Fantuzzi Reggiane Forklift FDC 500 G5 Operator & Parts + Electrical & Hydraulic Diagrams Manual

Fantuzzi Reggiane Forklift FDC 500 G5 Operator & Parts manual + Electrical & Hydraulic Diagrams Manual – PDF DOWNLOAD

FILE DETAILS:

Fantuzzi Reggiane Forklift FDC 500 G5 Operator & Parts manual + Electrical & Hydraulic Diagrams Manual – PDF DOWNLOAD

Language : English
Pages :658
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Fantuzzi Reggiane Forklift FDC 500 G5 Operator & Parts manual + Electrical & Hydraulic Diagrams Manual – PDF DOWNLOAD

Operator & Maintenance Manual 1
Operator’s Manual 3
Index 5
Introduction 7
Foreword 7
Use of the manual 7
Symbols used in the manual 8
Sign plates 8
General information 9
General safety precautions 9
Instructions for truck operation and use 10
Warning notice 10
Personnel training 10
Operator’s responsabilities 11
Warranty 11
After-sales service 11
Dismantling and scrapping the truck 12
Product disposal 12
First aid 12
Section 1 – General Information 13
General description & orientation 13
Dimensions 14
FDC 500 G5 14
FDC 450 G4 15
FDC 420 G3 16
Maximum lifting capacity 14
FDC 500 G5 14
FDC 450 G4 15
FDC 420 G3 16
Technical specifications 17
FDC 500 G5 17
FDC 450 G4 18
FDC 420 G3 19
Motor table 20
Important notice regarding braking 21
Section 2 – General safety 23
General information 23
Local laws 23
Using common sense 23
Terminology 24
Safety responsibility of the operator 25
General operating guidelines for safe operations 26
Protection 29
Get on and get down 29
Electric line 30
Operating in wind 32
Scapping the machine 32
Section 3 – Grouncrew safety guidelines 33
Communication between operator and groundcrew 33
Recommended safety guidelines for groundcrew 34
Responsibilities of the groundcrew for safe operation 35
Section 4 – Operator’s controls 37
Introduction 37
Instrument layout 38
Dashboard 39
Pedals 40
Brake pedal with switch 40
Instruments 41
Indicator lights 41
Upper beam headlight indicator 41
Blocked oil filter indicator 41
Low motor oil pressure indicator 41
Blocked air filter indicator 41
Battery recharge fault indicator 42
Parking brake indicator 42
Low transmission oil level indicator 42
Low brake oil pressure indicator 42
Side light indicator 43
Direction indicators working indicator 43
Glow plug preheating indicator 43
Neutral gear engaged indicator 44
Twistlock light 44
Low differential oil pressure indicator 44
Measuring instruments 45
Hour counter 45
Transmission oil thermometer 45
Fuel level indicator 45
Battery voltmeter 46
Revolution counter 46
Engine coolant thermometer 46
Control switches 47
Front windshield wiper and washer 47
Upper windshield wiper 47
Rear windshield wiper 47
Window Defrosters 47
Parking brake button 48
Emergency button 48
Work light switch 48
Right or left rotation selection switch 49
Free rotation lock switch 49
Spreader opening-closing button 50
Engine revolution adjustment button 50
Cab movement button 51
Shiftronic reset button 51
Ventilation system controls 52
Heating adjustment knob 52
Air Conditioning adjustment knob 52
Fan speed adjustment knob 52
Keys 53
Ignition key 53
Gear change mode selection key 53
Moving cab automation interruption key 53
Key for opening/closing spreader with twistlocks secured 53
Bromma spreader release key 54
Safety bypass keys 55
Lifting bypass key 55
Twistlock bypass key 56
Power cabinet for FDC 500 56
Gear selector 57
Direction indicator – horn – lights lever 58
Joystick control 59
Mast luffing 60
Lift – Lower the spreader 60
Spreader translation and rotation controls 61
Twistlock rotation control 61
Spreader side-sloping function 62
Motor control indicator lights 63
QSM11 – Fault code information 64
Seat adjustments 67
Section 5 – Operating procedures 69
Introduction 69
Pre-operational inspection 71
Prior to starting the engine 71
After starting the engine (running at idle) 71
Motor Oil Level 72
Motor coolant level 73
Hydraulic Oil Level 74
Transmission oil level 74
Leaks 75
Fuel tank 76
Tyres 77
Operator’s Cab 78
Operator ’s Controls 78
Dry powder fire extinguisher (optional) 78
Structure 79
Lights 79
Warning Devices 80
Windshield Wipers 80
Welding 81
Engine start-up procedures 82
Normal Start 83
Cold Weather Start 84
Using Booster Batteries or Starting Generators 85
Machine heating up procedure 87
Stopping the engine 88
Driving 89
Traslations 90
General information 90
Speed 91
Operating on gradients (slopes) 91
Steering 92
Load handling 93
Lifting unit controls 93
Picking up a stacked container 94
Procedure for picking up a stacked container 95
Stacking a container 96
Container stacking procedure 97
Parking procedures 98
Towing 99
Section 6 – Warranty100
General Warranty Conditions100
International Warranty102
Introduction102
Production Changes102
Warranty Period102
Test prior to delivery103
Items covered by the warranty104
