Terex Reachstacker T45 T45X T45S Maintenance Manual - PDF DOWNLOAD

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Translation of original instructions

Maintenance Manual Reachstacker T45 T45X T45S

Terex Operation Italy Srl Via Cisa Ligure 51/a 42041 Lentigione di Brescello (RE) - Italy Tel. +39.0522.967444 - Fax +39.0522.680426 www.terexportsolutions.com - info.portequipment@terex.com CoverT45MN_EN











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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN

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Mastro MN

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SUMMARY

S

Introduction 6 SECTION 1 - GENERAL INFORMATION Ground personnel General warnings related to maintenance Control logbook

7 7 8 9

Generic control logbook example How to fill out the control logbook

10 11

Interpretation of manual symbols System maintenance

13 14

Screw tightness torque table Conversion table

21 22

SECTION 2 - ROUTINE MAINTENANCE Indications for consultation

25 26

Introduction 14 Preventive maintenance 14 Inspection 14 Restore 14 Maintenance programming 14 Hydraulic oil systems 14 Inspections 15 Maintenance 16 Restore 18 Eliminating malfunctions 18 Restoring hydraulic components 19 Electrical systems 19 Inspections 19 Maintenance and restore 20

Inches - Millimetres 22 Volume 23 Pressure 23 Speed 23 Temperature 23 Length 23 Power 23 Strength 23

Control list for maintenance TABLE OF CONTROLS

26 27

Lubrication 29 LUBRICATION TABLE

29

Routine maintenance procedure

30

Representation of vehicle bonnets Panel for checking and topping up "Engine- Transmission" oil Main right compartment Secondary left compartment Expansion tray for diesel engine coolant Engine oil level check Engine coolant level check Transmission oil level check Checking oil level for cooling oil bath brakes TMNI0002.E.R0







31 31 32 32 33 34 35 35 36





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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Topping up oil for cooling oil bath brakes

36 37 37 38 39 40 41 42 42 42 42 42 42 43 44 45 46 47 49 49 50

S Hydraulic oil level check

Position of hydraulic oil level indicators Diesel engine oil top up (Cummings) Diesel engine oil top up (Volvo) Radiator cooling fluid top up Filling the diesel oil tank (800 litre capacity) Position of the cap and fuel level indicators Refilling the AdBlue tank (only with Volvo TAD1360VE engine) The tank is positioned in the AdBlue/DEF tank compartment (see section 4 of the operator manual).

The on board computer display signals the quantity of AdBlue present in the tank to the operator.

Topping up washer fluid Washer fluid tank cap Checking junction tightness Inflating tyres Movement sliders adjustment Pressure control points Pressure adjustment and measurement points located in the main right compartment Pressure measurement points located in the secondary right compartment Pressure measurement and adjustment points located in the "Pump-Transmission" compartment Pressure adjustment and measurement points located in the cabin rear The points are located in the lower part of the cabin rear. Cabin translation movements refer to the hydraulic circuit. 50 Oil level check and top up for the differential axle and wheel hubs 51

Cleaning 52 CLEANING TABLE Cleaning the fuel tank Cleaning the oil cooling circuit

52 53 53

Programmed replacement

54

SECTION 3 - EXTRAORDINARY MAINTENANCE

68

SECTION 4 - TROUBLESHOOTING

69

PROGRAMMED REPLACEMENT TABLE Diesel oil tank filter replacement Coolant replacement Transmission oil filter replacement Transmission oil replacement Replacement of fixed boom movement sliders Replacement of movable boom movement sliders Hydraulic oil tank replacement Hydraulic oil tank filter replacement Position and representation of hydraulic oil tank filters Air filter replacement Hydraulic pump oil tank filter replacement Replacing the oil in the differential axle and wheel hubs Filling table for Reachstacker T45 FILLING TABLE FOR REACHSTACKER T45 (with temperatures up to -35°C)

54 55 55 56 57 58 59 60 61 62 63 63 64 66 67

Diesel Engine 70 Maximum pressure valve 75 Check valve 75 Direction adjustment valves 76 Pressure adjustment valve 76 Filters 77 4











TMNI0002.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Pressure gauges 77 Gearbox and torque converter 77 Steering 79 Overload control system 79 Braking system 80

SECTION 5 - TRANSPORT AND ASSEMBLY

81

SECTION 6 - INTERPRETATION OF SYMBOLS ATTACHMENTS Simboli idraulici Simboli elettrici

82 82 97

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN i INTRODUCTION The following document supplies information on inspections, maintenance, repairs and adjustments necessary for proper operation of your vehicle.

This manual includes electrical and hydraulic diagrams as a quick reference to be used when searching for a malfunction. Your vehicle may not have all options illustrated in these diagrams.

The contents of this manual are based on information and specifications available at the time it was approved for print. As part of our product we have a program of continuous updates to improve products and services. We reserve the right to change the product and information without advance notice and without being required to update.

This manual is property of Terex Operation Italy Srl and cannot be reproduced, in its entirety nor partially, nor disclosed to third parties without written authorisation on the part of Terex Operation Italy Srl.

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TMNI0003.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SECTION 1 - GENERAL INFORMATION

1

GROUND PERSONNEL Maintenance personnel must read and observe not only the instructions contained in this chapter, but also all that is written in the remaining parts of the manual.

Job title Description Mechanical maintenance Operator in charge of the machine's mechanical maintenance. personnel Electrical maintenance Operator in charge of maintenance of the machine's personnel electrical system.

Specialized operator, an employee of the Manufacturer or of the authorised after-sales service centre, is instructed and authorised to perform extraordinary maintenance or repairs TEREX technician that require particular knowledge of the machine, its operation, the safety devices and their mode of intervention.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN GENERAL WARNINGS RELATED TO MAINTENANCE

1

This paragraph contains general warnings, to always be considered during a truck maintenance or repair intervention.

• • • • • • • • • • • • • •

8

Display signs indicating “Maintenance works in progress”.

Do not allow unauthorised personnel on the truck.

Use appropriate equipment and tools.

Do not weld pipes or channels containing hydraulic oil or flammable substances.

Never pour flammable fluids in open, ample and short containers.

Do not pile up rags soaked in oil or grease, because the represent a fire hazard; instead, place them in a closed metal container.

Do not keep flammable material on the truck or in its immediate vicinity.

Keep an extinguisher close by when doing works that may cause a flame.

Immediately clean platforms, landings, ladders, or handrails that a dirty with oil or grease.

Do not loosen pipes or connections before being certain these is no pressure.

Before carrying out repairs to the main structures of the truck, check the materials being used and obtain authorisation from the manufacturer.

Do not make any changes to the structure but limit to restoring the previous state. If in doubt or in case of need, contact the manufacturer.

Calibration values of the hydraulic system safety valves cannot be changed, comply with the values supplied by the manufacturer.

For interventions with compressed air, use suitable protections for eyes, also use air with a maximum pressure of 2 kg/cm2.











TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN CONTROL LOGBOOK Each maintenance must be written down on a special log book.

For this purpose, we supply a “Control log book” model where the main items to be filled out in case of intervention on the vehicle.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN

Generic control logbook example

Date

Hour counter Daily

7

11

Rear rim replaced

Rear rim replaced

Replacement of a chain tooth

Chain and twistlock replacement

12

Executor

13

Control

Signature

.............................................

Various

Tyres OK Rims NO

Notes

Model

9

Forks OK Twistlock OK

Tyres OK Rims OK

Tyres OK Rims NO

Forks OK Twistlock NO

Forks OK Twistlock OK

Forks OK

Annual

Safety controls

.............................................

10

Serial No.

8

Quarterly

Chains OK

Chains OK

Chains OK

Replacement of 20' proximity switches Twistlocks verification

Chains NO

Chains NO

Replace the gasket kit and lifting cylinders

Turbo compressor revision Injector revision Replaced by a lifting pump

Replacement of 40' proximity switches

Steering cylinder pipe replacement

Repairs and/or revisions

Operations description

6

/

/

D

Extraordinary

Maintenance Ordinary

Machine hours

4

End

3

Start

2 A

5

1 / OK

A

/

A

C

1268 1281 OK

/

/

/

1293

6980

4950

3015

1761

/

16-01-02 /

16-02-02

16-04-02

15-04-03

1503

15-01-02 17-01-02 18-01-12

15-02-02

15-04-02

15-04-03

24-04-04

09-06-05

TMN10001.E.R0











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21-01-04

05-06-05

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN HOW TO FILL OUT THE CONTROL LOGBOOK No. 1 = DATE WORKS BEGIN => 20.09.01 No. 2 = DATE WORKS END => 20.09.01 No. 3 = WORK HOURS => 2352 No. 4 = DAILY CHECK BEFORE BEGINNING SERVICE => OK NO. 5 / 6 = WE HAVE ROUTINE MAINTENANCE OPERATIONS: 250h = A 500h = B 1500h = C

1

AND EXTRAORDINARY MAINTENANCE 3000h = D 6000h = E 12000h = F FOR THIS REASON IT IS POSSIBLE TO WRITE IN BOX No. 5 A = x 250h B = x 500h C = x 1500h Example: 1000h = A 1250h = B 1500h = C 1750h = A 2000h = B and so on FOR THIS REASON IT IS POSSIBLE TO WRITE IN BOX No. 6 D = x 3000h E = x 6000h F = x 12000h Example: 2750 h = A 3000 h = D 3250 h = A 3500 h = B ....

6000 h = E 6250 h = A ....

9000 h = E ....

12000 h = F TMN10001.E.R0











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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN No. 7 REPAIRS / REVISIONS Brief description of repair and/or revision works

1 N° 8 SAFETY CONTROLS

In this case it is sufficient to write down the type of part being checked and write down the result in the corresponding column: No. 9 FORKS (annual/1500h) No. 8 CHAINS (quarterly) No. 9 TWISTLOCKS (annual/3000h) No. 10 TYRES/ VARIOUS RIMS (when replaced)

No. 11 NOTES Highlight any consequences on control: Example: Rim replacement No. 12 SIGNATURE OF THE EXECUTOR OR SUPERVISOR OF THE WORK No. 13 SIGNATURE OF THE CONTROL SUPERVISOR P.S. IF THE SPACE RESERVED TO THE DESCRIPTION OF OPERATIONS IS NOT CONSIDERED SUFFICIENT, IT IS POSSIBLE TO CREATE A SECONDARY BOOKLET ONLY USED FOR SAFETY VERIFICATIONS.

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TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN INTERPRETATION OF MANUAL SYMBOLS Symbol

Description

1

General warning signal

Electrical risk warning signal

Suspended loads warning signal

Slippery surface warning signal

Corrosive substance warning signal

Explosive material warning signal

Flammable material warning signal

Warning signal: obstacle on the floor.

Hot surface warning signal

Crushing warning signal

Naked flames prohibition signal.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SYSTEM MAINTENANCE

1

Introduction This paragraph contains certain basic system maintenance concepts. It is recommended to read and understand what is described here below, before consulting individual chapters of the manual.

According to standard DIN 31051 the "maintenance" concept includes the following fields of activity: Preventive maintenance Preventive maintenance includes steps suitable to maintain the desired condition, that is to reduce the so called wear reserve throughout its useful life to a minimum.

Inspection Inspection includes steps destined to recognise the actual condition, identifying the reasons and ways to decrease the wear reserve.

Restore The restore includes steps destined to obtain the desired condition, that is to compensate for a performance reduction and restore the wear reserve.

Maintenance programming Maintenance measures must be programmed and executed according to the importance of functions carried out by the system, the required operational rhythm (that may be from an intermittent service to continual use for multiple shifts), the extent of consequences of a possible malfunction (from the single system destined to secondary tasks up to a system inserted in a process line, where the malfunction of an individual component may cause the entire line to stop) and finally, the desired degree of reliability. In the first hours of operation, the vehicle it is particularly important to program a complete control of all machine parts. These controls will later be carried out according to the schedule foreseen in the maintenance table.

