdfmanuals com...

Page 214: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 15 10 15 10 https www forkliftpdfmanuals com...

Page 215: ...1 1 5 5 C C W W e e t t D D i i s s c c B B r r a a k k e e s s C C o o o o l l i i n n g g S S y y s s t t e e m m https www forkliftpdfmanuals com...

Page 216: ...Section 15C Section 15C https www forkliftpdfmanuals com...

Page 217: ...cated to service brake cooling COOLING COOLING CHECK VALVE CHECK VALVE Illustration 15C Illustration 15C 1 1 Cooling Check Cooling Check V Valve alve Cooling Check Valve Cooling Check Valve Illustrati...

Page 218: ...5 Re Refe fer t r to Pr o Prob oble lem 2 m 2 in the in the Brake Brake Control System Troubleshooting Control System Troubleshooting chart in chart in Section 15 Section 15 2 2 Lo Low C w Coo ooli l...

Page 219: ...ring Orbitrol Refer to Refer to Section 22 Section 22 for opera for opera tion of the steering orbitrol tion of the steering orbitrol Steer Cylinder Steer Cylinder Illustration 16 1 Illustration 16 1...

Page 220: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 16 2 16 2 PRELIMINARY PRELIMINARY Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 221: ...ev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN A FOLDE A FOLDER ENVE R ENVELOPE LOPE Illustration 16 1 16 2364 SHT 2 ANSI Illustrat...

Page 222: ...Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 223: ...nd valve caps daily for any damage damage Bias and Bias and radial constructi radial constructions must ons must never be never be mixed on dual pair mixed on dual pair Tire Inflation Tire Inflation T...

Page 224: ...try code and be of the same construc industry code and be of the same construc tion both bias or both radials tion both bias or both radials lead to the underinflated tire rubbing the other tire lead...

Page 225: ...o tighten the wheel nuts to the proper torque value torque value Inspection Inspection Mixing parts Mixing parts of one m of one manufacturer s rims anufacturer s rims with with those of another is th...

Page 226: ...y solely Never rely solely upon jacks o upon jacks or hoists to r hoists to support the lift truck while removing tire support the lift truck while removing tire wheel wheel Before placing Before plac...

Page 227: ...e of another is potentially dangerous potentially dangerous Always check manufacturer for approval Always check manufacturer for approval Do Do not b not be careless e careless or or take chances take...

Page 228: ...ll also increase with an increase in ambient temperature and when sub increase in ambient temperature and when sub jected to direct sunlight jected to direct sunlight If the vapor and If the vapor and...

Page 229: ...strial trucks 5 7 which require inspecting industrial trucks daily before being placed in service removing daily before being placed in service removing trucks from service if cracks are found and mak...

Page 230: ...efer t er to Co o Corre rrecti ction 1 on 1 a abov bove an e and d avoid overloading the truck avoid overloading the truck 3 3 Ref Refer t er to Co o Corre rrecti ction 1 on 1 abo above a ve and nd if...

Page 231: ...ch to identify fatigue cracks or structural damage t structural damage to the chassis o the chassis Be very descript Be very descriptive of ive of damage to the chassis i e location depth length damag...

Page 232: ...l roperly y 7 7 The t The tilt ilt steeri steering m ng must ust lock lock firml firmly int y into pos o position ition Failure to adhere to any of the Failure to adhere to any of the above could lead...

Page 233: ...TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 20 2 20 2 2 2 0 0 A A A A i i r r C C o o n n d d i i t t i i o o n n i i n n g g S S y y s s t t e e m m https www forkliftpdfmanuals c...

Page 234: ...https www forkliftpdfmanuals com...

Page 235: ...d by an EPA warm high pressure liquid to the expansion warm high pressure liquid to the expansion valve valve The drier is The drier is equipped with a equipped with a binary switch binary switch whic...

Page 236: ...m es a warm high high pressure liquid from the condenser and sends a pressure liquid from the condenser and sends a sure gas sure gas The cold The cold low pressure low pressure gas is sent gas is sen...

Page 237: ...emove fi e filters lters from from filte filter cov r covers a ers and c nd clean lean with with low pressure air low pressure air Replace old filters Replace old filters with new with new filters if...

Page 238: ...e ambient temperature will then defrost the evaporator coil fins evaporator coil fins 6 6 The 1 The 12 VDC s 2 VDC sign ignal fr al from th om the the e thermo rmosta stat mus t must t pass through a...

Page 239: ...itch in the air position position 12 12 Replac Replace heat air swit e heat air switch ch 13 13 Connec Connect or tighten harne t or tighten harness ss connector s connector s 14 14 Contact Contact ce...

