MANUALES DE TALLER Y REPARACION AUTOMOTRIZ

Manual de operación y mantenimiento CATERPILLAR V250B

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Format: PDF Language: English Brand: CAT Caterpillar Type of Machine: Forklift Type of Manual: Operation & Maintenance Manual Model: CAT V250B Forklift Date: 2015 Content: SEBU5918-02-00 Introduction SEBU5918-02-01 Foreword SEBU5918-02-02 Safety SEBU5918-02-03 Operation Section SEBU5918-02-04 Maintenance Section Cat Pub List Publication List (Service, Operator, & Parts Manuals) Mast Tilting Angles Mast Tilting Angles REF-18-0001C How To Determine Correct Mast Rails Lift Cylinders And Mast Hosing REF-18-0001C How To Determine Correct Mast Rails Lift Cylinders And Mast Hosing (Spanish) REF-18-0002C How To Locate Fluid Capacities REF-18-0002C How To Locate Fluid Capacities (Spanish) REF-18-0003C How To Use A Pick List REF-18-0003C How To Use A Pick List (Spanish) REF-18-0007C Abbreviations And Acronyms List REF-18-0008C Diagnostic Trouble (Error) Codes This part manual inlcude all spare parts number you need inside this model, for you easier in fixing your forklift replace new spare part hight performance. This service manual is a guide for servicing Cat Lift Trucks. For your convenience the instructions are grouped by systems as an easy reference. This Original Instructions (Operator’s) Manual describes operating procedures, daily checks and simple maintenance for safe usage of your Cat lift truck. SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION 1.1 Model View 1.2 Models Covered 1.2.1 Lift Truck Nomenclatures and Definitions 1.3 Serial Number Locations 1.4 Dimensions 1.5 Technical Data 1.6 Performance CHAPTER 2 COOLING SYSTEM 2.1 Specifications 2.2 Structure 2.3 Removal and Installation 2.3.1 Fan Belt Removal 2.3.2 Suggestions for Removal 2.3.3 Installation 2.4 Inspection and Adjustment 2.4.1 Fan Belt Inspection 2.4.2 Fan Belt Tension 2.4.3 Connecting Hoses 2.4.4 Coolant 2.4.5 Radiator Cap CHAPTER 3 ELECTRIC SYSTEM 3.1 Chassis Electrical Devices Wiring Outline 3.1.1 Harnesses Layout 3.1.2 Components Layout 3.2 Structure 3.2.1 Console Box 3.2.2 Major Electrical Components 3.2.3 Table of Lamps 3.3 Console Box 3.3.1 Disassembly 3.4 Battery Maintenance 3.4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment 3.4.2 Specific Gravity Reading and State of Charge 3.4.3 Charging Precautions 3.5 Instrument Panel 3.5.1 Instrument Panel Screen Element 3.5.2 Basic Screen Display 3.5.3 Basic Operation 3.5.4 When An Error Occurs 3.5.5 Warning Lamps 3.5.6 Optional Functions 3.5.7 Hour Meters 3.5.8 Troubleshooting 3.6 Wire Color 3.6.2 List of Wire Colors 3.7 Troubleshooting 3.7.1 Starter System 3.7.2 Gauges 3.7.3 Lighting System 3.8 Electrical Schematic CHAPTER 4 CONTROLLERS 4.1 