OM PIMESPO TSX Type 4522 CTX Type 4523 CTXi Type 4535 WORKSHOP MANUAL – PDF DOWNLOAD
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OM PIMESPO TSX Type 4522 CTX Type 4523 CTXi Type 4535 WORKSHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 680
Downloadable : Yes
File Type : PDF
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OM PIMESPO TSX Type 4522 CTX Type 4523 CTXi Type 4535 WORKSHOP MANUAL – PDF DOWNLOAD
General Safety Rules
Accident Prevention
The majority of mishaps or accidents in the workshop occur because someone failed to observe the basic, simple safety precautions and standards in place. Most accidents and their consequences can be avoided if everyone exercised the necessary caution and good sense to prevent them from happening in the first place. No matter how well a machine has been engineered or built it is impossible to eliminate all the causes of accidents, but a careful and prudent mechanic can offer the best guarantee against mishaps. Many serious accidents can be avoided simply by paying scrupulous attention to a single, basic safety precaution.
SAFETY INSTRUCTIONS
General description
Follow all maintenance and repair procedures carefully
- Do not wear rings, wristwatches, jewelry, or loose, dangling, or torn clothing such as ties and scarves, or unbuttoned or unzipped jackets that could become caught in moving parts. Wear approved, protective clothing such as hard hats, non-slip shoes, gloves, and safety glasses. Do not service the machine with someone in the operator’s seat, unless it is a qualified technician helping with the maintenance operations.
- Do not operate the machine or its equipment from anywhere except the operator’s seat. Stop the engine and make sure that the pressure has been released from all hydraulic systems before removing caps or covers. Refer to the appropriate instructions in this manual.
- Take all the necessary precautions when performing any service operation. Make sure that ladders and service platforms used in the shop or at the site comply with current safety standards. Label all the controls to indicate that the vehicle is being serviced.
- Place blocks under the machine or any part that must be lifted. Do not smoke while checking or topping up the battery due to the flammability of the fluids. Stabilize the machine with blocks or other similar devices because the brakes become inactive when released manually for the purposes of servicing the machine. Use a trailer or lowered flatbed truck, if available, to transport a broken down machine.
- Load and unload the machine onto or from the transport vehicle on a flat surface that firmly supports the wheels of the trailer or the truck. Secure the machine firmly to the flatbed of the truck or trailer and block the wheels.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
OM PIMESPO TSX Type 4522 CTX Type 4523 CTXi Type 4535 WORKSHOP MANUAL – PDF DOWNLOAD
Workshop Manual General Table of Contents
General Safety Rules Page 1
Accident prevention Page 1
Safety instructions Page 1
Electrical system Page 3
Hydraulic system Page 3
Detachment and reattachment of parts Page 3
Part I – TSX
Introduction Page I – 1.1
Description Page I – 1.1
Technical specifications Page I – 1.2
Fork tolerances table Page I – 1.4
Speed tolerances table Page I – 1.4
Standards and certifications Page I – 1.5
Operating position Page I – 1.6
Environmental operating conditions Page I – 1.7
Documentation provided with the truck Page I – 1.8
Inspection and maintenance table Page I – 1.9
Primary screws and tightening torques table Page I – 1.10
Motor brushes wear table Page I – 1.10
Manifold minimum diameter table Page I – 1.10
Batteries Page I – 2.1
Battery dimensions and weights Page I – 2.1
Battery connectors (plug and socket) Page I – 2.1
Extra socket set for double shifts (Optional) Page I – 2.1
Battery replacement Page I – 2.2
Fixed/movable battery rack (Optional) Page I – 2.2
Battery removal Page I – 2.3
Built-in rectifier (Optional) Page I – 2.3
Plug and socket parts list table Page I – 2.12
Truck body Page I – 3.1
Dashboard-controls-instruments Page I – 3.1
Emergency stop button Page I – 3.1
Ignition switch Page I – 3.1
I.B.S. + hour meter instrument Page I – 3.2
Battery charger power cable access compartment (optional) Page I – 3.4
Motor compartment hood removal Page I – 3.5
Battery compartment removal Page I – 3.9
Hood assembly Page I – 3.10
Separation of the movable frames Page I – 3.11
