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BT Forklift LPE200, LPE220 Repair Manual – PDF DOWNLOAD
BT Forklift LPE200, LPE220 Repair Manual – PDF DOWNLOAD
FILE DETAILS:
BT Forklift LPE200, LPE220 Repair Manual – PDF DOWNLOAD
Language : English
Pages : 614
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift LPE200, LPE220 Repair Manual – PDF DOWNLOAD
1. Contents................................................................................................0 2. General introduction....................................................................................0 2.1 How to use this manual.............................................................................0 2.2 Warning levels and symbols.........................................................................0 2.3 Pictograms.........................................................................................0 3. General safety rules....................................................................................0 3.1 Work safety........................................................................................0 3.2 Electrical systems.................................................................................0 3.3 Safe lifting.......................................................................................0 3.4 Truck modifications................................................................................0 4. Operation and connection sequences......................................................................0 Symbols on keypad and display..........................................................................0 4.1 Battery is connected...............................................................................0 4.2 Login via keypad...................................................................................0 4.3 Tiller arm lowered for driving.....................................................................0 4.4 Driving in fork direction..........................................................................0 4.5 Driving in the drive wheel direction...............................................................0 4.6 Neutral position braking...........................................................................0 4.7 Reverse braking....................................................................................0 4.8 Mechanical braking.................................................................................0 4.9 Emergency reversal.................................................................................0 4.10 Fork lifting......................................................................................0 4.11 Fork lowering.....................................................................................0 5. Parameters..............................................................................................0 5.1 General parameters.................................................................................0 5.1.1 Show/change parameters.......................................................................0 5.2 Operator parameters................................................................................0 5.2.1 Overview.....................................................................................0 5.2.2 Connection to logged-in operator.............................................................0 Description of operator parameters.............................................................0 Parameters 1, 2, 5, 6 and 7 – Maximum travel speed.............................................0 Parameters 3 and 4 – Acceleration/Deceleration.................................................0 5.3 General service parameters.........................................................................0 5.3.1 Overview.....................................................................................0 5.3.2 Description..................................................................................0 Parameter 101/104 – Service/Log-out............................................................0 Verifying parameter settings for freely ventilated batteries (lead-acid batteries).............0 Verifying the parameter setting for valve-regulated batteries (Exide)..........................0 5.4 Service parameters, travel functions...............................................................0 5.4.1 Overview.....................................................................................0 5.4.2 Description..................................................................................0 5.5 Service parameters, hydraulic functions............................................................0 5.5.1 Description..................................................................................0 5.6 Factory parameters.................................................................................0 5.6.1 Overview.....................................................................................0 5.6.2 Description..................................................................................0 Factory parameters # 1003 to 1042 - configurable optional functions............................0 5.7 Calibration parameters.............................................................................0 5.7.1 Overview.....................................................................................0 5.8 Calibration........................................................................................0 5.8.1 Steering angle calibration “1”...............................................................0 5.8.2 Calibration “2” (Not applicable).............................................................0 5.8.3 Calibration of weight measuring "3"..........................................................0 5.8.4 Calibration “4” (Not applicable).............................................................0 5.8.5 Calibration “5” (Not applicable).............................................................0 5.8.6 Calibration of weight measuring "6"..........................................................0 5.8.7 Calibration “7” (Not applicable).............................................................0 5.8.8 Calibration “8” (Not applicable).............................................................0 5.8.9 Calibration “9” (Not applicable).............................................................0 5.8.10 Steering angle manual steering "10".........................................................0 5.8.11 Calibration of weight measuring "11"........................................................0 6. Installation and commissioning..........................................................................0 6.1 Transporting the truck.............................................................................0 6.2 Transporting the fork carriage.....................................................................0 6.3 Lifting the truck..................................................................................0 6.3.1 Lift using an eye bolt.......................................................................0 6.3.2 Lift using a jack............................................................................0 6.4 Battery installation...............................................................................0 6.4.1 Safety for battery handling..................................................................0 6.4.2 Installing the battery.......................................................................0 6.5 Using PIN codes....................................................................................0 6.5.1 General......................................................................................0 6.5.2 PIN code for resetting after a collision.....................................................0 6.5.3 Programming PIN codes........................................................................0 6.5.4 PIN code defaults............................................................................0 6.6 Setting parameters.................................................................................0 6.6.1 Setting impact sensor parameters (option)....................................................0 6.6.2 Setting battery parameters...................................................................0 6.7 Function check.....................................................................................0 