Outline 4.2 Main Functions 4.2.2 Instrument Panel 4.2.3 VCM (Vehicle Control Module)1-M 4.2.4 ECM (Gasoline Engine Control Module) 4.2.5 Remote Input/Output Units 4.2.6 GSE Connector 4.3 Service Tool Functions 4.3.1 Service Tool Menus 4.3.2 Service Tool Box 4.4 Mast Interlock System 4.4.1 Function 4.4.2 VCM1-M Controller, Mast Interlock System Checking Procedure 4.4.3 Active Test Inspection Procedure 4.5 Driving Interlock System 4.5.1 Function 4.5.2 Driving Interlock System Checking Procedure for Powershift T/M Lift Trucks 4.5.3 Active Test Inspection Procedure 4.6 Seat Belt Warning Lamp 4.6.1 Function 4.6.2 Seat Belt Warning Lamp Checking Procedure 4.7 Parking Brake Warning Buzzer and Lamp 4.7.1 Function 4.7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure 4.7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF Position 4.8 Harness Codes 4.9 Controller Details 4.9.1 VCM1-M Controller 4.9.2 Seat Switch/Seat Belt Switch 4.9.3 Parking Brake Switch 4.9.4 Direction Lever 4.9.5 Speed Sensor 4.9.6 T/M Solenoid 4.9.7 Unload Solenoid 4.9.8 Lift Lock Solenoid 4.9.9 Warning Buzzer 4.9.10 Warning Buzzer Relay 4.9.11 Warning Buzzer Circuit 4.9.12 Instrument Panel 4.10 Error Codes and Troubleshootings 4.10.1 Error Code Display 4.10.2 Diagnosis Table (F Code) 4.10.3 Error Codes and Troubleshooting 4.11 Locations of Sensors and Switches CHAPTER 5 POWER TRAIN 5.1 Removal and Installation (MC Models) 5.1.1 Removal of Engine and Transmission Assembly 5.1.2 Removal of Engine and Transmission Assembly (for Gasoline-Engine Lift Trucks) 5.2 Removal and Installation (FC Models) 5.2.1 Removal of Engine and Transmission Assembly CHAPTER 6 POWERSHIFT TRANSMISSION 6.1 Structure and Functions 6.1.1 Transmission 6.1.2 Torque Converter 6.1.3 Control Valve 6.1.4 Hydraulic System Schematic of Powershift Transmission 6.2 Removal and Installation 6.2.1 Removal 6.2.2 Installation 6.3 Control Valve 6.3.1 Disassembly 6.3.2 Reassembly 6.4 Input Shaft Assembly 6.4.1 Disassembly 6.5 Oil Pump Assembly 6.5.1 Disassembly 6.5.2 Reassembly 6.6 Inspection and Adjustment 6.6.1 Oil Pressure Measurement 6.6.2 Clutch (Inching) Pedal Adjustment 6.6.3 Inching Cable, Adjustment 6.7 Troubleshooting 6.8 Tightening Torque 6.9 Service Data CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL 7.1 Structure 7.1.1 Front Axle 7.1.2 Reduction Differential 7.2 Removal and Installation 7.2.1 Front Wheels 7.3 Front Axle 7.3.2 Reduction Differential 7.4 Disassembly and Reassembly 7.4.1 Front Axle 7.4.2 Reduction Differential 7.5 Troubleshooting 7.6 Service Data CHAPTER 8 REAR AXLE 8.1 Structure and Functions 8.1.1 Rear Axle in General 8.1.2 Structure of Each Component 8.1.3 Steering Cylinder 8.2 Removal and Installation 8.2.1 Rear Wheel and Rear Axle Assembly 8.3 Disassembly