Hydraulic oil systems In hydraulic oil system, a reduction of the wear reserve may show itself in the following manners: • an increase in play between slider and related housing • dynamic seal wear • erosion of command edges • wear on bearing materials • increase in play between bushings and shafts • damage to pump and valve cavitation • chemical alterations of the fluid.

All of these wear phenomenon cause a slow consumption of reserves considered during the design phase, up to the point that one falls below the programmed values (point that does not necessarily coincide with system malfunction), or up to a sudden breakdown of individual components.

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TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Inspections Here below is a more detailed description of a few inspection items present on the manual.

Heat exchangers (air-oil): In the very dusty areas heat exchange worsens rapidly as a result of dust deposits on the exchanger surface. If the cooling air also contains oil mist due to external leaks, the thermal exchange may actually be interrupted.

Oil operating temperature: An increase in oil temperature may have the following causes: poor heat exchanger efficiency (dirty surface, malfunctioning fan). An increase in heat development in the pumps and hydraulic motors due to damage to bearings. Reduced hear dispersion from the tank, the piping system and components due to polluting deposits. An increase in internal leaks for individual components. Intervention of limiter valves at pressure values that are too low, system operation outside allowed conditions, etc.

Pressure verification: Verify opening pressure of pressure limiting valves for the primary and secondary adjustment circuits, check gas pressure in accumulators, verify calibration pressure of reducing, sequence and discharge valves.

Verify noise levels: This verification only makes sense if it allows establishing noise variations compared to the state of the new system. When the pressure limiter valves open, they normally emit a hiss. If a crackle or a whistle is hear.d instead, this indicates that there is a damage Even cylinders my emit crackles or squeaking during exit and re-entry movements.

This may indicate that there is wear on guides or impediments of various nature, such as junctions blocked by oxidation, non suitable fluid, etc... An increase in pump or hydraulic motor noise as pressure increases may indicated there is damage from erosion or CAVITATION on distribution plates, a play increase in volumetric elements or an incipient damage to roll bearings. An unpleasant intense noise from the pumps, independent form the pressure load, yet growing more than proportionally with an increase in rotation speed, indicates a deficiency in feed pressure or an excessive depression in the suction pipe.

Checking leak capacity: For hydraulic motors and certain pumps, it is possible to recall the wear of the leak capacity. This is also true for a series of command, adjustment an intercept valves. The slow movement of a loaded cylinder with the distributor closed makes it possible to conclude that piston gaskets are defective or worn.

Bearing temperature control. When the first pittings form on the antifriction bearings, it is possible that there is a temperature increase in the installation area of the bearing caused by significant energy dissipation. The condition necessary to be able to come to a conclusion is to compare the temperature after the first system start up, that is under normal conditions and at that point measure it and write it down as a reference temperature with preset work cycles.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN 1

Checking rigid and flexible piping: It is necessary to verify the seal of piping and connections and junctions and make sure that the pipes are firmly anchored to the brackets. Loosened pipes may rub against each other or the structures and related connections maybe exposed to unacceptable mechanical stress. The crushed or curved areas increase flow resistance causing loss of power and additional fluid heating. On flexible piping it is necessary to check if there is any rubbing and areas with bulging. During the first hours of the machine's operation, it is necessary to check and tighten all piping connections.

Maintenance Here below is a more detailed description of a few maintenance and restore items present on the manual.

Oil Top up: In general when adding oil one must use the same one present in the system.

If oils of the same kind from different manufacturers are mixed, in case of damage it will not be possible to invoke any warranty. Often additives are offered with hydraulic fluid to reduce mechanical friction, to eliminate the so called “stick - slip” effect and extend fluid life. Before placing these additives in the system one must request supplier approver to be certain of its compatibility. Often fluid producers decline any liability if an additive from any other producer is added to fluid they supply. The manufacturers of hydraulic components often act in the same manner since it is extremely difficult to determine the actual long term effect of these additives, also considering dosage variation and the stress the fluid is exposed to in individual applications.

Oil replacement: Every time the fluid is replaced one must also clean the tank. Both when topping up and for complete replacement it is necessary to consider that the new fluid as supplied is not normally suitable to be directly poured into the hydraulic system because of the many polluting substances it contains. The purification degree of the new fluid cannot be guaranteed due to the very long transportation train that goes from production to use (storage tank, oil tankers, tank trucks and various containers). For this reason new fluid is to be poured into the system, both for top up and complete replacement, exclusively using a filter whose quality must at least correspond to filters used in the plant is far as the dimension of holes. It is even better to use a filling filter with even smaller holes. This aspect of the instruction is very important because otherwise it is possible to run into operational anomalies immediately after replacing the fluid.

Filter cleaning: In general the cartridges must be cleaned or changed each time the fluid is replaced. Of all the filtering cloths used today, basically none can be cleaned without incurring a significant expense and therefore clogged cartridges must simply be replaced.

Since it is not possible to detect clogging in multi-layer cartridges, the degree of clogging of a cartridge can only be evaluated based on the pressure difference between upstream and downstream. Only filters that indicate visually or electrically through a clogging indicator when limit clogging has been reached should be used. When using filters without indicators it is necessary to replace the cartridges at sufficiently short intervals to be sure that bypass valve opening or destruction of clogged cartridges is avoided.

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TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Elimination of leaks from pipes: Restoring the seal of the piping system can only be carried out after resetting system pressure. Leaks in areas equipped with soft gaskets (O-rings, seal rings, etc...) cannot be eliminated by tightening since gaskets that leak are broken or hardened and the seal can only be restored through replacement.

System cleaning: At set time intervals hydraulic systems should be cleaned externally to locate any areas that leak, in order to avoid that polluting substances enter the system along with a top up, to avoid penetration of polluting substances when replacing the cartridges and to protect cylinder rods from scratching, to avoid reducing or interrupting the heat exchange between the system and the environment. During cleaning operations one must avoid introducing cleaning liquids into the hydraulic system. When using high pressure steam cleaning systems it is necessary to make sure that the cover of the tank, pipe passage ways, shaft gaskets, systems and electrical devices, etc..., are capable of resisting this cleaning system that is a very effective.

Replacement of warn parts: For most components it is not possible to foresee how they will malfunction. With regard to this, the usage condition is very important (dynamic pressure stress, fluid type and speed, thermal effects, environment influence etc...). With known usage conditions it is only possible to approximately calculate average bearing duration and dynamic seals. It maybe best to preventively replace bearings cylinder dynamic shaft gaskets, flexible piping if a malfunction of this components may cause serious damage (for example if a broken bearing may destroy an entire unit, if the uncontrolled descent of a cylinder may cause collisions with other part of the machine if a broken flexible pipe may generate environmental pollution or expose operator to dangerous situations). As for parts subject to wear, besides those already mentioned, it is also possible to list: All elastomer or polyurethane static and dynamic seal elements (soft gaskets), pieces of pressure limiting valves (especially for the main circuits), reducing valves, sequence valves and discharge valves. Filter cartridges (if the clogging limit is not checked continuously). Elastic parts of the coupling joint. Flexible high pressure piping.

Replacement of flexible piping: Correctly laying flexible piping increases its duration; for information about this see standard DIN 20066, part 4, installation of flexible piping. Avoid installing and leaving the flexible piping bent. Besides, the flexible piping is to be installed so it is not subject to traction except for that from its own weight. Do not go below the minimum curving radius allowed. If the flexible piping traces a curve, flexible piping length must be such that it respects linear segments. Select a terminal shape which avoids additional stress to the flexible piping. In order to protect flexible piping from undesired external actions, the structure and the areas of the system or the vehicle they come in contact with must be properly covered.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN 1

Restore The condition necessary for restoring a system is a systematic search for malfunction which leads to success. This requires access to all necessary documentation. Near the system there must be functional diagrams and spear parts list of the machine always available for consultation. The most important measurement instruments must also be available so that malfunction search can be carried out as quick as possible.

Eliminating malfunctions The broken components must not be replaced on the spot to repair accurately, because the necessary tools are not usually available in the installation area and besides, one cannot ensure that the area is as clean as necessary. On the spot replacement must therefore only interest complete components: • to only expose the system to environmental influence for the time that is strictly necessary • reduce fluid loss as mush as possible • to be certain, thanks to the installation of new or properly serviced and checked components, to reduce system stops as much as possible.

After locating the defective components it is very important to check if the malfunction has contaminated the entire system or a part of it due to detached fragments or a significant quantity of metal abrasion particles. If such contamination has occurred,(this can be ascertained by checking the filtering cartridges and the tank) the system in any case must be cleaned before becoming operational again (for example by flushing), the filter cartridges must be replaced and in certain circumstances and with some types of systems (small ones) it may be convenient to replace the fluid completely For large systems, the fluid should be cleaned and placed again in the preventively cleaned tank using a super fine filter or a centrifuge.

Only in this manner it is possible to prevent additional system failure or malfunction to other components as a consequence to the initial malfunction. In particular to increase safety in systems that must carry out delicate high precision control or adjustment functions it is best to equip the filters with cartridges that have a higher filtering strength compared to the design ones and keep filters in operation until they have reached the clogging limit for a limited amount of time. This procedure, with the currently available filters, can almost always be carried out. After restarting the restored system must be kept under observation for a certain amount of time in order to ensure that the repairs have effectively eliminated all problems. When it is not possible to completely remove air from a part of the system, sometimes it is possible to notice irregular operation (for example the cylinders have a pendulum movement or exceed pre-established positions, pumps develop discontinuous noise, etc...).

If the air from the systems must be removed spontaneously, these phenomenon may last many hours.

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TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Restoring hydraulic components When repairing components it is fundamental to decide which ones can be serviced by the system used and which ones can be sent back to the manufacturer. To repair hydraulic components it is necessary have a properly equipped workshop, with a higher than average level of cleanness. This result can only be obtained in a cost effective manner if the company has a great number of hydraulic powered systems. The additional necessary condition is to have personnel that is properly trained and equipped with the necessary tools and documentation.

Both conditions, however, are not economical and not effective unless one also has a properly assorted spare parts warehouse.

Basically, repairing hydraulic components that cannot be checked perfectly should be entrusted to the manufacturer, in order to be certain that subsequently the components in the warehouse a perfectly operational.

Electrical systems In electrical system, a reduction of the wear reserve may show itself in the following manners: • oxidation of electrical contacts • contact brush wear • over-voltage • short-circuits • reel and electrical winding overheating All of these wear phenomenon cause a slow consumption of reserves considered during the design phase, up to the point that one falls below the programmed values (point that does not necessarily coincide with system malfunction), or up to a sudden breakdown of individual components.

Inspections Here below is a more detailed description of a few inspection items present on the manual.

Fastening verification: The fastening of electrical equipment is a condition necessary for correct system operation. Verify that there is no equipment partially or totally detached from the related supports, loose screws, missing or defective fastening devices Verify contact wear: Verify oxidation of electrical contacts, an alarm signal may be symptom of a missing contact in the electrical circuit. For interventions of this type specific preparation in this field is necessary.

Verify contact brush wear: In certain cases, when needing to bring an electrical command to parts of the moving vehicle, contact brushes are used. Verify that the brushes are not in an advanced wear state or burnt, if that is they case, they must be replaced. Also check the contact surface of the brushes.

Verify equipment conditions: A visual check on equipment may detect breakdown or one about to happen. Blackened equipment may be symptom of component overheating due to system or equipment malfunction.

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Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN 1

Maintenance and restore Usually electrical equipment does not require special maintenance. Necessary interventions are almost always restoring initial operating conditions. For this reason personnel in charge of electrical system maintenance must have electrical technical knowledge and suitable training. Replacing broken equipment may not be sufficient if what caused the breakdown is upstream or downstream from the replaced component. In these cases it is necessary to contact the manufacturer before working on the system. Before proceeding, disconnect cables to replace a component, it is necessary to verify their marking, otherwise mark the cables before disconnecting them to be able to reconnect them correctly.

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TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SCREW TIGHTNESS TORQUE TABLE Tightening torque of the most commonly used screws.