7. Maintenance.............................................................................................0 7.1 Introduction.......................................................................................0 7.2 Maintenance instructions...........................................................................0 7.2.1 Cleaning and washing.........................................................................0 7.2.2 High-pressure washers........................................................................0 7.2.3 Degreasing agents............................................................................0 7.2.4 Cleaning the exterior........................................................................0 7.2.5 Cleaning the chain...........................................................................0 7.2.6 Cleaning the motor compartment...............................................................0 7.2.7 Electric components..........................................................................0 7.3 Oil and grease specification.......................................................................0 7.4 Symbols............................................................................................0 7.5 Periodic maintenance...............................................................................0 8. Troubleshooting.........................................................................................0 8.1 Towing a defective truck...........................................................................0 Tow using a tow truck and tow wagon:...............................................................0 8.2 Auxiliary functions................................................................................0 8.2.1 Emergency driving mode.......................................................................0 8.3 Error code history.................................................................................0 8.3.1 Extended error log...........................................................................0 8.4 Error code system..................................................................................0 8.5 Error codes........................................................................................0 8.6 Service information................................................................................0 8.7 Digital input/output status........................................................................0 8.7.1 Test mode “9” –..............................................................................0 8.7.2 Test mode “12” – Expansion unit SEU (option).................................................0 8.8 Built-in test function for the tiller arm..........................................................0 8.8.1 Display test.................................................................................0 8.8.2 Speed control................................................................................0 8.8.3 Safety reversing.............................................................................0 8.8.4 Controls for lifting/lowering................................................................0 8.8.5 Sensilift....................................................................................0 8.8.6 Keypad.......................................................................................0 9. Chassis C0000...........................................................................................0 9.0.1 Overview.........................................................................................0 9.1 Inspection covers C0340............................................................................0 9.1.1 Overview.....................................................................................0 9.1.2 Replacing the service cover..................................................................0 Removing the service cover.....................................................................0 Fitting the service cover......................................................................0 9.1.3 Replacing a side cover.......................................................................0 Removing a side cover..........................................................................0 Installing a side cover........................................................................0 9.1.4 Replacing the cover (without gate)...........................................................0 Removing the cover (without gate)..............................................................0 Fitting the cover (without gate)...............................................................0 9.1.5 Replacing the gate cover.....................................................................0 Remove the gate cover..........................................................................0 Fitting the gate cover.........................................................................0 9.1.6 Replacing a badge cover......................................................................0 Removing a badge cover.........................................................................0 Installing a badge cover.......................................................................0 9.1.7 Replacing an upper cover.....................................................................0 Removing an upper cover........................................................................0 Fitting the upper cover........................................................................0 9.1.8 Replacing the steering adapter cover.........................................................0 Removing the steering adapter cover............................................................0 Installing the steering adapter cover..........................................................0 9.1.9 Replacing the rubber seals...................................................................0 Removing rubber seals..........................................................................0 Installing rubber seals........................................................................0 9.2 Fork frame C0380...................................................................................0 9.2.1 Overview fork frame..........................................................................0 9.2.2 Replacing the fork carriage..................................................................0 Removing the fork carriage.....................................................................0 Installing the fork carriage...................................................................0 9.2.3 Checking the fork carriage...................................................................0 9.2.4 Replacing the torsion tube-linkage-wheel fork................................................0 Removing the torsion tube-linkage-wheel fork...................................................0 Fitting the torsion tube-linkage-wheel fork....................................................0 9.2.5 Checking the torsion tube-linkage-wheel fork.................................................0 9.2.6 Replacing the roller on the torsion tube.....................................................0 Removing the roller on the torsion tube........................................................0 Fit the roller on the torsion tube.............................................................0 9.2.7 Weld the push rod............................................................................0 9.3 Battery compartment parts C0390....................................................................0 9.3.1 Battery lock, fixed..........................................................................0 Overview.......................................................................................0 Description....................................................................................0 9.3.2 Battery lock, quick..........................................................................0 Overview.......................................................................................0 Description....................................................................................0 9.4 Drive unit suspension C0450........................................................................0 9.4.1 Overview.....................................................................................0 Table showing suspension/PT cylinder mechanical