Professional Documents
Culture Documents
APILADOR ELECTRICO Mechanical Maintenance
APILADOR ELECTRICO Mechanical Maintenance
APILADOR ELECTRICO Mechanical Maintenance
5 Mechanical maintenance
CAUTION
Lift or jack up the truck and support it with safety blocks or rigid stands.
Apply wheel chocks to the load wheels to prevent the truck from moving.
Figure 17 below indicates the correct jack points for lifting the truck up for maintenance.
Figure 18 below indicates the correct hoist points for hoisting the truck up for
maintenance. Make sure that the capacity of the lifting device is sufficient.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 31 (206)
NPP Service Manual
5.2 Transportation
When transporting the truck, it is important that you secure it safely to prevent it from
moving. Also support the traction wheel with blocks.
CAUTION
Do not tie the truck from the tiller arm or it may break.
Figure 19 below shows an example on how to secure the truck safely for transportation.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 32 (206)
NPP Service Manual
When ordering spare parts, always contact your maintenance centre. Only use original
spare parts. To ensure that you receive the correct parts, include the following
information in your order:
• Truck type
• Serial number of the truck
• Order number of the part
• Name of the part
• Number of parts ordered
CAUTION
Before opening the truck’s covers, turn the key switch to the OFF position and
disconnect the battery plug/connector.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 33 (206)
NPP Service Manual
WARNING
Never drive the truck without the electrical panel cover in place.
2. Lift the front cover off the attachment points at the base of the front cover.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 34 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 35 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 36 (206)
NPP Service Manual
NOTE: When closing the battery cover, make sure that the locking button returns all
the way to the locking position.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 37 (206)
NPP Service Manual
Remove the battery cover’s rubber absorbers by simply screwing them out.
There is no need to change the transmission gear lubricant during the truck's lifetime.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 38 (206)
NPP Service Manual
CAUTION
There is no need to change the bogie bearing lubricant during the truck's lifetime.
• The bearing rotates easily when the traction wheel is raised up.
• The drive unit’s mounting bolts are tightened properly.
CAUTION
Before installing the traction wheel, make sure that the wheel shaft, the face of the rim
mounting, the wheel nuts and wheel bolts are clean, free from grease and undamaged.
NOTE: To access the traction wheel, lift the truck up (see the correct lifting points in
section 5.1) and turn the transmission gear so that there is enough space for you to
access and remove the wheel.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 39 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 40 (206)
NPP Service Manual
If the wheel shaft bolts of the traction wheel are defective, you need to replace them.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 41 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 42 (206)
NPP Service Manual
NOTE: To access the load wheels, lift up the forks and the truck so that the load
wheels are off the floor (see the correct lifting points in section 5.1) and turn the load
wheel so that you can access the bolt holding the wheel in place.
Before you remove the forks or the load wheels, support the frame and forks of the
truck against the floor.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 43 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 44 (206)
NPP Service Manual
The lift cylinder handles the lifting of the fork carriage, while the push rod mechanism
assists in raising the fork tips. For stable lifting, it is important that there is not too much
play in the linkage mechanism. Below you can find the instructions regarding the
disassembly of the linkage mechanism. Assemble the linkage mechanism by repeating
the steps in reversed order.
NOTE: Before you remove the forks or the load wheels, support the frame and forks
of the truck against the floor.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 45 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 46 (206)
NPP Service Manual
NOTE: To access the castor wheels, lift the truck up (see the correct lifting points in
section 5.1).
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 47 (206)
NPP Service Manual
The castor wheel suspension mechanism makes the truck more stable. Check the
condition of the suspension rubbers at every maintenance. Also the wear of the castor
wheels and the traction wheel have a considerable effect on the truck’s driving
capability.
NOTE: To access the castor wheel suspension mechanism, lift the truck up (see the
correct lifting points in section 5.1).
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 48 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 49 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 50 (206)
NPP Service Manual
During the installation of the tiller arm, tighten the bolts of the tiller attachment crown
first by hand to make sure they fit the threads correctly. After that, cross-tighten the
bolts with a power tool, making sure that the crown is aligned correctly.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 51 (206)
NPP Service Manual
1. Remove the tiller arm and the tiller attachment crown. For instructions, see
section 5.12.