Page 240: ...e did did not not ris rise t e to op o opera eratin ting g temperature temperature 5 5 Ch Chec eck an k and fi d fill r ll rad adia iato tor r 6 6 All Allow ow engi engine e ne enou nough t gh time im...

Page 241: ...H TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 20A 6 20A 6 Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN https www forkliftpdfmanual...

Page 242: ...H TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 A FOLDE A FOLDER ENVE R ENVELOPE LOPE Illustration 20A 2 20A 2367 SHT 1 A C ANSI Illustration 20A 2 20A 2367 SHT 1 A C ANSI https www forkl...

Page 243: ...https www forkliftpdfmanuals com...

Page 244: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 20A 8 20A 8 2 2 0 0 H H H H e e a a t t i i n n g g S S y y s s t t e e m m https www forkliftpdfmanuals com...

Page 245: ...https www forkliftpdfmanuals com...

Page 246: ...roster heater defroster circuits circuits They must They must be fully open be fully open for maximum for maximum operation operation If any of If any of the the shut off valves are closed there will...

Page 247: ...esho shoot i ot isol solate a ate and re nd repla place ce wire wire 2 2 He Heat ater er de defr fros oste ter r fan is turning but fan is turning but no warm air is no warm air is present present 1 1...

Page 248: ...0H 2 Hoist Circuit Hoist Circuit PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN A FOLDE A FOLDER ENVE R ENVELOPE LOPE Illustration 20H 2 20A 2367 SHT 2 Defroster ANSI Illustra...

Page 249: ...20H 3 20H 3 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 https www forkliftpdfmanuals com...

Page 250: ...and is then directed then directed to the hoist to the hoist and tilt valv and tilt valves es When steering load When steering load sense pressure builds from the orbitrol which sense pressure builds...

Page 251: ...ed at the hydraulic ORF1 and check valve CK1 to start the accumu ORF1 and check valve CK1 to start the accumu lator charging lator charging process process As pressure As pressure builds in builds in...

Page 252: ...FILTER PILOT FILTER Illustrati Illustration on 22 13 22 13 SYSTEM COOLER SYSTEM COOLER Illustration 5 3 Illustration 5 3 ACCUMULA ACCUMULATORS TORS Illustratio Illustration n 22 12 22 12 MANIFOLD MAN...

Page 253: ...PPM PPM RV2 RV2 LC3 LC3 LC2 LC2 ORF3 ORF3 Illustration 22 3 Illustration 22 3 Manifold Manifold Mast Mast Side Side LC2 LC2 Logic Control Controls flow to steering Logic Control Controls flow to steer...

Page 254: ...rimary pump for primary pump P1 P1 Pump One Main Pump Primary pump Pump One Main Pump Primary pump inlet to manifold inlet to manifold CK1 ORF1 CK1 ORF1 Check valve number one and Check valve number o...

Page 255: ...il to operate depressing the Should a function fail to operate depressing the override switch will override all the electrical actu override switch will override all the electrical actu ated functions...

Page 256: ...h Bolts Lift Bank Through Bolts Lift Tilt Tilt Side Side BOLTS BOLTS TORQUE TORQUE TO 32 FT TO 32 FT LBS 9 16 LBS 9 16 SOCKET SOCKET Illustration 22 8 Illustration 22 8 Valve Valve Bank Through Bolts...

Page 257: ...E 750 RPM 13 GPM 49 LPM FLOW RATE 2200 RPM 22 GPM 83 LPM FLOW RATE 2200 RPM 22 GPM 83 LPM FLOW RATE 750 RPM 7 GPM 26 LPM FLOW RATE 750 RPM 7 GPM 26 LPM Illustration 22 10 TX H 180 360 Main Pump Illust...

Page 258: ...ons 1 1 Park t Park the tr he truck on a ha uck on a hard le rd level s vel surf urface ace blo block ck the wheels in both directions apply the park the wheels in both directions apply the park ing b...

Page 259: ...hering to the above pro cedure can lead to overfilling of the hydraulic cedure can lead to overfilling of the hydraulic tank tank As a result As a result hydraulic fluid hydraulic fluid will be for wi...

Page 260: ...Rem Remove t ove the re he retur turn fi n filte lter r r refe efer to r to Hydraulic Hydraulic Return Filter Replacement Return Filter Replacement for removal pro for removal pro cedures cedures 6 6...

Page 261: ...R CAP w DIPSTICK w DIPSTICK HYDRAULIC HYDRAULIC FLUID TEMPERA FLUID TEMPERA TURE SENDER TURE SENDER Illustration 22 16 Illustration 22 16 Hydraulic T Hydraulic Tank ank truck with the manual lowering...