steering.......................................0 9.4.2 Overview,....................................................................................0 Table showing suspension/PT cylinder power steering............................................0 Table showing suspension/PT cylinder mechanical steering.......................................0 Description....................................................................................0 9.4.3 Replacing the drive unit suspension..........................................................0 Removing the small drive unit suspension.......................................................0 Fitting the small drive unit suspension........................................................0 Removing the large drive unit suspension.......................................................0 Fitting the large drive unit suspension........................................................0 9.4.4 Relieving spring force using the special tool................................................0 9.4.5 Tensioning spring force using the special tool...............................................0 9.4.6 Adjusting the tool...........................................................................0 9.4.7 Replacing the initial pressure spring........................................................0 Removing the initial pressure spring...........................................................0 Fitting the initial pressure spring............................................................0 9.4.8 Replacing the PowerTrak spring...............................................................0 Removing the PowerTrak spring..................................................................0 Fitting the PowerTrak spring...................................................................0 9.4.9 Replacing the PowerTrak cylinder.............................................................0 Removing the PowerTrak cylinder................................................................0 Fitting the PowerTrak cylinder.................................................................0 9.5 Platform including fixing points C0560.............................................................0 9.5.1 Overview, Standard and Cold store............................................................0 9.5.2 Overview, platform...........................................................................0 9.5.3 Replacing the platform.......................................................................0 Removing the platform..........................................................................0 Installing the platform........................................................................0 9.5.4 Replacing an gas strut.......................................................................0 Removing a gas strut...........................................................................0 Installing a gas strut.........................................................................0 9.5.5 Checking the gas spring......................................................................0 9.5.6 Replacing the spring.........................................................................0 Removing the platform suspension...............................................................0 Fitting the platform suspension................................................................0 9.5.7 Adjusting the platform suspension............................................................0 9.5.8 Replacing the platform inductive position sensor.............................................0 Removing the platform inductive position sensor (B119).........................................0 Fitting the platform inductive position sensor (B119)..........................................0 Removing the lower platform inductive position sensor (B120)...................................0 Fitting the lower platform inductive position sensor (B120)....................................0 9.5.9 Checking the position sensor (B120), std platform............................................0 9.5.10 Adjusting the presence sensor...............................................................0 9.5.11 Fixed side guard............................................................................0 9.5.12 Overview....................................................................................0 9.5.13 Replacing the fixed side guard..............................................................0 Removing the fixed side guard..................................................................0 Fitting the side guard.........................................................................0 9.5.14 Photo cells, fixed side guard...............................................................0 Overview, positioning..........................................................................0 9.5.15 Overview, platform with fixed side guard....................................................0 9.5.16 Replacing a platform with fixed side guard..................................................0 Removing a platform with fixed side guard......................................................0 Fitting a platform with fixed side guard.......................................................0 9.5.17 Checking the position sensor (B120), fixed side guards......................................0 9.5.18 Adjusting the presence sensor...............................................................0 9.5.19 Adjusting platform suspension...............................................................0 9.5.20 Back guard..................................................................................0 9.5.21 Overview....................................................................................0 9.5.22 Replacing the back guard....................................................................0 Removing the back guard........................................................................0 Fitting the back guard.........................................................................0 9.5.23 Checking the position sensor (B120), back guard.............................................0 9.5.24 Adjusting the presence sensor...............................................................0 9.5.25 Adjusting platform suspension...............................................................0 9.6 Operator protection C0840..........................................................................0 9.6.1 Gate.........................................................................................0 Overview.......................................................................................0 9.6.2 Replacing a gate.............................................................................0 Removing the gate assembly.....................................................................0 Fitting the gate assembly......................................................................0 9.6.3 Replacing the gate damper....................................................................0 Removing the gate damper.......................................................................0 Installing a gate damper.......................................................................0 9.6.4 Replacing the gate damper....................................................................0 Removing the gate damper.......................................................................0 Fitting the gate damper........................................................................0 9.6.5 Replacing the pad............................................................................0 Removing the pad...............................................................................0 Fitting pads...................................................................................0 9.6.6 Replacing the gate bar.......................................................................0 Removing the gate bar..........................................................................0 Installing a gate bar..........................................................................0 9.6.7 Checking the gate bar........................................................................0 9.6.8 Replacing the upper inductive position sensor................................................0 Removing the upper inductive position sensor...................................................0 Fitting the upper inductive position