2. Remove the tiller head. For instructions, see section 8.1.1.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 52 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 53 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 54 (206)
NPP Service Manual
0.
To assemble the tiller arm joint, repeat the steps in reversed order.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 55 (206)
NPP Service Manual
0.
1. Open the battery cover. For instructions, see section 5.4.3.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 56 (206)
NPP Service Manual
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 57 (206)
NPP Service Manual
Inspect and lubricate the chains after each 300 hours of operation (or more frequently in
severe or extreme environments). During the inspection, check the chains for the
following:
Elongation
Measure the chains from the section that moves over the chain wheel as that part of the
chain flexes the most.
When a chain with the original length of 330.2 mm has elongated to the length of
336.8 mm, replace the chain.
Edge wear
Check the chains for link plate edge wear by running your finger back and forth over the
chain edge. See Figure 37 below.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 58 (206)
NPP Service Manual
A highly loaded chain operated with inadequate lubrication can generate abnormal
friction between the pins and the link plates. In extreme cases, the torque can surpass
the press fit force between the pins and the outside plates, resulting in pin rotation.
When a chain is operated in such a condition, a pin or a series of pins can begin to twist
out of the chain, resulting in failure. See Figure 38 below.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 59 (206)
NPP Service Manual
Check the chain pin heads to make sure that all the flats are still correctly aligned.
Replace chains with rotated or displaced heads or abnormal protrusion immediately. Do
not attempt to repair the chain by welding or driving the pin(s) back into the chain. Any
wear patterns on the pin heads or the sides of the link plates indicate misalignment.
Such wearing damages the chain and increases frictional loading and should always be
corrected.
Inspect all the chains periodically for any cracked plates, see Figure 39 below.
Check the chains very carefully from all sides. If there is a cracked plate in a chain, the
whole chain must be replaced. However, before you replace the chain, determine the
cause of the crack to prevent the condition from repeating itself.
Fatigue cracking
Fatigue cracks are a result of repeated cyclic loading exceeding the chain’s endurance
limit.
Fatigue cracks nearly always start at the link plate pin hole (the point of the highest
stress) and are perpendicular to the chain pitch line. In their early stages, fatigue cracks
are microscopic. Unlike with stretching, there is no noticeable yielding or stretching of
the material.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 60 (206)
NPP Service Manual
Stress-corrosion cracking
The chain’s outside link plates, which are heavily press fitted to the pins, are particularly
susceptible to stress-corrosion cracking. Like other cracks, stress-corrosion cracks also
initiate at the highest stress point (pin hole), but tend to extend in an arch-like pattern
between the holes of the plate. A link plate often has more than one crack.
Never attempt to electroplate a leaf chain or its components. The plating process
releases hydrogen, causing hydrogen embrittlement cracks, which look similar to stress-
corrosion cracks.
If a plated chain is required, contact the manufacturer. Plated chains are assembled
from modified, individually plated components, which may reduce the chain’s rating.
Corrosion fatigue
Appearance-wise, corrosion fatigue cracks are very similar (and in many cases
identical) to normal fatigue cracks. They normally start at the pin hole and move
perpendicularly to the chain pitch line.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 61 (206)
NPP Service Manual
This type of failure is caused by overloads that far exceed the maximum load of the
pallet.
Tight joints
All the joints in a leaf chain should flex freely. Tight joints resist flexing and increase
internal friction, thus increasing the chain tension required to fit a given load. Increased
tension accelerates wearing and causes more fatigue problems.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 62 (206)
NPP Service Manual
The tension of the chains should be checked every week. The chain pair should have
equal tension to ensure proper load distribution.
To determine if chain pair has equal tension, hoist the unloaded lifting carriage to place
the chains under tension. Then press the center of the chains in the chain pair. Both the
chains should have equal give. If the chains do not give in equally, adjust the chains as
instructed in 5.14.2.2
Adjust the tension of the chains by tightening or loosening the nuts of the chain anchors.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 63 (206)
NPP Service Manual
0.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 64 (206)
NPP Service Manual
1. Remove the ergo lifting carriage from the truck frame. For instructions, see
section 5.14.1.
Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 65 (206)