and Reassembly 8.3.1 Wheel Hub, Disassembly and Reassembly 8.3.2 Knuckle (King Pin), Disassembly and Reassembly 8.3.3 Steering Cylinder, Disassembly and Reassembly 8.3.4 Tie Rod, Disassembly and Reassembly CHAPTER 9 BRAKE SYSTEM 9.1 Structure 9.1.1 Brake System 9.2 Disassembly and Reassembly 9.2.1 Master Cylinder 9.2.2 Wheel Brakes 9.2.3 Wheel Cylinder 9.3 Inspection and Adjustment 9.3.1 Automatic Adjuster Test 9.3.2 Manual Adjustment 9.3.3 Parking Brake Cable Adjustment 9.3.4 Brake Pedal Adjustment 9.3.5 Brake Lines Bleeding 9.3.6 Braking Performance Test 9.3.7 Parking Brake Lever 9.4 Troubleshooting 9.5 Service Data CHAPTER 10 STEERING SYSTEM 10.1 Structure and Functions 10.1.1 Steering System 10.1.2 Steering Valve 10.1.3 Steering Column 10.2 Disassembly and Reassembly 10.2.2 Steering Wheel and Steering Valve, Removal and Installation 10.2.3 Steering Wheel 10.2.4 Steering Valve 10.2.5 Tilt Lock Lever 10.3 Steering Valve 10.3.1 Disassembly 10.3.2 Reassembly 10.4 Troubleshooting 10.5 Service Data CHAPTER 11 HYDRAULIC SYSTEM 11.1 Structure and Functions 11.1.1 Outline 11.2 Hydraulic Circuit Diagram (For Models With MC Control Valve) 11.3 Hydraulic Circuit Diagram (For Models With FC Control Valve) 11.4 Hydraulic Tank 11.5 Hydraulic Pump (Gear Pump) 11.6 Control Valve 11.7 Flow Regulator Valve (for Models with FC Control Valve Only) 11.8 Down Safety Valve 11.9 Lift Cylinder 11.10 Tilt Cylinder 11.11 Disassembly and Reassembly 11.11.1 Hydraulic Pump 11.11.2 Lift Cylinder 11.11.3 Tilt Cylinder 11.11.4 Flow Regulator Valve 11.11.5 Piping 11.11.6 Suction Strainer and Return Filter 11.12 Inspection and Adjustment 11.12.1 Hydraulic Tank 11.12.2 Control Valve 11.12.3 Descent Test 11.12.4 Forward Tilt Test 11.13 Troubleshooting 11.13.2 Hydraulic System Cleaning After a Component Failure 11.14 Service Data 11.15 MC Control Valve 11.15.1 Structure and Operation 11.15.2 Control Valve, Removal and Installation 11.15.3 Disassembly and Assembly 11.16 FC Control Valve 11.16.1 Structure and Operation 11.16.2 Disassembly and Assembly CHAPTER 12 MAST AND FORKS 12.1 Simplex Mast 12.1.1 Mast System 12.2 Structure and Functions 12.2.1 Simplex Mast (5A15C to 5A33C) 12.2.2 Mast Operation 12.3 Removal and Installation 12.3.1 Mast and Lift Bracket Assembly 12.4 Disassembly and Reassembly 12.4.1 Simplex Mast Disassembly 12.4.2 Simplex Mast Reassembly 12.5 Removal and Installation of Mast Rollers and Strips without Removing 12.5.1 Simplex Mast 12.6 Inspection and Adjustment (Simplex Mast) 12.6.2 Forks 12.6.3 Chain Tension Inspection and Adjustment 12.6.4 Checking Chain Elongation 12.6.5 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12.6.6 Mast Roller Clearance Adjustment 12.6.7 Mast Strip Clearance Inspection and Adjustment 12.6.8 Tilt Angle Adjustment 12.6.