1 Screw resistance class S SS UNI

UNI

UNI

5931/32

5933÷36

5923÷30

3

2,5

8

4

1

10

1,25

13

1

8.8 8.84.8 10.9 12.9 8.8 10.9 8.8 12.9 12.9 4.8 10.9 8.8 12.910.9 S 10.9

12.9

Normal

Galvanized

Normal

Galvanized

Normal

Galvanized

2

3,2

2,8

4,4

3,9

5,3

4,8

3

2,5

6,1

5,5

8,7

7,8

10,3

9,3

5

4

3

10,6

9,5

14,8

13,3

17,8

16,0

6

5

4

25,1

22,5

35,4

31,8

42,5

30,2

13

6

5

4

26,5

23,8

37,3

33,5

44,7

40,3

1,5

17

8

6

5

51,1

46,0

71,9

64,7

86,3

77,6

1,25

17

8

6

5

53,4

48,1

75,1

67,5

90,2

81,1

1,75

19

10

8

6

86,5

77,8

121,4

109,2

145,9

131,3

1,25

19

10

8

6

92,4

83,2

129,5

116,6

156,1

140,5

2

22

12

10

6

137,7

123,9

193,8

174,4

232,6

209,3

mm

mm

4

0,7

7

5

0,8

6 8 10 12

4.8 S4.8 S 4.8

S SSS

14 16 18 20 22

Nm

Nm

Nm

Nm

Nm

Nm

1,5

22

12

10

6

145,9

131,3

206,1

185,5

246,9

222,0

2

24

14

10

8

209,1

188,2

293,8

264,4

353,0

317,7

1,5

24

14

10

8

218,3

196,5

308,1

277,3

369,3

332,4

2,5

27

14

12

8

288,7

259,8

406,1

365,5

487,7

436,9

1,5

27

14

12

8

314,2

282,8

442,8

398,5

530,6

477,5

2,5

30

17

12

10

408,1

367,3

573,4

516,1

687,7

618,9

1,5

30

17

12

10

439,7

395,8

619,3

557,4

742,8

662,5

2,5

32

17

-

12

542,3

488,5

763,2

686,9

915,3

823,7

1,5

32

17

-

12

582,6

524,3

819,3

737,4

983,6

885,3

3

36

19

-

12

705,1

634,5

990,8

891,7

1193,3

1074,4

2

36

19

-

12

745,3

671,3

1051,0

945,9

1255,1

1129,5

27

3

41

19

-

-

1036,0

927,5

1448,9

1304,0

1734,6

1561,2

2

41

19

-

-

1091,8

982,6

1530,6

1377,5

1836,7

1653,0

30

3,5

46

22

-

-

1307,9

1258,1

1989,3

1772,4

2357,1

2121,4

2

46

22

-

-

1510,2

1359,1

2122,4

1910,2

2540,8

2286,7

3,5

50

24

-

-

2000,0

1800,0

2800,0

2520,0

3400,0

3060,0

2

50

24

-

-

1610,0

1450,0

2300,0

2070,0

2690,0

2420,0

4

55

27

-

-

2600,0

2340,0

3700,0

3330,0

4300,0

3870,0

3

55

27

-

-

2800,0

2520,0

3900,0

3510,0

4600,0

4140,0

39

4

60

27

-

-

3400,0

3060,0

4800,0

4320,0

5600,0

5040,0

3

60

27

-

-

3600,0

3240,0

5100,0

4590,0

5900,0

5310,0

48

3

75

36

-

-

6450,0

5800,0

8000,0

7200,0

9600,0

8600,0

24

33 36

TMN10001.E.R0











21

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN CONVERSION TABLE Inches - Millimetres

1

22

inch.

1/64” 1/32” 3/64” 1/16” 5/64” 3/32” 7/64” 1/8”

mm.

0.396875 0.793750 1.190625 1.587500 1.984375 2.381250 2.778125 3.175000

inch.

33/64” 17/32” 35/64” 9/16” 37/64” 19/32” 39/64” 5/8”

mm.

13.09687 13.49375 13.89062 14.28750 14.68437 15.08125 15.47812 15.87500

9/64” 5/32” 11/64” 3/16” 13/64” 7/32” 15/64” 1/4”

3.571875 3.968750 4.365625 4.762500 5.159375 5.556250 5.953125 6.350000

41/64” 21/32” 43/64” 11/16” 45/64” 23/32” 47/64” 3/4”

16.27187 16.66875 17.06562 17.46250 17.85937 18.25625 18.65312 19.05000

17/64” 9/32” 19/64” 5/16” 21/64” 11/32” 23/64” 3/8”

6.746875 7.143750 7.540625 7.937500 8.334375 8.731250 9.128125 9.525000

49/64” 25/32” 51/64” 13/16” 53/64” 27/32” 55/64” 7/8”

19.44687 19.84375 20.24062 20.63750 21.03437 21.43125 21.82812 22.22500

25/64” 13/32” 27/64” 7/16” 29/64” 15/32” 31/64” 1/2”

9.921875 10.31875 10.71562 11.11250 11.50937 11.90625 12.30312 12.70000

57/64” 29/32” 59/64” 15/16” 61/64” 31/32” 63/64” 1”

22.62187 23.01875 23.41562 23.81250 24.20937 24.60625 25.00312 25.40000











TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Volume 1 gallon

231 in3

1 gallon

3.785 litres

1 fourth of a gall.

0.946 litres

1 litre

61.02 in3

1

Pressure 1 bar

14.5 psi

1 atmosphere

14.7 psi

1 kgf/cm

14.2 psi

1 in-Hg

0.491 psi

1 bar

100 kPa

1 psi

6.89 kPa

2

Speed 1 ft/sec

0.3048 m/sec

1 in/min

0.0254 m/min

1 M/h

1.609 km/h

Temperature Centigrade Temp. C°

5/9 X (Temp. F° - 32) Fahrenheit

Temp. F°

(9/5 X Temp. C°) + 32

Length 1 in (inches)

25.4 mm

1 metre

39.37 in

1 micron

0.000039 in

Power 1 HP

0.7457 kW

1 HP

42.4 BTU/min

1 HP

2546 BTU/Hr

1 HP

550 ft.-lbf/sec.

Strength 1 N (newton)

TMN10001.E.R0

0.2248 lbs











23

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN 1

24











TMN10001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SECTION 2 - ROUTINE MAINTENANCE To ensure vehicle's correct operation it is necessary to carry out controls and recurring and preventive maintenance operations according to the tables and following indicated 2 maintenance timetable.

Not respecting what was mentioned above exempts the manufacturer from any warranty liability.

The scheduled routine maintenance includes inspections, controls and interventions which, to prevent halts and malfunctioning, keep under systematic control: • the mechanical conditions of the vehicle and, in particular, of the drivers; • the vehicle's lubrication state.

The indicated schedules refer to normal operating conditions, that comply with foreseen and contractually bound usage conditions.

Attention: Before starting routine maintenance operations it is recommended to make sure no one is starting the vehicle, unless specifically required.

TMN20001.E.R0











25

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN INDICATIONS FOR CONSULTATION The routine maintenance tables consist of control lists to be carried out for the vehicle's routine maintenance.

2

CONTROL LIST FOR MAINTENANCE Items to be checked

Intervention frequency (hours)

Intervention type

10

50

c

b

a

100

250

500

1500

3000

Notes 6000

d

The number and chapter title regarding the machine's part that needs to be checked is shown. b Type of intervention to be carried out. c Intervention frequency in work hours. “(1)” = means that every year the intervention is to be carried out in any case.

The display “(2)” = means that the intervention is to be carried out by particularly d expert personnel. “(3)” = means that the chain inspection and wear verification must be carried out every three months and noted on a booklet reserved for safety verifications.

Safety verifications are labelled with “(*)”. a

26











TMN20001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN TABLE OF CONTROLS Items to be checked Main structure

Pins

Intervention frequency (hours)

Intervention type

10

50

100

•

(1)

Structural integrity control

•

(1)

Locking plates tightening control

• •

Radiator

Visual control: • verify fastening • verify integrity • verify seal

•

Cooling liquid level control

•

Visual control: • verify fastening • verify integrity • verify seal

•

Visual control: • verify fastening • verify integrity • verify seal

•

Transmission

Oil level control

•

Differential axle

Visual control: • verify fastening • verify integrity • verify seal

•

Hubs and differential oil level control

•

Visual control: • verify fastening • verify integrity • verify seal

•

Tightening control

•

Visual control: • verifica fissaggio • verifica integrità • verifica tenuta

•

Bearings and linkage play control Wheels

•

Visual control: • fastening verification (wheels, steering levers) • verify integrity • verify seal

•

Tyres pressure control

•

Wheel parallelism control

•

Telescopic boom

Fixed boom sliders visual control

•

Hydraulic oil tank

Pipes and brackets control



(2)

•

Oil level control

TMN20002.E.R0

Notes 6000

Bolts tightening control

•

Steering Axle

3000

(1)

Oil bleed and leakage control

Cardan shafts

1500

•

Plates and pins state control

Fuel system

500

Welded and bolted joints control

Diesel engine

Fumes discharge system

250

•









27

2

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN TABLE OF CONTROLS Items to be checked Hydraulic pumps

2

Intervention frequency (hours)

Intervention type

10

50

100

250

Visual control

•

Noise control

•

Oil bleed and leakage control

•

Pressure and capacity controls Hydraulic motors

Visual control

•

Noise control

•

Oil bleed and leakage control

•

Pressure and capacity controls Hydraulic cylinders

Visual control Gas preload control

Oil cooling

Visual inspection

•

Distributors

Visual control

•

Manipulators

Pressure and capacity control

•

Joystick

Oil bleed and leakage control

•

Brake cooling oil tank (if present)

Brake cooling oil level control Pipes and brackets control

•

Batteries

Fastening control

•

Charge control

•

Electrolyte level control

•

Notes 6000

•

(2)

•

(2)

•

(2)

•

Terminal tightening control

•

Efficiency check

•

Fastening control

•

Switch and board control

•

Paint

Control and possible touch-up

Safety devices

Emergency device operation control

•

Brake efficiency control

•

Light efficiency control

•



3000

•

Hydraulic accumulators

28

1500

•

Pins control

End-run - relay

500





(2)

•





TMN20002.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN LUBRICATION Here below is a list of parts to be lubricated and the frequency operations are carried out at.

LUBRICATION TABLE Items to be checked

2

Intervention frequency (hours)

Intervention type

10

LUB001 Pins

Lubrication

LUB002 Cardan shafts

Junction lubrication and movement area

LUB003 Steering Axle

Greasing

LUB004 Telescopic boom

Movement sliders greasing

LUB005 Hydraulic cylinders

Ball joint greasing

50

100

250

500

1500

3000

Notes 6000

• • • • •

LUB002

LUB004

LUB003

TMN20003.E.R0











29

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN ROUTINE MAINTENANCE PROCEDURE Here below is a list of procedures for routine maintenance to be carried out on the vehicle.

2

Warning: Before starting the inspection it is recommended to make sure no one is starting the vehicle, unless specifically required.

Attention: It is recommended no to proceed with repairs on support structures, possibly damaged by collisions or overloads, without previously obtaining the opinion from Terex Operation Italy Srl.

30











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Representation of vehicle bonnets 1

FRONT

6

2

4

Figure 1 Position 1 2 3 4 5

5

2

3

Description Bonnets for accessing the "Pump-Transmission" compartment Bonnet for accessing the "Engine-Transmission" compartment Bonnet for accessing the "Engine" compartment Protection of suction for the diesel engine Panel for checking and topping up "Engine- Transmission" oil Door to checking and topping up engine oil (only with diesel engines manufactured by VOLVO)

6

Panel for checking and topping up "Engine- Transmission" oil The panel is different for Cummins or Volvo motorisation.

CUMMINS

Front 1 ENGINE OIL LEVEL

2

3

TRANSMISSION OIL LEVEL

FILLING TRANSMISSION OIL

CUMMINS

VOLVO

1 Back

TRANSMISSION OIL LEVEL

2

1

Dipstick for checking "Diesel engine oil level"

2

Dipstick for checking "Transmission oil level"

3

Plug for topping up transmission oil

1

Dipstick for checking "Transmission oil level"

2

Plug for topping up transmission oil

3

Not used

VOLVO

3

FILLING TRANSMISSION OIL

With Volvo motorisation, the dipstick to check "Diesel engine oil level" is located under door No. 6 in Figure 1.