sensor....................................................0 9.6.9 Checking the upper inductive position sensor B121............................................0 9.6.10 Replacing the lower inductive position sensor...............................................0 Removing the lower inductive position sensor...................................................0 Fitting the lower inductive position sensor....................................................0 9.6.11 Checking the lower inductive position sensor B122...........................................0 9.7 Signs, warnings, labels C0850......................................................................0 10. Motors C1000...........................................................................................0 10.1 Electric pump motor C1710.........................................................................0 10.1.1 Overview....................................................................................0 10.1.2 Replacing the pump motor....................................................................0 Removing the pump motor........................................................................0 Installing the pump motor......................................................................0 10.1.3 Replacing the carbon brushes................................................................0 Removing the carbon brushes....................................................................0 Fitting the carbon brushes.....................................................................0 10.2 Steering motor C1730..............................................................................0 10.2.1 Overview....................................................................................0 10.2.2 Replacing the steering motor................................................................0 Removing the steering motor....................................................................0 Fitting the steering motor.....................................................................0 10.2.3 Removing the control unit...................................................................0 10.2.4 Installing the control unit.................................................................0 10.3 Motor control fans................................................................................0 10.3.1 Overview....................................................................................0 10.3.2 Replacing the motor control fans............................................................0 Removing the motor control fans................................................................0 Fitting the motor control fans.................................................................0 10.4 Drive motor.......................................................................................0 10.4.1 Tightening torques - Drive motor............................................................0 10.5 1.8, 2.5 kW.......................................................................................0 10.5.1 Overview....................................................................................0 10.5.2 Connecting wiring harness 1.8 - 2.5 kW......................................................0 10.5.3 Replacing the drive motor 1.8, 2.5 kW.......................................................0 Removing the drive motor.......................................................................0 Installing the drive motor.....................................................................0 10.6 2.8 KW............................................................................................0 10.6.1 Overview....................................................................................0 10.6.2 Connecting wiring harness, 2.8 kW...........................................................0 10.6.3 Replacing the motor 2.8 kW..................................................................0 Removing the motor 2.8 kW......................................................................0 Fitting drive motor 2.8 kW.....................................................................0 10.6.4 Replacing the temperature sensor............................................................0 10.6.5 Replacing the rpm-sensor....................................................................0 Removing the rpm-sensor........................................................................0 Installing the rpm-sensor......................................................................0 10.6.6 Replacing the speed sensor toothed wheel....................................................0 Removing the speed sensor toothed wheel........................................................0 Fitting the speed sensor toothed wheel.........................................................0 10.6.7 Cleaning....................................................................................0 11. Transmission/Drive gear C2000..........................................................................0 11.1 Description.......................................................................................0 11.2 Gears.............................................................................................0 11.2.1 Small gear..................................................................................0 11.2.2 Overview....................................................................................0 11.2.3 Large gear..................................................................................0 11.2.4 Overview....................................................................................0 11.3 Replacing the drive gear..........................................................................0 Removing the drive gear............................................................................0 Fitting the drive gear.............................................................................0 11.4 Oil check and oil change, large gear..............................................................0 11.4.1 Draining oil................................................................................0 11.4.2 Checking/refilling oil......................................................................0 11.4.3 Replacing the steering bearing..............................................................0 Removing the steering bearing..................................................................0 Fitting the steering bearing...................................................................0 11.5 Oil check and oil change, small gear..............................................................0 11.5.1 Draining oil................................................................................0 11.5.2 Checking/refilling oil......................................................................0 11.5.3 Replacing the steering bearing..............................................................0 Removing the steering bearing..................................................................0 Fitting the steering bearing...................................................................0 11.5.4 Replacing studs.............................................................................0 11.6 Replacing the wheel hub seal......................................................................0 Removing the seal..................................................................................0 Fitting the seal...................................................................................0 12. Brake system/Wheels C3000..............................................................................0 12.1 Brake system C3100................................................................................0 12.1.1 Description.................................................................................0 Travel brake...................................................................................0 Parking brake..................................................................................0 Emergency brake................................................................................0 12.2 Parking brake - C3370.............................................................................0 12.2.1 Overview....................................................................................0 12.2.2 Checking the parking brake gap (adjustable brakes only).....................................0 12.2.3 Checking the