Page 262: ...manual lowering valve the manual lowering valve 1 1 Rem Remove t ove the s he stem tem scr screw a ew and co nd colla llar r 2 2 Re Remo move ve th the l e loc ock p k pla late te 3 3 Mak Make sur e...

Page 263: ...e ge ind indi i cations should be as specified in the cations should be as specified in the HYDRAULIC PRESSURE SETTINGS HYDRAULIC PRESSURE SETTINGS chart in chart in the the Appendices Appendices If n...

Page 264: ...fork positioners work sections are factory set and non adjustable set and non adjustable Hydraulic System Troubleshooting Hydraulic System Troubleshooting Troubleshooting Common Steering Problems Trou...

Page 265: ...he the engine engine Tu Turn rn the the igniti ignition on switc switch t h to o it s ignition it s ignition position 1st position 1st click click Bleed the brake Bleed the brake pressure to zero by r...

Page 266: ...e and re d repa pair ir 9 9 R Re ef fe er r t to o Slide Bearing Blocks Slide Bearing Blocks Shimming Shimming in in Section 27 Section 27 and prop and prop erly shim the mast erly shim the mast 3 3 S...

Page 267: ...tion of n of the the man manual ual ove overri rride de switch will confirm defective sole switch will confirm defective sole noid Replace noid Replace 6 6 C Ca al li ib br rat ate e 7 7 Is Isol olat...

Page 268: ...Rem Remove ove and and cle clean an UNL UNL1 1 Ins Inspec pect t UNL1 s port for debris UNL1 s port for debris 4 4 R Re ep pl la ac ce e 5 5 Rem Remove ove and and cle clean an RV RV3 3 Ins Inspec pe...

Page 269: ...of the manifold 13 13 Crack Cracked manif ed manifold old 14 14 Refer als Refer also to Problem 5 of the o to Problem 5 of the Brake Control System Brake Control System Tr Trouble ouble shooting shoot...

Page 270: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 22 20 22 20 Hoist Circuit Hoist Circuit https www forkliftpdfmanuals com...

Page 271: ...80S 400L Rev 4 23 07 PLACE THE FOLLOWING ILLUSTRATION IN PLACE THE FOLLOWING ILLUSTRATION IN A FOLDE A FOLDER ENVE R ENVELOPE LOPE Illustration 22 20 22 2896 SHT 2 Main Hyd ANSI Illustration 22 20 22...

Page 272: ...https www forkliftpdfmanuals com...

Page 273: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 22 22 22 22 2 2 2 2 E E A A c c c c u u m m u u l l a a t t o o r r https www forkliftpdfmanuals com...

Page 274: ...https www forkliftpdfmanuals com...

Page 275: ...OWN position for approximately one minute DOWN position for approximately one minute 2 2 Rem Remove t ove the v he valv alve gua e guard an rd and cap d cap fro from the m the accumulator accumulator...

Page 276: ...ck precharge Recheck precharge one week one week after charging after charging for pressure loss for pressure loss 5 5 6 6 7 7 8 8 9 9 10 10 11 11 1 1 2 2 3 3 4 4 BAR BAR HANDLE HANDLE NITROGEN NITROG...

Page 277: ...stresses of to fluctuating stresses of signifi signifi cant magnitude these cracks cant magnitude these cracks will grow will grow This is This is known as fat known as fatigue crack growth igue crac...

Page 278: ...ers new rollers Chain Rollers Chain Rollers Illustration 27 4 Illustration 27 4 The chain rollers The chain rollers use sealed ball beari use sealed ball bearings ngs Check the chain Check the chain r...

Page 279: ...ance the carriage moved and shim the shim the bottom c bottom carriage slide arriage slide bearings bearings See See NOTE NOTE below procedure 5 below procedure 5 4 4 Ali Align the b gn the bott ottom...

Page 280: ...RR SIRR in the in the Appendices Appendices Notify Taylor Notify Taylor Machine Works Machine Works Inc for proper Inc for proper repair procedures repair procedures 1 1 M Met etal f al fat atig igue...

Page 281: ...RING BLOCK BLOCK SLIDE SLIDE BEARING BEARING HOUSING HOUSING SHIM SHIM REPLACE BEARING BLOCKS WORN REPLACE BEARING BLOCKS WORN TO 1 3 4 44 5 mm THICK OR BLOCKS TO 1 3 4 44 5 mm THICK OR BLOCKS THAT AR...