TMN20004.E.R0











31

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Main right compartment

2

1 2

Position 1 2

Description Cock for emptying the hydraulic tank.

"Aux Pump Emergency" auxiliary pump (optional).

Secondary left compartment

1 2

Position 1 2

32

Description Cock for emptying the fuel tank.

Electrical compartment for point heaters (optional).











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Expansion tray for diesel engine coolant

2

Position

3

1 2 3

1

Description Attention: For mixing coolant, refer to the attached sub-supplier manual.

Maximum allowed level Minimum allowed level Plug for topping up coolant

2

TMN20004.E.R0











33

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Engine oil level check Important: If the engine has been started, a recovery time of about 15 minutes is necessary.

2

Necessary PPE

Daily check the engine oil level.

The oil level must be between notches "H" (high) and "L" (low). It is recommended however to keep the oil level as close as possible to notch "H".

Attention: Never activate the engine if the oil level is below the "L" (low) notch or above the "H" (high) notch.

Consult the use and maintenance of the engine for maintenance related information.

34











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Engine coolant level check Necessary PPE

2 Visually check coolant level on the expansion tray.

Check while the engine is cold, making sure that the level is included between the minimum and the maximum.

Warning: Never remove the radiator of the filling cap if the engine is hot. IT is possible that the coolant is under pressure and comes out with an explosive force. In order to avoid burns, remove the radiator cap or the filler cap only when the engine is cold.

Transmission oil level check Necessary PPE

Daily check the oil level at a temperature between 82 - 93°C with the engine idle. The oil level must be between notches "H" (high) and "L" (low). It is recommended however to keep the oil level as close as possible to notch "H".

Refer to the attached sub-supplier manual.

TMN20004.E.R0











35

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Checking oil level for cooling oil bath brakes Necessary PPE

2 Brake oil level dipstick

Procedure: Step 1 2 3 4 5 6

Action Park the vehicle in horizontal position.

Wait for the diesel engine and the brakes oil to cool down.

Move the cabin forward.

Lift bonnet No. "3". In the right part of the compartment you will find the dipstick for checking brake oil level.

Remove the dipstick to verify that the oil level is between the minimum and maximum notches.

Insert the dipstick and close bonnet "No. 3" if the result of the verification is positive.

Otherwise, proceed with oil topping up.

Retract the cabin.

Topping up oil for cooling oil bath brakes Procedure: Step 1 2 3 4 5 36

Action Remove the brake oil level dipstick (see procedure for control).

Using a funnel, pour oil until the maximum tank level has been reached.

Verify if the maximum level has been reached using the brake oil level dipstick.

Once the maximum oil level has been reached, insert the dipstick and close bonnet "No. 3".

Retract the cabin. 









TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Hydraulic oil level check Necessary PPE

2 The hydraulic oil level must be checked when the vehicle is horizontal, with the lifting boom completely lowered and retracted. The spreader must be positioned at an opening of 20'.

Warning: Do not carry out oil control or replacement before it has cooled down.

The hydraulic oil tank is located on the frame, at the right of the driver's seat.

Check the hydraulic oil level with the engine off, verifying that the level reaches the maximum notch. Before topping up, check that the area around the filler cap is clean.

Only use oil taken from a clean container.

Warning: Do not weld or use oxy-hydrogen flame in proximity of the hydraulic oil tank.

Position of hydraulic oil level indicators On the tank there are two inspection windows that show the oil level.

See figure below.

MAX

MIN TMN20004.E.R0











37

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Diesel engine oil top up (Cummings) Important:

2

Level top up operations on the vehicle MUST be carried out with the machine in horizontal position and the boom completely lowered and retracted.

Necessary PPE

Required quality: CUMMINS QSM11 diesel engine Cummins CES 20078 Refer to the attached sub-supplier manual.

Cummins QSX11.9 diesel engine Cummins CES 20081 Refer to the attached sub-supplier manual.

The oil top up for Volvo diesel engine must be completed as described below: Step 1

Action Image • Move the cabin forward.

• Open bonnet "No. 3" to access the "Engine" compartment.

• Unscrew the engine oil top up cap.

 2 3

Pour oil until the maximum tank level has been reached.

• Verify if the maximum level has been reached using the engine oil level control dipstick (see Panel for checking and topping up the "Engine - Transmission" oil).

• Once the "MAX" oil level has been reached, tighten the top up cap, close bonnet "No. 3" and move the cabin and close door No. 6. 

Engine oil top up cap

Engine oil level control dipstick

For the oil top up procedure, refer to the attached sub-supplier manual.

38











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Diesel engine oil top up (Volvo) Important: Level top up operations on the vehicle MUST be carried out with the machine in horizontal position and the boom completely lowered and retracted.

Necessary PPE

Required quality: VOLVO TAD 1340 VE diesel engine VOLVO VDS3. In alternative: VDS2 For additional information see the attached sub-supplier manual.

VOLVO TAD 1360 VE diesel engine VOLVO VDS3 For additional information see the attached sub-supplier manual.

The oil top up for Volvo diesel engine must be completed as described below: Step

Action

Image

1

• •

Open door "No. 6"; Unscrew the engine oil top up cap.

2

Pour oil until the maximum tank level has been reached.

3

Verify if the maximum level has been reached using the engine oil level control dipstick.

4

Once the maximum oil level has been reached, tighten the top up cap and close door "No. 6".

Engine oil level control dipstick

For the oil top up procedure, refer to the attached sub-supplier manual.

TMN20004.E.R0











39

2

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Radiator cooling fluid top up Important:

2

Level top up operations on the vehicle MUST be carried out with the machine in horizontal position and the boom completely lowered and retracted.

Warning: Disengage the battery disconnecting switch before carrying out any maintenance intervention on the engine.

Attention: The coolant may have an elevated temperature. Before opening the cap of the tray, make sure the engine is off and the radiator has cooled down.

Necessary PPE

If the coolant level in the expansion tray is no longer between the minimum and maximum level, proceed as described here below: Step 1 2 3

40

Action Slowly loosen the cap of the coolant tray.

Pour the coolant up to the maximum allowed notch level.

Strongly tighten the cap of the coolant tray.











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Filling the diesel oil tank (800 litre capacity) Important: Diesel oil filling operations on the vehicle MUST be carried out with the machine in horizontal position and the boom completely lowered and retracted.

2

Important: The sulphur content of the fuel influences engine oil replacement intervals. For additional information, refer to the attached sub-supplier manual.

Attention: While refuelling there is always a danger of accidents and explosions. When carrying out this operation smoking is prohibited and the engine must be off. Never excessively fill the fuel tank.

Carefully close the filler hole cap.

Warning: In order to avoid damage to Tier IV (Volvo TAD1360VE and Cummins QSX11.9) diesel engines it is necessary to only use "Ultra-Low Sulphur Diesel" fuels with a sulphur content that does not exceed 15 ppm.

Necessary PPE

Fuel specifications: The fuel must, as a minimum, satisfy the standards indicated by national and international norms for fuel, for example: • EN 590 (with environmental requirements and resistance to low temperatures that responds to national standards).

• ASTM D975 No. 1-D and 2-D • JIS KK 2204 Note: • For TIER III diesel engines, if the sulphur content exceeds 0.5% of the weight, change oil replacement intervals.

• For TIER IV diesel engines, the sulphur content must not exceed 15 ppm.

Diesel oil refuelling must be carried out as described: Step 1 2 3

Action Unscrew the diesel fuel tank cap.

Pour diesel oil until the tank has been filled completely.

Once the desired quantity of fuel has been reached, carefully close the filler hole cap.

TMN20004.E.R0











41

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Position of the cap and fuel level indicators

2

MAX

MIN Refilling the AdBlue tank (only with Volvo TAD1360VE engine) The tank is positioned in the AdBlue/DEF tank compartment (see section 4 of the operator manual).

The on board computer display signals the quantity of AdBlue present in the tank to the operator.

For the procedure for AdBlue refilling, refer to the attached sub-supplier manual.

Topping up washer fluid Important: Add anti-freeze to the windshield washer fluid once external temperature falls below 0°, to allow freezing that would make it impossible to spray water on the windshield.

Washer fluid tank cap

42











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Checking junction tightness Necessary PPE

2 The junction tightness moment can be checked in two ways: • with torque spanner; • with nut/bolt.

Using a torque spanner, tighten until the desired tightness value marked on the spanner has been reached.

Using nut/bolt, proceed as described: Step 1 2 3 4

Action Mark the nut and bolt to identify their relative position.

Loosen the nut with a rotation of at least 60°.

Tighten the nut.

Check if applying the prescribed moment brings the nut back to the original position.

Attention:

If even one bolt in a joint does NOT correspond to tightness provisions, all joint bolts must be checked again.

TMN20004.E.R0











43

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Inflating tyres Attention: Position next to the wheel at a distance of at least 2 metres form the centre of the wheel. (see figure)

M

in

.

2

m

2

Necessary PPE

To inflate the tyres, proceed as described: Step 1

44

Action Insert the self-locking air inlet on the pneumatic valve.

2

Start to inflate (proceed with caution).

Note: Check that pressure does not exceed the value indicated on the plate.

3 4

Once the pressure is correct, disconnect the self-locking air inlet.

Tighten the closing cap onto the valve.











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Movement sliders adjustment Necessary PPE

2 Complete the movement slider adjustment procedure if they are worn.

This procedure must be completed in order to avoid that play develops in the movable boom.

Proceed as described: Step 1 2 3 4 5 6

2

Action Completely retract the telescopic boom.

Access the boom using a specific lifting platform (up to CE standard).

Loosen the counter-nuts.

Tighten the adjusting screw to reduce the space between the movement slider and the movable boom. Maintain a maximum space of 5 mm per side.

Once the adjustment has been made, tighten the counter-nuts.

Repeat the procedure from the opposite side of the boom.

1

Position 1 2

TMN20004.E.R0

Description Counter-nut Adjusting screw



1









2

45

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Pressure control points Using the pressure gauge supplied with the vehicle, verify pressure points every time anomaly occurs. Pressure must be verified and adjusted with the diesel engine started (RPM in idle mode) and parking brake engaged.

2 Pressure adjustment instructions Step 1 2

1

3

2

4

Action Connect the pressure gauge to the measurement point.

Using the hexagonal key, loosen the nut (1).

Using an Allen key, rotate the screw (2) to adjust pressure.

Rotate clockwise to increase and anticlockwise to decrease.

Tighten the screw (1) once the required pressure has been obtained.

Pressure measurement instructions Step 1

3

2

3

Action Loosen the measurement point cap (3).

Tighten the connector (4) to connect the pressure gauge to the measurement point.

Loosen the connector (4) to disconnect the pressure gauge and tighten the cap (3) one the measurement is terminated.

4

46











TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Main right compartment

2

1

2

3

Pressure adjustment and measurement points located in the main right compartment 1.

Hydraulic circuit for cabin and transmission oil cooling fan movement.

2.

Hydraulic circuit of service brakes and equipment levelling cylinders (it does not include the hydraulic circuit for damping movements).

3.

Hydraulic circuit for hydraulic oil cooling fan movements.

Point 1

A

A B

B

Adjustment point (30 Bar) Measurement point (30 Bar)

TMN20004.E.R0











47

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Point 2

2 B1

A

A B1 B2

B2

Adjustment point for the hydraulic circuit of equipment levelling cylinders (30 Bar) Measurement point for the hydraulic circuit of equipment levelling cylinders (30 Bar).

Measurement point for the hydraulic circuit of service brakes (150÷160) Bar

Point 3

B

A

A B 48

Adjustment point (80 Bar).

Adjust pressure using the handle (Rotate clockwise to increase or anticlockwise to decrease).

Measurement point (80 Bar). 









TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Main right compartment

B1

2

B2

B3

Pressure measurement points located in the secondary right compartment Pressure detected in the points shown must be 30 Bar. IT is the pressure necessary to open the "oil distributor" for the following hydraulic circuits: 1.

Lower the telescopic boom (B1); 2.

Raise the telescopic boom (B2); 3.

Equipment hydraulic supply (B3).

"Pump-Transmission" Compartment

P1 P2

Pressure measurement and adjustment points located in the "Pump-Transmission" compartment P1 P2

Point 1 "measurement and adjustment of the left pump" Point 2 "measurement and adjustment of the right pump"

TMN20004.E.R0











49

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Points P1 and P2 of the "Pump-Transmission" compartment

B1

2

A1

B2 A1 B1 B2

Adjustment point for DeltaP pressure (25 Bar) Measurement point for DeltaP pressure (25 Bar) Measurement point for maximum pressure (325 Bar)

Hydraulic circuit for hydraulically translatable cabin movements (optional) Cabin rear

B A

Pressure adjustment and measurement points located in the cabin rear The points are located in the lower part of the cabin rear. Cabin translation movements refer to the hydraulic circuit.

A B 50

Adjustment point (40 Bar) Measurement point (40 Bar) 









TMN20004.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Oil level check and top up for the differential axle and wheel hubs Necessary PPE

2

1 2 4

3

Step 1 2 3 4

5

Action Position under the differential axle when the vehicle is parked horizontally.

Using a hexagonal key loosen the "3" screw Verify the presence of oil inside the hole.

Pour oil inside the hole if the level is insufficient.

Once the oil reaches the level, tighten then screw "3" to close the hole.

Checking oil level in wheel hubs

Image

Move the truck so that the front wheels are positioned as shown in the photo on the side.

Using an Allen key loosen the screw "1".

Verify the presence of oil inside the hole.

Pour oil inside the hole if the level is insufficient.

Once the oil reaches the level, tighten then screw "1" to close the hole.

Repeat step 5 for the other wheel.

TMN20004.E.R0









1



51

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN CLEANING Here below is a list of parts to be cleaned and the frequency operations are carried out at.

CLEANING TABLE

2

Items to be checked

Intervention frequency (hours)

Intervention type

10

Radiator

Radiator cleaning - maintain clean from dust and/or impurity

Fuel system

System water purge

50

100

250

500

1500

•

Tank cleaning

(1)

•

Slider area cleaning - maintain clean from dust and/or impurity

Steering Axle

Surface cleaning - maintain clean from dust and/or impurity

Hydraulic oil tank

Pump aspiration filter cleaning

Hydraulic cylinders

Rod cleaning

Oil cooling

Water side exchanger cleaning

• • •

(1)

• •

•

Oil side exchanger cleaning

•

Batteries

Clamp cleaning - - maintain clean from dust and/or impurity

•

Electrical commands

Switch and board cleaning

•

Safety devices

Cleaning traces of oil and grease



Notes 6000

•

Cardan axle

52

3000





(2)

•





TMN20005.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Cleaning the fuel tank Necessary PPE

2 To clean the fuel tank, proceed as described: Step NOTE 1 2 3

Action The procedure can be simpler after a long period of vehicle inactivity, since condensation water has a tendency to deposit at the bottom of the tank.

Connect a flexible pipe to the cock located in the left secondary compartment.

Pre-set a container for collecting the fluid.

Open the cock to empty the condensation water and/or impurities.

Let the water drain until clean diesel oil comes out, then close the cock and disconnect the flexible piping.

Cleaning the oil cooling circuit Necessary PPE

To clean the oil cooling circuit, water side, proceed as described: Step 1 2

Action Remove the back panel.

Proceed with pipe brushing.

To clean the oil cooling circuit, oil side, proceed as described: Step 1 2

Action Flush with a solvent to degrease the aluminium parts, circulating water upstream for 30 minutes.

Eliminate residues by flushing with water.

TMN20005.E.R0











53

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROGRAMMED REPLACEMENT Here below is a list of parts to for programmed replaced and the frequency operations are carried out at.

2

PROGRAMMED REPLACEMENT TABLE Items to be checked

Intervention frequency (hours)

Intervention type

Fuel system

Diesel oil filter replacement

Radiator

Coolant replacement

Transmission

Oil filter replacement

10

50

100

250

500

1500

• •

Differential axle

Replacement of hub and differential oil

•

Telescopic boom

Replacement of fixed boom sliders

•

Replacement of movable boom sliders

•

(1) (1)

Oil filter replacement

•

Oil replacement

•

Replacement of air filter cartridge Oil filter cartridge replacement

•

Brake cooling oil tank (if present)

Oil filter replacement

•

Oil replacement



(1)

•

Hydraulic pumps

54

Notes 6000

•

Oil replacement

Hydraulic oil tank

3000

•









TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Diesel oil tank filter replacement Necessary PPE

2 For diesel oil tank filter replacement, follow the procedure described below: Step 1 2 3

Action Bring the vehicle above a maintenance hole or lift it using suitable lifting equipment.

Unscrew the diesel fuel tank filter.

Replace it with one of equal characteristics.

Diesel oil filter

Diesel oil filter position Coolant replacement Necessary PPE

For radiator coolant filter replacement, follow the procedure described below: Step 1 2 3 4

Action Unscrew the fluid drain plug located under the radiator.

Pour fresh water to rinse the circuit.

Once clean water comes out, close the drain plug.

Fill with new coolant.

TMN20006.E.R0











55

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Transmission oil filter replacement Necessary PPE

2 For transmission oil filter replacement, follow the procedure described below: Step 1 2 3

Action Bring the vehicle above a maintenance hole or lift it using suitable lifting equipment.

Loosen the transmission oil filter.

Replace it with one of equal characteristics.

Transmission filter position

Transmission filter

56











TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Transmission oil replacement Necessary PPE

2 For transmission oil replacement, follow the procedure described below: Step 1 2 3 4 5 6 7

Action Bring the vehicle above a maintenance hole or lift it using suitable lifting equipment.

Loosen the drain plug.

Allows all oil to be replaced to come out.

When the liquid has all come out, close the drain plug.

Take position above the vehicle.

Unscrew the transmission oil cap and pour the new fluid.

Check that the maximum level has been reached using the level dipstick positioned at the right of the oil cap.

Drain plug

Transmission oil cap Oil level control dipstick

TMN20006.E.R0











57

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Replacement of fixed boom movement sliders Necessary PPE

2 For fixed boom movement slider replacement, follow the procedure described below: Step 1 2 3 4 5

Action Rest the boom with spreader onto a container, without lifting the load.

Loosen screws (6) and (1) removing the slider support (3).

Loosen the locking screws (5) and remove the worn sliders.

Before positioning the new slider, verify that there is no slag in the housing that may compromise perfect alignment of the slider.

Correctly position the slider and tighten the screws (5).

5

1

4

2

7 3

58





6







TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Replacement of movable boom movement sliders Necessary PPE

2 For movable boom movement slider replacement, follow the procedure described below: Step 1 2 3 4 5

Action Rest the boom with spreader onto a container, without lifting the load.

Loosen screws (1) and (6) removing the slider support (3).

Loosen the locking screws (5) and remove the worn sliders.

Before positioning the new slider, verify that there is no slag in the housing that may compromise perfect alignment of the slider.

Correctly position the slider and tighten the screws (5).

Note: Side slider (8) wear is less than that of the upper and lower slides. Their replacement is however recommended.

8

4 5 3

2

1

7 6

8

3

Attention: Once the replacement has been completed, grease the sliders extending the boom and applying a thin layer of grease on the surfaces.

TMN20006.E.R0











59

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Hydraulic oil tank replacement Important: The procedure must be completed with the machine positioned horizontally with the lifting unit completely lowered and retracted. The spreader must be at an opening of 20'.

2

Necessary PPE

For replacing the oil contained in the hydraulic oil tank, follow the procedure described below: Step 1 2 3 4 4 5 6 7

60

Action Connect a flexible pipe to the cock located in the right main compartment.

Prepare a container to collect the oil being replaced.

Drain the oil by opening the cock.

Once the tank is empty, close the cock and disconnect the flexible piping.

Open and remove the hydraulic tank cap.

Carefully eliminate all impurities (without using tools that leave filaments).

Fill up the maximum level indicated on the tank with new oil.

Tighten the hydraulic tank cap.











TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Hydraulic oil tank filter replacement Note: Return oil filters located on the upper part of the tank are equipped with electrical clogging indicators. The clogged filter signal appears on the display of the operator cabin.

2

Necessary PPE

For replacing the cartridges for hydraulic oil tank filters, follow the procedure described below: Step 1 2 3 4 5 6 6 8

Action Take position on the right side of the platform. Lift the door (3) located above the filters.

Loosen the 4 screws (2) and remove the cover (4) and the spring (6).

Remove the oil filter cartridge (7).

Insert the new oil filter cartridge (7) equipped with its gasket (8).

Insert the spring (6).

Insert the cover (4) equipped with its gasket (5).

Tighten the cover using the 4 screws (2).

After replacing all filters, close the door (3).

TMN20006.E.R0











61

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Position and representation of hydraulic oil tank filters

2 2 1 3

Position

Description

1

"Clogged oil filter" sensor

2

Filter tightening screws.

3

Door for removing filters.

4

Cover

5

Cover gasket

6

Spring

7

Oil filter cartridge

8

Oil filter cartridge gasket

2

8

7 6

5 4

62











TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Air filter replacement Necessary PPE

2 For replacing the air filter for hydraulic oil tank filters, follow the procedure described below: Step 1 2 3 4 5

Action Being the cabin to back position and lock it.

Lift bonnets "No. 1" where the filter is positioned.

Release the two manual hooks to open the filter holder.

Replace the filter.

Make sure that manual hooks are locked properly and lower "No. 1" bonnets.

Hydraulic pump oil tank filter replacement Necessary PPE

For hydraulic pump oil filter replacement, follow the procedure described below: Step 1 2 3

Action

TMN20006.E.R0











63

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Replacing the oil in the differential axle and wheel hubs Necessary PPE

2

1 2 4

3

Step 1

2

3

4

5

6

64

Action Position under the differential axle when the vehicle is parked horizontally.

Using a hexagonal key loosen the "3" screw Position a container to collect the used oil (minimum capacity of 80 litres) in the lower part of the differential axle.

Using an Allen key loosen the screw "4".

Wait for the oil to drain out completely and clean the screw "4" from any impurities.

Tighten the screw "4" to close the drain hole. Remove the container and dispose of the oil according to the regulations on environmental protection.

Pour the oil into hole "3" until the required level has been reached.

If foam forms while filling, wait the necessary amount of time to verify the actual oil level.

Once the required level has been reached, close the filling hole using the screw "3".









Image



TMN20006.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN Wheel hub oil replacement

7

8

9

10

Move the truck so that the front wheels are positioned as shown in the photo on the side.

Using an Allen key loosen the screw "1".

Position a container to recover the exhaust oil (minimum capacity of 15 litres).

Using an Allen key loosen the screw "2".

Wait for the oil to drain out completely and clean the screw "2" from any impurities.

1

2 2

Tighten the screw "2" to close the drain hole. Remove the container and dispose of the oil according to the regulations on environmental protection.

Pour the oil into hole "1" until the required level has been reached.

If foam forms while filling, wait the necessary amount of time to verify the actual oil level.

Once the required level has been reached, close the filling hole using the screw "1".

Repeat steps from 7 to 10 for the other wheel.