Location of the identification plates and stickers Page I – 3.14
Series 4522-4523
Index
Edition September 2001
Updating March 2002 Index Page 2
Traction unit Page I – 4.1
Traction speed Page I – 4.1
Speed limit when traveling in the direction of the operator Page I – 4.1
Automatic speed reduction when curving Page I – 4.1
Traction lockout Page I – 4.2
Traction motor Page I – 4.2
Traction motor and reducer unit removal Page I – 4.2
Traction motor overhaul Page I – 4.10
Reducer unit drawing Page I – 4.18
Reducer unit overhaul Page I – 4.20
Crown wheel assembly drawing Page I – 4.25
Reducer unit and traction motor assembly Page I – 4.26
Traction unit assembly diagram Page I – 4.29
Traction unit parts list table Page I – 4.30
Traction motor replacement Page I – 4.31
Traction motor assembly Page I – 4.36
Braking system Page I – 5.1
Electromagnetic brake Page I – 5.1
Electromagnetic brake calibration table Page I – 5.1
Description of the electromagnetic brake Page I – 5.2
Description of the electromagnetic brake plates Page I – 5.3
Power, voltage, coil resistance Page I – 5.4
Tools required for the electromagnetic brake Page I – 5.5
Friction disk assembly for sizes 06-16 Page I – 5.6
Brake flange assembly Page I – 5.6
Electromagnetic brake assembly steps Page I – 5.7
Rubber protector assembly Page I – 5.9
Electrohydraulic bracke (optional) Page I – 5.10
Regenerative braking Page I – 5.10
Electromagnetic brake assembly diagram Page I – 5.11
Electromagnetic brake wiring diagram Page I – 5.12
Rollers and levers Page I – 6.1
Load rollers and pallet entry rollers Page I – 6.1
Lever removal Page I – 6.2
Bushing removal and replacement Page I – 6.9
Lever assembly Page I – 6.11
Series 4522-4523
Index
Edition September 2001
Updating March 2002 Index Page 3
Tiller unit Page I – 7.1
Tiller head controls Page I – 7.1
Tiller body Page I – 7.1
Tiller card / COMBI system connection diagram Page I – 7.2
Traction control butterfly-shaped lever Page I – 7.3
Traction accelerator potentiometer Page I – 7.3
The redundant potentiometer Page I – 7.4
Tiller safety button Page I – 7.4
Tiller head buttons Page I – 7.5
Tiller unit removal Page I – 7.6
Tiller arm assembly (front view) Page I – 7.13
Tiller arm assembly (side view) Page I – 7.14
Tiller arm assembly (below-above) Page I – 7.15
Tiller arm parts list table Page I – 7.16
Tie rod barrel overhaul Page I – 7.17
Tiller unit assembly Page I – 7.19
Tiller wiring diagram (front view) Page I – 7.20
Tiller wiring diagram (side view) Page I – 7.21
Tiller arm parts list table Page I – 7.22
Tiller unit calibration Page I – 7.23
Traction potentiometer replacement Page I – 7.24
Traction control unit Page I – 7.29
Traction potentiometer Page I – 7.31
Tiller card Page I – 7.33
Tiller sheath Page I – 7.36
Movable operator side panels Page I – 8.1
Operator side panel positions Page I – 8.1
Enabling traction Page I – 8.2
Side panel unit removal Page I – 8.3
Side panel assembly diagram Page I – 8.5
Hub pair assembly diagram Page I – 8.6
Side panel unit parts list table Page I – 8.6
Movable operator platform Page I – 9.1
Operator platform positions Page I – 9.2
Platform removal Page I – 9.3
Platform assembly diagram Page I – 9.5
Sprag assembly diagram Page I – 9.6
Platform assembly parts list table Page I – 9.6
Sprag removal Page I – 9.7
Platform assembly Page I – 9.8
Fixed spring platform and fixed side panels without
backrest (OPT) Page I – 9.11
Fixed spring platform with backrest (OPT) Page I – 9.12
Fixed spring platform with backrest parts list table Page I – 9.13
New movable operator platform Page I – 9.14
Series 4522-4523
Index
Edition September 2001
Updating March 2002 Index Page 4
Sprag assembly diagram Page I – 9.15
New operator platform parts list table Page I – 9.16
General notes about the new operator platform Page I – 9.16
Hydraulic castor wheel unit Page I – 10.1
Smart hydraulic castor wheels (OM Pimespo patent) Page I – 10.1
Operating principle Page I – 10.1
Functioning of the valves under different operating conditions Page I – 10.3
Castor wheel unit removal Page I – 10.5
Castor wheel unit Page I – 10.11
Castor wheel unit assembly diagram Page I – 10.12
Wheel assembly diagram Page I – 10.13
Castor wheel unit parts list table Page I – 10.14
Castor wheel assembly parts list table Page I – 10.14
Castor wheel removal Page I – 10.14
Castor wheel hydraulic system diagram Page I – 10.15
Castor wheel hydraulic system overhaul Page I – 10.16
First method of bleeding the hydraulic system Page I – 10.17