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.7 Troubleshooting (Simplex Mast) 12.8 Service Data (Simplex Mast) 12.9 Duplex Mast 12.9.1 Mast System 12.10 Structure and Functions 12.10.1 Duplex (Dual Full-Free Panoramic) Mast (5B15C to 5B33C) 12.10.2 Mast Operation 12.11 Removal and Installation 12.11.1 Mast and Lift Bracket Assembly 12.12 Disassembly and Reassembly 12.12.1 Duplex Mast Disassembly 12.12.2 Duplex Mast Reassembly 12.13 Removal and Installation of Mast Rollers and Strips without Removing 12.13.1 Duplex Mast 12.14 Inspection and Adjustment (Duplex Mast) 12.14.1 Inspection and Adjustment (Duplex Mast) 12.14.2 Forks 12.14.3 Chain Tension Inspection and Adjustment 12.14.4 Checking Chain Elongation 12.14.5 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12.14.6 Mast Roller Clearance Adjustment 12.14.7 Mast Strip Clearance Inspection and Adjustment 12.14.8 Tilt Angle Adjustment 12.14.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.15 Troubleshooting (Duplex Mast) 12.16 Service Data (Duplex Mast) 12.17 Triplex Mast 12.17.1 Mast System 12.18 Structure and Functions 12.18.1 Triplex (Triple Full-Free Panoramic) Mast (5C15C to 5C33C) 12.18.2 Mast Operation 12.19 Removal and Installation 12.19.1 Mast and Lift Bracket Assembly 12.20 Disassembly and Reassembly 12.20.1 Triplex Mast Disassembly 12.20.2 Triplex Mast Reassembly 12.21 Removal and Installation of Mast Rollers and Strips without Removing 12.21.1 Triplex Mast 12.22 Inspection and Adjustment (Triplex Mast) 12.22.2 Forks 12.22.3 Chain Tension Inspection and Adjustment 12.22.4 Checking Chain Elongation 12.22.5 Adjusting Clearance between Lift Bracket Roller and Inner Mast 12.22.6 Mast Roller Clearance Adjustment 12.22.7 Mast Strip Clearance Inspection and Adjustment 12.22.8 Tilt Angle Adjustment 12.22.9 Right and Left Lift Cylinder Stroke Inspection and Adjustment 12.23 Troubleshooting (Triplex Mast) 12.23.1 Troubleshooting (Triplex Mast) 12.24 Service Data (Triplex Mast) 12.24.1 Triplex Mast CHAPTER 13 SERVICE DATA 13.1 Maintenance Schedule 13.2 Maintenance Note 13.2.1 Brake System 13.2.2 Cooling System 13.2.3 Electric System 13.2.4 Engine System 13.2.5 Frame and Chassis 13.2.6 Fuel System 13.2.7 Hydraulic System 13.2.8 Ignition System 13.2.9 Intake System 13.2.10 Front End Section 13.2.11 Steering and Axle System 13.2.12 T/M and Drive System 13.2.13 Wheels and Tires 13.2.14 General 13.3 Tightening Torque for Standard Bolts and Nuts 13.4 Periodic Replacement Parts 13.4.2 Location of Periodic Replacement Parts 13.5 Lubrication Instructions 13.5.1 Lubrication Chart 13.5.2 Fuel and Lubricant Specifications 13.5.3 Adjustment Value and Oil Quantities 13.6 Special Service Tools 13.6.1 Special Service Tools (Standard Tools for Both MC and FC