TMN20006.E.R0











65

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN FILLING TABLE FOR REACHSTACKER T45 QUANTITY (Litres)

RECOMMENDED LUBRICANT

TEMPERATURE min. / max. (°C)

SPECIFICATIONS OF THE RECOMMENDED PRODUCT

Volvo TAD 1340

36

Cummins QSM 11

-15° / +40°

38

AGIP-ENI i-Sigma Performance 15W-40 (SAE J300)

Volvo VDS3 Cummins CES 20078

Volvo TAD 1360

36

AGIP-ENI i-Sigma Top MS 15W-40 (SAE J300)

-15° /+40°

Volvo VDS4 Cummins CES 20081

USE

2 Engine

Cummins QSX 11.9 SCR

Volvo TAD1360

20

AdBlue/DEF ISO 22241 DIN 70070

AdBlue/DEF ATF

Transmission

Dana TE 32

90

Differential

77

HYPOID GEAR OIL

12 (X2)

AGIP-ENI ROTRA MP/S 85W-90 (SAE J306)

Differential axle Wheel hub (X2)

DEXRON III

AGIP-ENI DEXRON III

-15° / +35°

U.T.T.O.

Oil bath brake cooling

Separated tank

60

AGIP-ENI ROTRA JD/F 80W (SAE J306)

-25° / +35°

API GL 5 MIL 2105D

Mineral oil with LS additive (Limited Slip) anti friction Viscosity 40°C = 55 mm2/s Viscosity index = 140

U.T.T.O.

Hydraulic system

Tank

Anti-freeze for diesel engine coolant

50% Water 50% Anti-freeze

800

AGIP-ENI ROTRA JD/F 80W (SAE J306)

-25° / +35°

HVLP ISO DIN 51524-3 50% anti-freeze for temperatures up to -38°C

AGIP ANTIFREEZE EXTRA

Key: • Volvo VDS = Volvo Drain Specification: Technical specifications for Volvo manufacturer.

• Cummins CES = Cummins Engineering Specification: Technical specifications for Cummins manufacturer.

• ATF = Automatic Transmission Fluid: Automatic transmission oil.

• U.T.T.O. = Universal Tractor Transmission Oil: Universal oil suitable for hydraulic circuits, transmissions and oil bath braking systems.

• HVLP ISO DIN 51524-3 = Lubricants with additives against corrosion, oxidation and wear. Viscosity index greater than 140.

• HYPOID GEAR OIL = Lubricant for gears, designed to lubricate epicycloidal gear reducers and supporting extreme pressure.

66











TMN20007.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN FILLING TABLE FOR REACHSTACKER T45 (with temperatures up to -35°C) QUANTITY (Litres)

USE

Engine

Volvo TAD 1340

36

Cummins QSM 11

38

Volvo TAD 1360

36

RECOMMENDED LUBRICANT

Shell Rotella T6 5W-40 (SAE J300)

Cummins QSX 11.9 SCR

Volvo TAD1360

20

Transmission

Dana TE 32

90

2

Shell Rimula R6 LME 5W-30 (SAE J300)

AdBlue/DEF ATF Shell Spirax S3 ATF MD3 HYPOID GEAR OIL

Differential

77

Shell Spirax S5 ATE 75W-90 (SAE J306)

Differential axle

HYPOID GEAR OIL

Wheel hub (X2)

12 (X2)

Shell Spirax S5 ATE 75W-90 (SAE J306)

U.T.T.O.

Oil bath brake cooling

Separated tank

60

Shell Spirax S6 TXME 10W-30 (SAE J300) 85W (SAE J306)

U.T.T.O.

Hydraulic system

Tank

Anti-freeze for diesel engine coolant

50% Water 50% Anti-freeze

800

Shell Spirax S6 TXME 10W-30 (SAE J300) 85W (SAE J306) BASF Glysantin G48

Key: • Volvo VDS = Volvo Drain Specification: Technical specifications for Volvo manufacturer.

• Cummins CES = Cummins Engineering Specification: Technical specifications for Cummins manufacturer.

• ATF = Automatic Transmission Fluid: Automatic transmission oil.

• U.T.T.O. = Universal Tractor Transmission Oil: Universal oil suitable for hydraulic circuits, transmissions and oil bath braking systems.

• HVLP ISO DIN 51524-3 = Lubricants with additives against corrosion, oxidation and wear. Viscosity index greater than 140.

• HYPOID GEAR OIL = Lubricant for gears, designed to lubricate epicycloidal gear reducers and supporting extreme pressure.

TMN20007.E.R0











67

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SECTION 3 - EXTRAORDINARY MAINTENANCE For extraordinary maintenance operations of the machine, contact authorized service center.

3

68











TMN30001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SECTION 4 - TROUBLESHOOTING The troubleshooting procedure is a guide for the most common cases of machine malfunction.

To reduce machine stoppages to a minimum, the nature and location of the fault must be determined as quickly as possible. In many cases, mechanical faults can be determined visually.

4

Attention: always read and follow the general safety regulations shown in this manual and the warning notices on the machine itself.

Attention: persons charged with inspecting, servicing and repairing the machine must wear protective clothing, accident-prevention footwear, eyewear, gloves and a helmet. Before proceeding, it is also

necessary to inform the operators, by means of special warning notices, that the machine is not operative as it is undergoing maintenance.

Attention: before disconnecting the hydraulic pipes, lower the spreader so the hydraulic circuit no longer has to bear any weight.

TMN40001.E.R0











69

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

DIESEL ENGINE Bleeder line. See motor instruction manual1 Make sure the batteries are charged and check Generator or starting motor the connections between operation fault1 battery body and starter motor1 Place the gear lever in Gear lever engaged2 neutral2 Low fuel level3 Fill3 Dirty fuel pre-filter and filter3 Replace filter and clean3 Water in fuel3 Clean the fuel supply circuit3 Injection pump faulty3 Repair or replace the pump3 Regulate the accelerator Accelerator cable too slack4 cable4 Injection pump regulator Repair or replace4 faulty4 The turbosupercharger is Repair or replace4 not working properly4 Air filter dirty5 Clean or replace the air filter5 Injection pump regulator Repair or replace5 faulty5 The turbosupercharger is Repair or replace5 not working properly5 Loss of lubrication causing Ensure correct lubrication, seizure of rollers and make sure the bleeder line corresponding pins6 is open6 Penetration of foreign bodies, due to bad cleaning or filtering capacity of the air filter. The presence Check the condition of the of foreign bodies could air filter6 damage the rotor and consequently also the motor. 6 The lubricating oil in bad condition, could cause Replace the oil at regular premature wear and intervals6 SMT.0001R.E00 seizures. 6 Air in the fuel supply circuit1 The engine fails to start1

4 The starter motor fails to start2

The engine stops3

Low engine power (exhaust in order)4

Low engine power (exhaust not in order)5

Turbosupercharger fault6 SMT.0001D.E00

SMT.0001C.E00

70











TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM HYDRAULIC MOTORS

The motor fails to turn over or does not develop correct speed and/or torque.1

POSSIBLE FAULT

REMEDY

SMT.0001C.E00

Kinematic control motion blocked due to misalignment. 1

Carefully realign. 1

Maximum pressure valve stuck. 1

Remove the impurities from the pressure adjustment plunger ball. 1

The motor plate is not correctly angled (in the case of adjustable motors). 1 Maximum pressure valve setting too low. 1 Pump pressure or flow rate are too low. 1 Kinematic motor motion mechanically restricted.1

Adjust at pump corner. 1 Check system pressure and regulate valve. 1 Check pump delivery and motor pressure and speed. 1 Remove the obstacle.1

External oil leaks from motor.2

Leaking gaskets.2

Replace.2 Fill with oil. 3

There is no flow rate or motors fail to turn when correctly controlled.3

No oil in tank. 3 Wrong direction of feed motor rotation. 3 Broken joint or coupling. 3 Broken joint key. 3 Discharge (or maximum pressure) valve open. 3 Pressure duct blocked. 3 Pump problems. 3 Bad actuator operation. 3 Supply pipe crushed or disconnected. 3 Bad operation of actuator direction adjustment.3

TMN40001.E.R0









Remedy. 3 Repair or replace. 3 Replace. 3 Remedy. 3 Free the duct. 3 Check the pump. 3 Check the actuator. 3 Remedy. 3 Check the direction valve. 3



71

4

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

No oil in tank. 4

4

Fill with oil. 4

Pressure gauge broken or faulty. 4 Discharge valve or maximum pressure valve fully open. 4

No pressure or pressure too low.4 SMT.0002D.I00

Replace. 4 Correct. 4 Determine cause and eliminate. 4 Regulate.4

Excessive leaks. 4 Pressure limiter too low.4 SMT.0002C.E00

72









SMT.0002R.E00



TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

PUMPS Pump-motor unit not aligned. 1 Oil level too low. 1

Carefully realign. 1 Fill tank.1 Use a good clean hydraulic fluid, with required viscosity.

Oil type not suitable. 1

1

Too much pump noise. 1

Excessive operating temperature. 2

TMN40001.E.R0

Pour the hydraulic fluid on the unions and around the Air in the intake duct, drainage duct, shaft gaskets. shaft and check whether the 1 operating noise changes; tighten or replace. 1 Allow the tank to breath Tanks not aerated. 1 so the oil level can vary if necessary. 1 Make sure the inlet is not Limited flow in the intake blocked by rags or other duct. 1 foreign bodies. 1 Replace: the phenomenon Pressure seal worn. 1 is due to hot, fluid, dirty or lack of oil. 1 Filter blocked. 1 Clean. 1 Parts worn or broken.1 Replace. 1 Clean or replace the Tank breather pipe blocked.1 breather pipe.1 Operation at higher pressure Reduce pressure to correct than contemplated. 2 setting. 2 Check the viscosity of the Excessive sliding. 2 fluid. 2 Oil level in tank too low.2 Fill the tank.2











73

4

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

Gaskets incorrectly fitted. 3

4

Change the installation. 3 Check to see whether the internal drainage is blocked; Pressure in pump casing. 3 check to see whether there is excessive counterpressure in the drainages. 3 Realign pump and motor Misalignment of couplings. 3 shafts. 3 Replace the sets of gaskets; Gaskets damaged; shaft carefully fit the gaskets seals damaged or stretched.3 on the splines to prevent dents.3 Use the recommended type Unsuitable fluid. 4 of fluid. 4 Metal residues or foreign Make sure the oil is clean. 4 substances in bearings. 4 Realign the pump and the Misalignment of couplings.4 motor.4 Always keep the level of the Oil level in tank too low. 5 oil in the tank well above the intake. 5 Apply a good sealant to the Air in intake. 5 pipes that is insoluble in oil and tighten the unions. 5 Intake filter or duct blocked. Remedy. 5

Oil seal leaks. 3

Bearing failure. 4

5

Pump fails to deliver oil.5

Use more fluid oil for a specific use and temperature. 5 Replace the damaged parts; eliminate impurities, foreign substances or other probable causes of failure. 5 Replace. 5 Tighten the bolts on the lid.5

Excessive oil viscosity. 5

Pump shaft, kinematic motion or rotor damaged. 5 Spline cut. 5 Pump cover too large.5

74











TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

Pump without pressure.6 SMT.0003D.E00

POSSIBLE FAULT

REMEDY

Remove the pump and check whether there is any Pump blocked. 6 trapped dirt or over-viscous oil. 6 Pump speed too low. 6 Check minimum speed. 6 Check the pressure in the circuit. Check the openOil offtake to tank. 6 centre valves or other valves that drain into the tank. 6 Remedy; eliminate the Faulty pressure gauge or impurities blocking the pressure gauge duct closed.6 SMT.0003C.E00 pressure gauge outlet.6 SMT.0003R.E00

MAXIMUM PRESSURE VALVE

No pressure.1

Pressure not adjustable.2

Pressure too high.3 Noisy or irregularly performing valve.4 SMT.0004D.E00

CHECK VALVE Stops flow.1

Valve blocked during opening. 1 Pump without delivery. 1 Valve badly set or spring broken.1 Box blocked during opening. 2

Free the ball or box.1 See pump table. 1 Adjust or replace.1 Free the box. 2 Make sure the other max pressure valve is set at same pressure.2

Setting lower than another maximum pressure valve.2 Box blocked during closening. 3 Internal drainage line blocked.3 Valve dirty. 4 Air in system.4

Free the box. 3 Check the valve.3 Clean the valve. 4 Eliminate origin.4

SMT.0004C.E00

SMT.0004R.E00

Parts broken. 1 Pump without delivery.1

Dismantle and check. 1 See pump table.1 Replace housing and eliminate cause of damage.2