Second method of bleeding the hydraulic system Page I – 10.21
Third method of bleeding the castor wheel hydraulic system Page I – 10.23
New castor wheel unit oil reservoir Page I – 10.25
Hydraulic lifting system Page I – 11.1
Lifting, lowering, and interlock mechanism Page I – 11.1
Hydraulic system motors Page I – 11.1
TSX 2000 Kg hydraulic lifting system diagram Page I – 11.2
TSX 3000 Kg hydraulic lifting system diagram Page I – 11.3
Electropump unit removal Page I – 11.4
Electropump unit assembly Page I – 11.6
Lift cylinder removal Page I – 11.7
Lift cylinder overhaul Page I – 11.11
Lift cylinder assembly Page I – 11.15
Lift cylinder assembly parts list table Page I – 11.16
Lift cylinder assembling Page I – 11.17
Traction wheel Page I – 12.1
Drive wheel Page I – 12.1
Slick rubber drive wheel version Page I – 12.1
Traction wheel replacement Page I – 12.2
Lubrication Page I – 13.1
Reducer oil top up Page I – 13.1
Hydraulic oil top up Page I – 13.2
Greasing Page I – 13.3
Greasing the castor wheel hubs Page I – 13.5
Greasing the L.E.S. gear motor pinion Page I – 13.5
Lubricants table Page I – 13.6
Series 4522-4523
Index
Edition September 2001
Updating March 2002 Index Page 5
COMBI System Page I – 14.1
COMBI specifications Page I – 14.1
COMBI system assembly Page I – 14.3
Pump motor control diagram Page I – 14.4
Armature control diagram Page I – 14.5
Field control diagram Page I – 14.6
Energy recovery Page I – 14.8
COMBI Diagnostics Page I – 14.9
List of menus Page I – 14.10
Parameter Change Page I – 14.11
Signal monitoring Page I – 14.13
Programming the accelerator voltage Page I – 14.15
Config menu Page I – 14.16
Pimespo menu Page I – 14.18
Allarms Page I – 14.19
Replacement of the COMBI system EPROM Page I – 14.23
Evolution of the EPROM Page I – 14.27
COMBI system input/output diagram for the TSX Page I – 14.28
Comments about EPROM updates Page I – 14.30
Maximum speed reduction in both directions of travel Page I – 14.30
Electrical system Page I – 15.1
Sheaths and connectors Page I – 15.1
Fuse protection Page I – 15.1
Sensor and connectors Page I – 15.2
Functional diagram Page I – 15.5
Cable and sheath location diagram Page I – 15.6
Electrical diagram Page I – 15.9
Overall sheath diagram Page I – 15.12
Sensor connection diagram (preproduction) Page I – 15.16
Sensor connection diagram Page I – 15.19
Series 4522-4523
Index
Edition September 2001
Updating March 2002 Index Page 6
L.E.S.Electric Drive Page I – 16.1
Steering System Page I – 16.1
L.E.S. EPROM Releases Pege I – 16.2
L.E.S. Electronic control module Page I – 16.3
L.E.S. control unit inputs/outputs table Page I – 16.4
Diagnostic through PC with “Service” Software Page I – 16.5
Menù description Page I – 16.6
Menù diagram Page I – 16.7
Description of displayed parameters Page I – 16.8
Parameter setting Page I – 16.9
Troubleshooting Page I – 16.9
Allarms Page I – 16.10
Allarm table Page I – 16.11
Electric drive reduction unit assembly Page I – 16.15
Electric drive reduction unit assembly details Page I – 16.16
Electric drive unit removal Page I – 16.17
Electric drive unit overhauling Page I – 16.20
Electric drive calibration Page I – 16.31
L.E.S. interface connection diagram Page I – 16.33
Electric setpoint calibration Page I – 16.37
Steering potentiometer calibration test Page I – 16.40
Driving wheel potentiometer calibration test Page I – 16.41
L.E.S. System Eprom Replacemet Page I – 16.45
L.E.S. System Connector removal and introduction Page I – 16.47
Thermal sensor for L.E.S. – gearmotor Page I – 16.48
Fan for L.E.S. gearmotor Page I – 16.49
3K1 relay replacement Page I – 16.50
Electric drive input/output diagram Page I – 16.51
Steering potentiometer diagram Page I – 16.53
Driving wheel potentiometer diagram Page I – 16.56
Electric drive sheath diagram Page I – 16.59
Optionals Page I – 17.1
Summary table Page I – 17.1
Notes for the technician Page I – 18.1
Percussion extractor Page I – 18.2
Threaded pins for the percussion extractor Page I – 18.3
Spring preloading tool for the tiller Page I – 18.4
Insertion and extraction tool for the lift cylinder Page I – 18.4
Plug for the castor wheel hydraulic unit Page I – 18.5
Platform for bleeding the castor wheel unit Page I – 18.6
Centering tool for the TSX – CTX tiller arm Page I – 18.7
Centering tool for the TSX – CTX tiller arm Page I – 18.9
Centering tool for the TSX reducer unit Page I – 18.11
Centering tool for the CTX reducer unit Page I – 18.13
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