Maintenance manual107
Index109
Introduction111
Section 1 – General Information113
General information113
Personnel employed113
Inspection schedule113
General precaution concerning maintenance114
Check register115
Section 2 – Planned Maintenance127
How to refer to the maintenance instructions127
List of checks for maintenance128
General filling instructions134
Filling table FDC 100 – FDC 120135
Filling table FDC 150 – FDC 160 – FDC 180136
Filling table FDC 18 K – FDC 20 K137
Filling table FDC 25 K138
Filling table FDC 200139
Filling table FDC 240 – FDC 250140
Filling table FDC 280 – FDC 320 – FDC 350141
Filling rable FDC 380 – FDC 420 – FDC 450142
Filling table FDC 500143
Oil comparison table144
Section 3 – Structure145
Main frame145
Function145
Safety precautions145
Service145
Pins147
Function147
Safety precautions147
Service147
Section 4 – Diesel Engine149
Diesel motor149
Radiator150
Funtion150
Safety precaution150
Service150
Fume exhaust system151
Function151
Safety precautions151
Service151
Fuel system152
Function152
Safety precaution152
Service152
Section 5 – Transmission153
Transmission153
Function153
Safety precautions153
Service153
Automatic transmission154
Function154
Automatic mode154
Manual mode155
Safety functions155
Connection155
Section 6 – Drive axle159
Differential axle159
Function159
Safety precautions160
Service161
Cardan shafts162
Function162
Safety precautions162
Service162
Section 7 – Steering axle163
Steering axle163
Function163
Safety precautions163
Service164
Axle structure165
Section 8 – Wheels167
Wheels167
Function167
Safety precautions167
Service168
Wheel and tyre fitting170
Materials required170
First stage170
Second Stage171
Third stage171
Fourth Stage172
Fifth Stage173
Periodical maintenance174
Procedure174
Tyre removal175
Removal procedure175
Rims176
Maintenance176
Checking the rims177
Section 9 – Hoist179
Description179
Thrust shoes181
Lifting chain182
Function182
Precautions183
Servicing183
Periodic inspection points184
Checking for wear187
Fork dimensional checks187
Fork inclination check188
Fork shape checks189
Fork straightness check190
Recommended non-destructive checks191
Section 10 – Equipment192
Spreader192
Function192
Technical specifications193
Spreader type193
Dimensions193
Operations194
Side shift194
Pile sloping194
Electrical System194
Hydraulic system194
Lifting capacity194
Weight194
Surface treatment194
How to replace the twistlock195
Maintenance196
Greasing points197
Section 11 – Hydraulic system198
Hydraulic system198
Safety precautions198
Hydraulic fluid sump199
Function199
Safety precautions199
Service199
Pumps201
Function201
Safety precautions201
Service202
Considerations202
Motors203
Function203
Service203
Hydraulic cylinders204
Function204
Safety precautions204
Service204
Hydraulic accumulators205
Function205
Safety precautions205
Service205
Fluid cooling circuit206
Function206
Safety precautions206
Service206
Distributors207
Function207
Safety precautions207
Service207
Section 12 – Electrical System208
Batteries208
Function208
Safety precautions208
Service208
Limit switch209
Function209
Safety precautions209
Service209
Electrical controls210
Function210
Safety precautions210
Service210
Section 13 – Air Conditioning System212
Refrigeration cycle diagram212
Heating system – conditioner213
Heating evaporator unit214
Compressor215
Evaporator216
Condenser217
Filter218
Filter head219
Pressure switch trinary220
Expansion valve221
Thermostat222
Test check223
Diagnosis of A/C system failure224
System malfuction225
The system doesn’t cool225
The system undercool226
Section 14 – Painting228
Paint228
Function228
Safety warnings228
Service228
Section 15 – Troubleshooting230
Troubleshooting230
Function230
Safety precautions230
Fault diagnosis231
Diesel engine231
Hydraulic motors234
Pumps237
Maximum pressure valve241
Check valve242
Direction adjustment valves242
Pressure adjustment valve243
Filters244
Pressure gauges244
Gearbox and torque converter245
Steering249
Overload control system250
Braking system251
Inching253
Section 16 – Technical Data254
Torque wrench setting254
Conversion chart and formulas255
Section 17 – Graphic Symbols258
Hydraulic Graphic Symbols258
Electrical Graphich Symbols274
Section 18 – Schematics280
Hydraulic System280
Electrical System280
Hydraulic schematic282
Component list283
Schematics284
Electric Diagram288
Legend289
Color code289
The component of electric system290
Plug and junction box list291
Component list292
Diagrams299
QSM11 viring diagram315
General layout316
Dashboard layout317
Steering column318
Joystick column322
Cabin uses324
Dead man device325
Electric box layout326
Spreader – joystick board330
joystick board331
Spreader333
Spare Parts340
Consulting the catalogue341
Sub group number index349
Analitic index370
Group index398

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