Does not maintain pressure.2 Damaged housing.2 SMT.0005D.E00

TMN40001.E.R0

SMT.0005C.E00





SMT.0005R.E00







75

4

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

DIRECTION ADJUSTMENT VALVES Check the power supply or whether the solenoid is burnt out. 1 Check source of pilot system pressure. 1 Check caps, connectors and ducts. 1 Remove, clean and wash. 1 Check drawing for correct assembly. 1 Remove the box, check this and the valve body. 1 Remove the box and clean with sandpaper.1 Replace the oil and run the pump to heat the oil. 2 Check the power voltage and frequency.2 Discharge and wash the system.2

Solenoids not operating. 1 Absence of piloting pressure. 1

4

Drainage piloting blocked. 1

The valve box fails to move.1

Impurities. 1 Bad re-assembly after overhauling. 1 Working residues. 1 Fine contaminants.1 Excessive oil viscosity at startup. 2 Incorrect solenoid operation. 2

Irregular box response.2 SMT.0006D.E00

Contaminants in system.2 SMT.0006C.E00

SMT.0006R.E00

PRESSURE ADJUSTMENT VALVE Box stuck.1 Pressure gauge broken or imprecise.1 Pump pressure too low. 2 Air release adjustment too low.2

Pressure too high.1

Pressure too low.2 SMT.0007D.E00

Clean the valve. 1 Check the pressure gauge.1 Check the outlet. 2 Regulate air outlet flow.2 SMT.0007R.E00

SMT.0007C.E00

76











TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

Replace the part.1 Check the diameter of the particles and switch to an adequate filtering degree.1 Follow the maintenance instructions.1

Replace the part.1 Check the diameter of the particles and switch to an adequate filtering degree.1 Follow the maintenance instructions.1

FILTERS

Dirty oil.1 SMT.0008D.E00

SMT.0008R.E00

4

SMT.0008R.E00

PRESSURE GAUGES Check and replace: the small broken pipe, the broken kinematic mechanism, the small pipe spring, the broken or deformed needle, the control shaft of the pressure gauge. 1 Check the pressure gauge against a sample instrument.1

Faulty pressure gauge.1 Wrong indication.1 SMT.0009D.E00

Imprecise pressure gauge.

SMT.0009C.E00

SMT.0009R.E00

GEARBOX AND TORQUE CONVERTER Low oil level.1 Pressure adjustment valve coupling blocked in open position.1 Faulty pump.1 Gear selection clutch low pressure.1

Top up1 Clean housing and fuse1 Replace pump1 Close line to power distributor. If the pressure returns to normal, the problem is in the distributor1

Faulty transmission.1 Piston or shaft grommets worn or broken.1 Clutch piston bleed valve blocked.1

Gear selection clutch high pressure .2

TMN40001.E.R0

Replace the grommets1 Clean the bleed valve1 Clean and check valve to make sure it is not worn or dirty. Replace if necessary2

Low pressure valve blocked in closed position.2











77

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

Low oil level.3 Suction filter blocked.3

4

Top up3 Clean3 Converter pump low Tighten unions or, if performance.3 Air in pump intake pipes.3 necessary, replace3 Faulty pump.3 Replace pump3 Oil grommets worn.4 Reposition converter4 Worn oil pump.4 Replace4 Low oil pressure.4 Top up4 Overheating.4 Air in intake line.4 Check and tighten unions4 Oil heat exchangers or pipes Clean and check the heat blocked.4 exchanger and pipes4 Dirty radiator fins.4 Clean the fins4 Worn gears.5 Replace5 Worn oil pump.5 Replace5 Noisy converter.5 Completely dismantle Turbine bearings faulty or the unit to find the worn worn.5 bearing5 Diesel engine fault.6 Check the diesel engine6 Low revs with converter Regulate the diesel engine stalled.6 and check the rev counter6 Power drop.6 Overheating.6 See Transmission Manual6 Converter pressure.6 See Transmission Manual6 Heat exchanger or oil pipe Check the heat exchanger blocked.7 and pipes7 High pressure exiting from Use recommended type of converter with engine at full Oil too viscose.7 oil7 speed and gear in neutral.7 When the converter heats, Cold oil.7 the pressure must drop7 The damage is to be Worn grommets and sought inside and requires gaskets.8 converter dismantling8 Low pressure exiting from converter.8 Worn oil pump.8 Replace8 SMT.0011D.E00 Safety valve blocked in open Clean and check the valve position.8 spring8 SMT.0011C.E00

78





SMT.0011R.E00







TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

STEERING Check and regulate the hydraulic pressure1 Remove and replace the pump1 Replace the power steering valve1 Check and adjust the pressure2

Oil pressure too low1 Stiff steering1

Faulty hydraulic pump1 Faulty power-steering valve1 Oil pressure to be regulated2

Steering not operating well2 SMT.0010D.E00

Internal leak in steering cylinder2

4

Remove and overhaul2 SMT.0010R.E00

SMT.0010C.E00

OVERLOAD CONTROL SYSTEM Complete system block1 System in alarm2

System block3 SMT.0012D.E00

Fuse or external cable damaged1 Faulty overload fuse1 Voltage not correct for single components2 Faulty proximity sensor3 Proximity sensor not correctly positioned3 Faulty motor or pump3 Pipes blocked or damaged3 Union leaks3

Replace1 Replace1 Check with manufacturer2 Replace3 Position correctly3 Replace3 Clean or replace3 Tighten or replace3

SMT.0012C.E00

TMN40001.E.R0









SMT.0012R.E00



79

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN PROBLEM

POSSIBLE FAULT

REMEDY

BRAKING SYSTEM Sudden braking1

4

Adjust the pressure under the pedal while checking the pressure by means of a pressure gauge1

Wrong pressure setting1

Dirty oil or loss of properties Replace the oil2 (noise levels increase)2 Insufficient braking (front Check the pressure and brakes)2 replace the seals or the The actuator cylinder is not cylinder if necessary 2 working properly2 Replace the oil-bath discs of the brake2 Insufficient braking (rear Worn disc brakes (noise Remove and replace the brakes - optional)3 levels increase)3 seals or change the cylinder3 The brake caliper is not Replace3 working properly3 Worn brake pads (noise Brake pressure not uniform4 Replace3 levels increase)3 Minimum pressure of Make sure the accumulator accumulator below max pressure is set correctly4 Continuous recharging of pressure of braking system4 batteries5 Battery nitrogen preloading Check accumulator preload5 too high or too low5 Braking capacity too high Regulate the accumulator for installed battery volume and/or check brake setting5 5 Feed pump always under pressure6 Worn pump6 Check the pump6 Dirty valve6 Clean the valve6 If the brake pedal is not Brake pedal not correctly freely released and pressure Brakes remain blocked7 released7 returns to the brakes, check pedal stop adjustment7 Regulate the pressure switch in the load valve, so this is at a pressure lower The indicator on the panel Wrong pressure switch than the minimum pressure does not light up or remains setting8 of the accumulator but on8 SMT.0014C.E00 SMT.0014D.E00 high enough to ensure 3 or 4 braking actions after the indicator has come on8 SMT.0014R.E00

80











TMN40001.E.R0

Maintenance Manual Reachstacker T45 - T45X - T45S Translation of original instructions

MN SECTION 5 - TRANSPORT AND ASSEMBLY Transporting and installing operations of the truck and its components must be done by people who are: • specialized in these operations • autorized and trained by the manufacturer • familiar with the machine, its components and its manual book If the manual is devoid of these instructions, contact contact Your TEREX technical service office.

Attention: The manufacturer is not liable for damages or injury caused by accidents caused from failure to follow instructions in this manual .

TMN50001.E.R0











81

5

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN SECTION 6 - INTERPRETATION OF SYMBOLS ATTACHMENTS SIMBOLI IDRAULICI Conformi alle specifiche CEI 3-25 pompe, compressori, pompe per vuoto pumps, compressor, vacuum pumps pompes, compresseurs, pompes à vide Pumpen, Verdichter, Vakuum-pumpen

6

pompa a cilindrata fissa fixed capacity pump pompes à cylindrée fixe Konstantpumpe

1 flow direction 2 flow direction

pompa a cilindrata variabile variable capacity pump pompe à cylindrée variable Verstellpumpe

1 flow direction 2 flow direction

compressore compressor compresseur Verdichter

always 1 flow direction

pompa per vuoto vacuum pump pompe à vide Vakuumpumpe

with environment discharge NOT ISO

motori motors moteurs Motoren motori idraulici hydraulic motors moteurs hydrauliques Hydromotoren motori a cilindrata fissa fixed capacity motor moteur à cylindrée fixe Konstantmotor

1 flow direction 2 flow direction

motore a cilindrata variabile variable capacity motor moteur à cylindrée variable Verstellmotor

82

1 flow direction 2 flow direction











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN motori pneumatici pneumatic motors moteurs pneumatiques Druckluftmotoren motore a cilindrata fissa fixed capacity motor moteur à cylindrée fixe Konstantmotor motore a cilindrata variabile variable capacity motor moteur à cylindré variable Verstellmotor

6

motore oscillante oscillating motor moteur oscillant Schwenkmotor

Hydraulic Pneumatic

pompe-motori pumps/motors units pompes-moteurs Pumpen-Motoren Inverted flow direction

pompa-motore a cilindrata fissa fixed capacity pump/motor unit pompes-moteur à cylindée fixe Konstantpumpe-Motor

1 flow direction 2 flow direction Inverted flow direction

pompa-motore a cilindrata variabile variable capacity pump/motor unit pompe-moteur à cylindrée variable Verstellpumpe-Motor

TMN60001.E.R0



1 flow direction 2 flow direction







83

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

variatore variable speed drive unit variateur Hydrokompaktgetriebe

6

cilindri cylinders vérins Zylinder

DETAILED

cilindro a semplice effetto single acting cylinder vérin à simple effet einfachwirkender Zylinder

SEMPLIFIED

Backing stroke: by unknow force

by a spring

simply rod

cilindro a doppio effetto double acting cylinder vérin à double effet doppeltwirkender Zylinder

twice rod

cilindro differenziale differential cylinder vérin différentiel Differentialzylinder cilindri con ammortizzatore cylinders with cushion vérins avec amortisseur Zylinder mit Dampfung from one side only

cilindro con ammortizzatore non regolabile cylinder with fixed cushion vérin avec amortisseur fixe Zylinder mit nicht verstellbarer Dampfung

84



both side









TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

cilindro con ammortizzatore regolabile cylinder with adjustable cushion vérin avec amortisseur réglable Zylinder mit verstellbarer Dampfung

from one side only both side

cilindro con impulso continuo cylinder with steady impulse vérin avec impulsion continue Zylinder mit Stetigantrieb

6 cilindro telescopico a semplice effetto single acting telescope cylinder vérin télescope à simple effet einfachwirkender Teleskopzylinder

backing stroke by external forces

cilindro telescopico a doppio effetto double acting telescope cylinder vérin télescope à double effet doppeltwirkender Teleskopzylinder

backing stroke by hydraulic system

DETAILED

SIMPLIFIED

moltiplicatori di pressione pressure intensifiers multiplicateurs de pression Druckubersetzer

scambiatori di pressione (aria - olio) air-oil actuators échangeurs de pression hydrauliques-pneumatiques Druckubersetzer distributori directional control valves distributeurs Wegeventile

TMN60001.E.R0









85

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN Device for pressure or flow regulation

quadrato singolo one single square une case einzel Quadrat

Hydraulic Pneumatic

Without discharge connection with tank discharge

6 due o più quadrati two or more squares plusieurs cases zwei or mehrere Quadrate

Pressure or flow distributor. The conne-ctions are shown as rest position Function positions are obtained by case shift.

segno grafico semplificato dell’apparecchio in caso di rappresentazione multipla simplified symbol for valves in cases of multiple repetition symbole simplifié d’appareil en cas de représentation multiple vereinfachtes Ventilsinnbild bei mehrfacher Wiederholung

vie o canali flow paths voies ou canaux Durchflusswege

1 way - 2 orifices 2 closed orifices 2 way - 4 orifices 2 way - 5 orifice (1 closed) 2 way transverse conn. 4 orifice 1 way in "by-pass" 4 orifice (2 closed)

86











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

distributori con posizioni fisse non-throttling directional control valves distributeurs sans étranglement nichtdrosselnde Wegeventile

2 service position

3 service position

with a middling position The first number is the first orifice.