Page 282: ...0L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 MAIN MAIN CHAIN CHAIN ROLLER ROLLER INNER INNER MAST MAST OUTER MAST OUTER MAST SLIDE BEARING SLIDE BEARING BLOCK BLOCK LIFT LIFT CYLINDER CYLINDER http...

Page 283: ...XH TXB 180S 400L Rev 4 23 07 27 6 27 6 ROLLERS ROLLERS SLIDE SLIDE BEARING BEARING BLOCKS BLOCKS OUTER OUTER MAST MAST Illustration Illustration 27 4 27 4 Mast Mast Assembly Assembly Components Compon...

Page 284: ...y fatigue cracks o identify fatigue cracks or structural damage to the or structural damage to the mast mast Be very Be very descriptive of damage to the mast i e location depth length descriptive of...

Page 285: ...if authorized by the manufacturer If trucks are used on a round the clock basis they If trucks are used on a round the clock basis they shall be examined shall be examined after each s after each shi...

Page 286: ...TXH TXB 180S 400L Rev 4 23 07 SLIDE BEARING SLIDE BEARING BLOCKS BLOCKS Illustration Illustration 28 1 28 1 Standard Standard Carriage Carriage MAIN MAIN ROLLERS ROLLERS SLIDE BEARING SLIDE BEARING B...

Page 287: ...lubricated Excess grease i Excess grease inside the nside the mast rails may cause the rollers to slide when mast rails may cause the rollers to slide when subjected to a subjected to a heavy load hea...

Page 288: ...ght and or fully side shifted height and or fully side shifted one side or the other one side or the other 5 5 Se Seve vere re du duty ty cy cycl cles es 6 6 T Tryi rying to u ng to use fo se fork po...

Page 289: ...en nt t A A 1 19 9 W We el ld di in ng g P Pr re ec ca au ut ti io on ns s A A 2 25 5 T To or rq qu ue e C Ch ha ar rt t N Nu ut ts s a an nd d B Bo ol lt ts s A A 2 29 9 L Lu ub br ri ic ca at ti io...

Page 290: ...TX TXH TXB 180S 400L 07 TX TXH TXB 180S 400L 07 https www forkliftpdfmanuals com...

Page 291: ...t corrected they can lead to a catastrophic failure causing serious not corrected they can lead to a catastrophic failure causing serious injury to personnel and or property injury to personnel and or...

Page 292: ...A 1 A 1 TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 https www forkliftpdfmanuals com...

Page 293: ...rdance with AWS These symbols are in accordance with AWS A2 4 76 Symbols for A2 4 76 Symbols for Non Destructive T Non Destructive Testing esting Periodic inspection is Periodic inspection is required...

Page 294: ...ental ing or wire brushing might prove detrimental to the test because surface discontinuities can to the test because surface discontinuities can be masked by cold working of the surface be masked by...

Page 295: ...steel Different steel grades are grades are used for used for different different components components Dif Dif ferent steel grades require different welding ferent steel grades require different wel...

Page 296: ...o on n 9 9 C Ch ha as ss si is s D De et ta ai il l 3 3 A A 1 14 4 I Il ll lu us st tr ra at ti io on n 1 10 0 C Ch ha as ss si is s D De et ta ai il l 4 4 A A 1 15 5 I Il ll lu us st tr ra at ti io o...

Page 297: ...6 A 6 Detail 1 Detail 1 Detail 4 Detail 4 Illustration 1 Illustration 1 Inner and Inner and Outer Mast Outer Mast Arrangement Arrangement Inner Mast Details Inner Mast Details Detail 1 Detail 1 VT 3...

Page 298: ...00L Rev 4 23 07 VT 3 VT 3 MT FS MT FS Illustration 2 Illustration 2 Inner Mast Inner Mast Details 1 Details 1 and 2 and 2 Outer Mast Details Outer Mast Details VT 3 VT 3 MT FS MT FS VT 3 VT 3 MT FS MT...

Page 299: ...A 8 VT 3 VT 3 MT FS MT FS Detail 3 Detail 3 Illustration 3 Illustration 3 Outer Mast Outer Mast Detail 3 Detail 3 Detail 4 Detail 4 Outer Mast Details Outer Mast Details VT 3 VT 3 MT FS MT FS VT 3 VT...

Page 300: ...XB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 Illustration 4 Illustration 4 Outer M Outer Mast D ast Detail 4 etail 4 VT 3 VT 3 MT FS MT FS Carriage Detail Carriage Detail https www forkli...