LiftTrucks) 13.6.2 Special Service Tools (for FC Lift Truck Only) 13.6.3 Special Service Tools (for Powershift Transmission) OPERRATION MANUAL CHAPTER 1 SAFETY RULES AND PRACTICES 1.1 SAFETY SIGNS AND SAFETY MESSAGES 1.2 WARNING SYMBOLS AND LEVELS 1.3 OPERATOR QUALIFICATIONS 1.4 SAFETY GUARDS 1.5 PERSONAL PROTECTIVE EQUIPMENT FOR OPERATING LIFT TRUCK 1.6 DAILY INSPECTION 1.7 OPERATOR RESPONSIBILITY 1.8 GENERAL 1.9 NO RIDERS 1.10 TRAVELING 1.11 LOADING 1.12 DOCKBOARDS (BRIDGE PLATES), TRUCKS AND RAILROAD CARS 1.13 SURFACE AND CAPACITY 1.14 FUEL HANDLING 1.15 INSTALLATION OF ATTACHMENTS 1.16 IN CASE OF TIP-OVER 1.17 TRANSPORTING LIFT TRUCK 1.17.2 APPROACH ANGLE, DEPARTURE ANGLE AND GANGWAY 1.17.3 HOISTING (LIFTING) UP THE TRUCK 1.18 FUNCTION TESTS 1.19 TRACTION BAR 1.20 POSITION OF DATA AND CAPACITY PLATES AND DECALS 1.21 DATA AND CAPACITY PLATES AND DECALS 1.21.2 DATA PLATE 1.21.3 IDENTIFICATION NUMBERS 1.21.4 CAUTION DRIVE DECAL (IN CASE OF TIP-OVER DECAL) 1.21.5 WARNING DRIVE DECAL (TRAINED AND AUTHORIZED) 1.21.6 PINCH POINT DECAL 1.21.7 CAUTION FORK DECAL 1.21.8 MAST WARNING DECAL 1.21.9 CAUTION DRIVE DECAL (OPERATION) 1.21.10 RADIATOR WARNING DECAL 1.21.11 COOLING FAN WARNING DECAL 1.21.12 ADJ LPG WARNING DECAL 1.21.13 LPG LATCH WARNING DECAL 1.21.14 LPG FUEL WARNING DECAL CHAPTER 2 OPERATING CONTROLS AND FUNCTIONS 2.1 APPLICATIONS 2.2 APPLICATION FOR CAT LIFT TRUCKS 2.3 PROHIBITED APPLICATIONS FOR CAT LIFT TRUCKS 2.4 MAIN COMPONENTS 2.5 METERS, INDICATORS AND WARNING LIGHTS 2.5.2 LCD 2.5.3 OPERATION BUTTONS 2.5.4 ! MULTIPURPOSE WARNING LIGHT 2.5.5 MALFUNCTION INDICATOR LIGHT-ENGINE CHECK WARNING 2.5.6 OIL PRESSURE WARNING LIGHT 2.5.7 CHARGE WARNING LIGHT 2.5.8 PARKING BRAKE WARNING LIGHT 2.5.9 SEAT BELT WARNING LIGHT 2.5.10 METER DISPLAY 2.5.11 WATER TEMPERATURE GAUGE 2.5.12 FUEL GAUGE 2.5.13 TRANSMISSION POSITION 2.6 MALFUNCTION AND WARNING INDICATIONS 2.6.2 MAST INTERLOCK WARNING 2.6.3 LPG LEVEL WARNING/LPG RACK LOCK WARNING 2.6.4 TORQUE CONVERTER FLUID TEMP WARNING 2.6.5 RADIATOR LEVEL WARNING 2.6.6 AIR CLEANER WARNING 2.6.7 SERVICE REMINDER DISPLAY 2.6.8 DISPLAYS WHEN MALFUNCTION OCCURS 2.7 DRIVER RECOGNITION MODE 2.8 LPG REMAINING TIME MANAGEMENT 2.9 SWITCHES 2.9.2 HORN BUTTON 2.9.3 REAR RIGHT GRIP WITH HORN BUTTON 2.9.4 IGNITION SWITCH 2.9.5 LIGHTING AND TURN SIGNAL SWITCHES 2.9.6 MAXIMUM SPEED CHANGE SWITCH (OPTION) 2.9.7 THROTTLE SENSITIVITY ADJUST SWITCH (OPTION) 2.9.8 BACK-UP OPERATION LIGHT SWITCH (OPTION) 2.10 OPERATING CONTROLS 2.10.2 SELECTOR LEVER 2.10.3 PARKING BRAKE LEVER 2.10.4 INCHING BRAKE PEDAL 2.10.5 BRAKE PEDAL 2.10.6 ACCELERATOR PEDAL 2.10.7 CARGO-HANDLING CONTROL LEVERS 2.10.8 ANSI/ITSDF STANDARDS FOR LIFT TRUCK CLAMP ATTACHMENTS 2.10.9 STEERING CHARACTERISTICS CHAPTER 3 OPERATING THE LIFT