6

The 2d, the position.

Pilot hole not shown.

Manual controlled. distributore 2/2 directional control valve 2/2 distributeur 2/2 2/2-Wegeventil

By pressure and retur-ning action spring (dis-charge).

By pressure from both side.

distributore 3/2 directional control valve 3/2 distributeur 3/2 3/2-Wegeventil

By solenoid control and returning action spring.

By solenoid control and returning action spring.

distributore 4/2 directional control valve 4/2 distributeur 4/2 4/2-Wegeventil

The same control valve with pilot distributor detailed.

Semplified distributore 5/2 directional control valve 5/2 distributeur 5/2 5/2-Wegeventil

TMN60001.E.R0

Pressure control both side.









87

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN a 2 stadi con asservimento meccanico two stage with mechanical feed-back à 2 étages avec asservissement mécanique zweistufiges elektrohydraulisches Servoventil mit mechanischer Ruckfurung

a 2 stadi con asservimento idraulico two stage with hydraulic feed-back à 2 étages avec asservissement hydraulique zweistufiges elektrohydraulisches Servoventil mit hydraulischer Ruckfiihrung

6 valvole unidirezionali non-return valves clapets de non-retour Sperrventile

Open, when the inlet pressure is bigger than outlet

valvola di non ritorno non-return spring loaded valve clapet de non-retour avec ressort Ruckschlagventil

Open, when the inlet pressure is bigger than outlet and spring force The closed position can be suppressed by the pilot

valvola di non ritorno pilotata pilot controlled non-return valve clapet de non-retour piloté ferngesteuertes Ruckschlagventil

The open position can be suppressed by the pilot

valvola di non ritorno con strozzamento one way restrictor clapet anti-retour avec étranglement Drosselruckschlagventil

The flow can be one direction only and restrictor in opposite direction

valvola selettiva di circuito shuttle valve sélecteur de circuit Wechselventil

The under pressure hole is automatically connected to outlet inlet closed

valvola di scappamento rapido rapid exhaust valve soupape d’echappement rapide Schnellentluftungsventil

In case of inlet pressure fall, the outlet is connected to open air

88











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN Rest position: normally closed one hole restricted

apparecchi di regolazione della pressione pressure control valves appareils de réglage de la pression Druckventile

Normally open one hole restricted 2 holes restricted

limitatore di pressione (valvola di sicurezza) pressure relief valve (safety valve) limiteur de pression (soupape de sureté) Druckbegrenzungsventil (Sicherheitsventil)

Pressure limitation on inlet hole by a discharge hole to the tank

limitatore di pressione a comando pilota pressure relief valve with remote pilot control limiteur de pression piloté par commande à distance ferngesteuertes Druckbegrenzungsventil

As above but the pressure is limited by an against force

limitatore proporzionale di pressione proportional pressure relief limiteur proportionnel de pression Druckstufenventil

The inlet pressure is limited by proportionally to pilot pressure

valvola di sequenza sequence valve soupape de séquence Zuschaltventil

With the inlet pressure bigger than the against spring force, the flow can go to the outlet hole

TMN60001.E.R0









6

89

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN riduttore di pressione pressure regulator or reducing valve (reducer of pressure) réducteur de pression ou détendeur Druckregelventil

without discharge hole

without discharge hole remote controlled

(the outlet pressure is constant independently to inlet pressure)

6

with discharge hole

riduttore di pressione pilotato pressure regulator with relief part, with remote control réducteur de pression avec orefice de décharge reglé a distance ferngesteuertes Druckregelventil

as above, but the outlet pressure is proportional to pilot pressure

riduttore di pressione differenziale differential pressure regulator reducteur de pression differentiel Druckgefalleventil

the outlet pressure is constant reduced relate to inlet pressure

the outlet press is reduced by a constant ratio with inlet pressure

riduttore di pressione proporzionale proportional pressure regulator réducteur de pression proportionnel Druckverhaltnisventil apparecchi di regolazione della portata flow control valves appareils de réglage du débit Stromventile

Manual controlled valvola di strozzamento throttle valve réducteur de débit Drosselventil

Mechanic controll with returning spring Simplified symbol

90











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN regolatore di portata flow control valve regulateur de debit geschaltetes Stromregelventil (2-Wege-Stromregelventil)

Detailed

Simplified (flow independent to functuating pressure)

As above, but with discharge to tank

regolatore di portata con ritorno in serbatoio by-pass flow control valve with relief port to reservoir regulateur de debit avec retour au réservoir parallelgeschaltetes Stromregelventil (3-Wege-Stromregelventil)

Detailed

6

Simplified

divisore di portata flow dividing valve diviseur de débit Stromteilerventil

The flow is divided about 50% each outlet

rubinetto d’isolamento shut-off valve robinet d’isolement Absperrventil

Simplified

sorgenti di energia sources of energy sources d’énergie Energiequellen

sorgente di pressione pressure source source de pression Druckquelle sorgente di pressione idraulica hydraulic pressure source source de pression hydraulique hydraulische Druckquelle

TMN60001.E.R0









91

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN sorgente di pressione pneumatica pneumatic pressure source source de pression pneumatique pneumatische Druckquelle motore elettrico electric motor moteur électrique Elektromotor

6

motore termico heat engine moteur thermique Verbrennungsmotor condotti e connessioni flow lines and connections conduites et connexions Leitungen und Verbindungen working return

tubazione flow line conduite Leitung

supply hose pilot hose typical leakage

tubazione flessibile flexible pipe conduite flexible biegsame Leitung

hose connected generally to mobile part

linea elettrica electric line életrique elektrische Leitung giunzione pipeline junction raccordement de conduites Leitungsverbindung incrocio crossed pipelines croisement de conduites Leitungskreuzung

without junction

air bleed discharge

spurgo d’aria e scarico d’aria air bleed and air exhaust port purge d’air et orifice d’evacuation d’air Entluftungestelle und Auslass ins Freie

92



without connections discharge with connections 







TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN diramazione power take-off prise Druckanschlusstelle

for measure and pressure check point:

innesto rapido quick-acting coupling raccordement rapide Schnellkupplung

connected:

closed with connected hose without non-return valve with non-return valve non connected:

open hose/pipe closed hose/pipe by non-return valve

giunto rotante rotary connection raccord rotatif Drehverbindung

6

hoses connection can rotate in service 1 way 3 ways

silenziatore silencer silencieux Schalldampfer open air

serbatoio reservoir réservoir Behalter

hose above the fluid level under fluid level with charge hose under pressure

accumulatori accumulators accumulateurs Druckspeicher accumulatore idraulico hydraulic accumulat or accumulateur hydraulique Hydrospeicher

fluid under pressure due to spring-load or compressed gas (air-nitrogen...)

accumulatore pneumatico pneumatic accumulator accumulateur pneumatique Druckluftspeicher TMN60001.E.R0









93

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN filtri, separatori, lubrificatori e apparecchi diversi filters, water traps, lubricators and miscellaneous apparatus filtres, lubrificateurs et appareillages divers Filter, Wasserabscheider, Schmier-und Wartungsgerate filtro filter filtre Filter

6

manual discharge

separatore di condensa water trap purgeur Wasserabscheider

automatic discharge manual discharge

filtro con spurgo filter with water trap filtre avec purgeur Filter mit Wasserabscheider

automatic discharge

essiccatore air dryer déshydrateur Trockner lubrificatore lubricator lubrificateur Oler gruppo di condizionamento conditioning unit groupe de conditionnement Wartungseinheit

scambiatori di calore heat exchangers échangeurs de chaleur Warmeaustauscher riscaldatore heater réchauffeur Vorwarmer 94

the arrows show the warm bringing











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN The arrows show the warm outlet: without cooler hoses

refrigeratore cooler refroidisseur Kuhler

with cooler hoses limitatore di temperatura temperature controller régulateur de température Temperaturbegrenzer

6 elementi meccanici mechanical components eléments mécaniques mechanische Bestandteile

albero rotante rotating shaft arbre tournant drehende Welle posizionatore detent dispositif de maintien en position Raste dispositivo di bloccaggio locking device dispositif de verrouillage Sperre dispositivo di scatto over-centre device basculeur Sprungwerk

articolazione pivoting device mécanisme d’articulation Gelenkverbindung

TMN60001.E.R0









95

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN general

comando manuale muscolar control commande manuelle Muskelkraftbetatigung

push button lever pedal

6

comando meccanico mechanical control commande mecanique mechanische Betatigung

finger spring roller roller single effect By coil

comando elettrico electrical control commande électrique elektrische Betatigung

1 coil 2 coil 2 coil variable action engine motor

comandi a pressione controls by application or release of pressure commandes par application ou par baisse de la pression Druckbetatigungen comando diretto direct acting control commande directe direkte Betatigung

by pression by depression by differential pressure

96











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN SIMBOLI ELETTRICI Conformi alle specifiche CEI 3-25

conduttore conductor conducteur

6

connessione di conduttori connection of conductor jointage de conducteurs

polo di una presa pole of a socket pole de une prise

polo di una spina polo of a plug born

terminale o morsetto terminal

TMN60001.E.R0









97

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

contatto di chiusura make contact contact de fermature

contatto di apertura break contact contact de ouverture

6 contatto di scambio con interruzione momentanea change-over break before make contact contact de échange avec interrption

contatto a due vie e a tre posizioni, con posizione centrale di apertura two-way contact with centre-off position contact à 3 positions avec contact centrale de ouverture

comando meccanico manuale (general symbol) manually operated control, general symbol commande mécanique manuel (symbole général) comando a pulsante operated by pushing commande à poussoir

comando a chiave operated by key commande à clef

98











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

contatto di chiusura make contact contact de fermature

contatto di apertura break contact contact de ouverture

6 contatto di scambio con interruzione momentanea change-over break before make contact contact de échange avec interrption

contatto a due vie e a tre posizioni, con posizione centrale di apertura two-way contact with centre-off position contact à 3 positions avec contact centrale de ouverture

comando meccanico manuale (general symbol) manually operated control, general symbol commande mécanique manuel (symbole général) comando a pulsante operated by pushing commande à poussoir

comando a chiave operated by key commande à clef

TMN60001.E.R0

t









99

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

massa, telaio frame, chassis chàssis +

batteria di accumulatori battery batterie -

6 fusibile (segno generale) fuse, general symbol fusible (symbole général)

resistore (segno generale) resistor, general symbol résistor (symbole général)

resistore variabile variabile resistor résistor variable

elemento riscaldante heating element élément de chauffage

diodo a semiconduttore (segno generale) semiconductor diode, general symbol diode à semiconducteur (symbole général)

100











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

M

massa, telaio frame, chassis chàssis

batteria di accumulatori battery batterie

G

6 fusibile (segno generale) fuse, general symbol fusible (symbole général)

resistore (segno generale) resistor, general symbol résistor (symbole général)

resistore variabile variabile resistor résistor variable

elemento riscaldante heating element élément de chauffage

TMN60001.E.R0









101

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

M

motorino avviamento starter moteur de démarrage

sensore di prossimità prosimity switch interrupteur de proximité

6

ton

cella di carico charging cell cellule de charge

inclinometro inclinometer inclinomètre

dispositivo, apparecchiatura, unità funzionale item, equipment, functional unit dispositif, appareillage, unité fonctionel

commutatore complesso (segno generale) general switch, general symbol commutateur complexe (symbole général)

elettrovalvola solenoid valve soupape électrique

contaore hours counter compteur heure

102

h











TMN60001.E.R0

Manuale di Manutenzione Reachstacker T45 - T45X - T45S Istruzioni originali

MN

6

TMN60001.E.R0









103