Page 301: ...180S 400L Rev 4 23 07 A 10 A 10 VT 3 VT 3 MT FS MT FS Illustration 5 Illustration 5 Carriage Carriage Detail Detail Detail 3 Detail 3 Detail 4 Detail 4 Chassis Arrangement Chassis Arrangement Detail...

Page 302: ...TX TXH TXB 180S 400L Rev 4 23 07 Detail 1 Detail 1 Detail 2 Detail 2 Illustration Illustration 6 6 Chassis Chassis Arrangement Arrangement Chassis Details Chassis Details Detail 1 Detail 1 VT 3 VT 3 M...

Page 303: ...TX TXH TXB 180S 400L Rev 4 23 07 A 12 A 12 VT 3 VT 3 MT FS MT FS Illustration 7 Illustration 7 Chassis Chassis Detail Detail 1 1 Chassis Details Chassis Details VT 3 VT 3 MT FS MT FS Detail 2 Detail 2...

Page 304: ...v 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 VT 3 VT 3 MT FS MT FS Illustration 8 Illustration 8 Chassis Chassis Detail Detail 2 2 Detail 3 Detail 3 Chassis Details Chassis Details VT 3 VT 3 MT FS MT FS...

Page 305: ...ev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 A 14 A 14 Illustration 9 Illustration 9 Chassis Chassis Detail Detail 3 3 Chassis Details Chassis Details VT 3 VT 3 MT FS MT FS Detail 4 Detail 4 https www...

Page 306: ...0S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 VT 3 VT 3 MT FS MT FS Illustration 10 Illustration 10 Chassis Chassis Detail Detail 4 4 Chassis Details Chassis Details Detail 5 Detail 5 https www...

Page 307: ...cracks must also include any This inspection for cracks must also include any special mounting mechanisms of the fork blank to special mounting mechanisms of the fork blank to Any fork that Any fork t...

Page 308: ...or wear be repaired be repaired by welding by welding When repairs When repairs necessitat necessitat ing resetting are required the fork shall subse ing resetting are required the fork shall subse q...

Page 309: ...ps containers marinas and other attachments all of which will place different dynamic paper roll clamps containers marinas and other attachments all of which will place different dynamic loads and loa...

Page 310: ...wear to a length of 12 360 in 314 mm 3 12 360 in 314 mm 3 it has exceeded the allowable it has exceeded the allowable wear limit wear limit The wear should be The wear should be measured in the area t...

Page 311: ...maximum 12 in 305 mm New 12 in 305 mm New 12 3 in 314 mm Worn 12 3 in 314 mm Worn Normal Wear Normal Wear Permanent deformation Permanent deformation stretch from overload stretch from overload Repla...

Page 312: ...eign substance Dirt or foreign substance packed in joints packed in joints Corrosion and rust Corrosion and rust Bent pins Bent pins Replace chain Replace chain Replace chain Replace chain Clean and r...

Page 313: ...ow anyone anyone to touch the controls while people are near the upright to touch the controls while people are near the upright II II Use Loc Use Lockout T kout Tagout Proc agout Procedure to red edu...

Page 314: ...jury could Death or serious injury could result from result from a runaway truck a runaway truck Park the truck Park the truck on on a hard level surface apply the parking brake a hard level surface a...

Page 315: ...lded assembly that is to be welded welded Disconnection of Electrical Components Disconnection of Electrical Components Some electrical components on the truck must be Some electrical components on th...

Page 316: ...TX TXH TXB 180S 400L Rev 4 23 07 TX TXH TXB 180S 400L Rev 4 23 07 A 26 A 26 TICS MD3 TICS MD3 DISPLAY MODULE DISPLAY MODULE https www forkliftpdfmanuals com...

Page 317: ...3 07 CAB MODULE CAB MODULE XA XA2 2 A1 A1 CHASSIS MODULE CHASSIS MODULE XA XA2 2 A0 A0 Illustration 2 Illustration 2 TICS Control Module TICS Control Module and Main Display Loc and Main Display Locat...

Page 318: ...ts must be of of the same SAE grade as the bolts on the chart the same SAE grade as the bolts on the chart When nuts and bolts are of different grades use When nuts and bolts are of different grades u...

Page 319: ...ad de e 8 8 1 12 2p pt t F Fe er rr ry y H He ea ad d C Ca ap ps sc cr re ew w NF Threads NF Threads T To or rq qu ue e T To or rq qu ue e T To or rq qu ue e f ft t l lb bs s N N m m f ft t l lb bs s...

Page 320: ...h internal hex drive used for retaining the slide bearing block housings found retaining the slide bearing block housings found on the mast and carriage on the mast and carriage 1 1 Do No Do Not use s...

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