TRUCK 3.1 OPERATION 3.2 INSPECTION BEFORE OPERATING 3.3 LIFT TRUCK OPERATING PRECAUTIONS 3.4 PRECAUTIONS FOR COLD AND HOT WEATHER 3.5 OPERATIONAL PROCEDURES 3.6 LPG LIFT TRUCK STARTING 3.7 PROCEDURE FOR JUMP STARTING EFI ENGINES 3.8 AUTOMATIC TRANSMISSION 3.9 LOADING 3.10 TRANSPORTING LOADS 3.11 UNLOADING 3.12 CLIMBING 3.13 STOPPING AND PARKING THE LIFT TRUCK 3.14 FORKS 3.15 SEAT ADJUSTMENT 3.15.1 SUSPENSION SEAT OPERATOR’S WEIGHT ADJUSTMENT 3.15.2 FORWARD AND BACKWARD CONTROL LEVER 3.15.3 BACKREST INCLINATION ADJUSTMENT 3.15.4 LUMBAR ADJUSTMENT 3.15.5 SWIVEL SEAT 3.16 SEAT BELT 3.17 TOP PANEL 3.18 TILT STEERING WHEEL 3.19 SERVICE RELEASE LATCH 3.20 RADIATOR COVER 3.21 REARVIEW MIRROR (OPTION) 3.22 LPG CYLINDER (TANK) HOLDER CHAPTER 4 GENERAL CARE AND MAINTENANCE 4.1 WET CELL BATTERY CARE AND MAINTENANCE 4.2 BATTERY SPECIFIC GRAVITY 4.3 DAILY INSPECTION 4.4 OPERATOR’S DAILY CHECKLIST (SAMPLE) 4.5 MAINTENANCE AND INSPECTION 4.5.1 ENGINE OIL LEVEL 4.5.2 REFILLING ENGINE OIL 4.5.3 ENGINE COOLANT LEVEL 4.5.4 REFILLING ENGINE COOLANT 4.5.5 COOLING SYSTEM BLEEDING INSTRUCTIONS 4.5.6 BRAKE FLUID LEVEL 4.5.7 REFILLING BRAKE FLUID 4.5.8 AUTOMATIC TRANSMISSION FLUID LEVEL 4.5.9 REFILLING AUTOMATIC TRANSMISSION FLUID 4.5.10 HYDRAULIC OIL LEVEL 4.5.11 REFILLING HYDRAULIC OIL 4.5.12 STEERING WHEEL PLAY 4.5.13 WHEEL AND TIRE 4.5.14 TIRE REPLACEMENT 4.5.15 CHECKING MAST 4.5.16 CHECKING LIFT CHAIN 4.5.17 FORK INSPECTION 4.5.18 FORK REPAIR 4.5.19 CHECKING HORN 4.5.20 CHECKING LIGHTS 4.5.21 CHECKING CARGO-HANDLING CONTROL LEVER(S) 4.5.22 CHECKING BRAKE PEDAL 4.5.23 PEDAL FREE PLAY 4.5.24 CHECKING PARKING BRAKE LEVER 4.5.25 CHECKING TOP PANEL LOCK 4.5.26 FUSES 4.5.27 CHECKING AIR CLEANER 4.5.28 CHECKING FAN BELT 4.5.29 DRAINING OF TAR FROM THE VAPORIZER 4.5.30 PRECAUTIONS FOR USING LPG 4.5.31 RECOMMENDED LPG FUEL TYPE 4.5.32 CYLINDER (TANK) SIZE 4.5.33 LPG CYLINDER (TANK) REPLACEMENT 4.5.34 REFILLING LPG CYLINDERS (TANKS) 4.5.35 PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE 4.5.36 PERIODIC MAINTENANCE AND LUBRICATION SCHEDULE FOR EMISSION CONTROL SYSTEM 4.5.37 LUBRICATION CHART 4.5.38 RECOMMENDED LUBRICANTS 4.5.39 RECOMMENDED SAE VISCOSITY CHART 4.5.40 PUTTING LIFT TRUCK IN STORAGE 4.6 SIDE SHIFT 4.6.1 OVERVIEW OF SIDE SHIFT 4.6.2 MAIN TERMS USED IN THIS SECTION 4.6.3 SAFETY RULES AND PRACTICES 4.6.4 SIDE SHIFT CONTROL LEVER OPERATION 4.6.5 SIDE SHIFT OPERATION 4.6.6 DAILY CHECKS AND SIMPLE MAINTENANCE CHAPTER 5 SPECIFICATIONS 5.1 MODEL IDENTIFICATION 5.1.1 MODEL VARIATION (LONG MODEL CODE) BREAKDOWN 5.2 MAIN TRUCK 5.2.1 MAIN TRUCK – 2C7000 AND 2C8000/2C8000-SWB 5.3 MAST 5.3.1 2C7000 AND 2C8000/2C8000-SWB 5.4 FUEL AND OIL CAPACITY 5.5 ENGINE 5.6 ENGINE OIL CAPACITY 5.7 NOISE LEVEL

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