parking brake gap (only for the small brake 21Nm in standard configuration)....0 12.2.4 Adjusting the parking brake gap.............................................................0 12.2.5 Emergency release of the parking brake......................................................0 12.2.6 Replacing the parking brake.................................................................0 Removing the parking brake.....................................................................0 Installing the parking brake...................................................................0 12.2.7 Checking the emergency stop/parking brake...................................................0 12.2.8 Replacing the friction disc.................................................................0 Removing the friction disc.....................................................................0 Fitting the friction disc......................................................................0 12.2.9 Replacing the brake hub.....................................................................0 Removing the brake hub.........................................................................0 Fitting the brake hub..........................................................................0 12.2.10 Cleaning the parking brake.................................................................0 12.3 Drive wheel.......................................................................................0 Overview...........................................................................................0 12.3.1 Replacing the drive wheel...................................................................0 Removing the drive wheel.......................................................................0 Installing the drive wheel.....................................................................0 12.4 Castor wheels.....................................................................................0 12.4.1 Replacing the castor wheel assembly.........................................................0 Removing the castor wheel assembly.............................................................0 Fitting the castor wheel assembly..............................................................0 12.4.2 Checking the castor wheels..................................................................0 12.4.3 Replacing the castor wheel (single).........................................................0 Removing the castor wheel (single).............................................................0 Fitting the castor wheel (single)..............................................................0 12.5 Fork wheels.......................................................................................0 12.5.1 Replacing single wheels.....................................................................0 Removing single wheels.........................................................................0 Single wheel installation......................................................................0 12.5.2 Replacing bogie wheels......................................................................0 Removing bogie wheels..........................................................................0 Fitting the bogie wheel........................................................................0 12.5.3 Replacing the wheel fork bushing............................................................0 Removing the bushing...........................................................................0 Installing the bushing.........................................................................0 12.6 Wheel wear........................................................................................0 13. Steering system C4000..................................................................................0 13.1 Steering arm C4110................................................................................0 13.1.1 Overview....................................................................................0 13.1.2 Replacing the keypad C9420..................................................................0 Removing the keypad............................................................................0 Fitting the keypad.............................................................................0 13.1.3 Replacing the tiller arm cover..............................................................0 Removing the tiller arm cover..................................................................0 Fitting the tiller arm cover...................................................................0 13.1.4 Replacing the upper cover C4110.............................................................0 Removing the upper cover.......................................................................0 Fitting the upper cover........................................................................0 13.1.5 Replacing the tiller arm handle.............................................................0 Removing the tiller arm handle.................................................................0 Fitting the tiller arm handle..................................................................0 13.1.6 Replacing the logic card....................................................................0 Removing the logic card........................................................................0 Fitting the logic card.........................................................................0 13.1.7 Checking the handle.........................................................................0 13.1.8 Update the software.........................................................................0 13.1.9 Replacing the signal button/switch..........................................................0 Removing the signal button/switch..............................................................0 Fitting the signal button/switch...............................................................0 13.1.10 Replacing the lift/lower button............................................................0 Removing the lift/lower button.................................................................0 Fitting the lift/lower button..................................................................0 13.1.11 Replacing the button.......................................................................0 Removing the push button.......................................................................0 Fitting the push button........................................................................0 13.1.12 Replacing the symbol disc - support arm lift/fork lift.....................................0 Removing the symbol disc, support arm lift/fork lift...........................................0 Fitting the symbol disc, support arm lift/fork lift............................................0 13.1.13 Replacing the safety reversing switch......................................................0 Removing the safety reversing switch...........................................................0 Fitting the safety reversing switch............................................................0 13.2 Steering arm C4110................................................................................0 13.2.1 Overview steering arm manual steering.......................................................0 13.2.2 Overview steering arm power steering........................................................0 13.2.3 Replacing the tiller arm (manual and power steering)........................................0 Removing the tiller arm........................................................................0 Fitting the tiller arm.........................................................................0 13.2.4 Replacing the tiller arm suspension (manual and power steering).............................0 Removing the tiller arm suspension.............................................................0 Fitting the tiller arm suspension..............................................................0 13.2.5 Replacing the safety switch (manual and power steering).....................................0 Removing the safety switch.....................................................................0 Fitting the safety switch......................................................................0 13.2.6 Replacing the steering yoke.................................................................0 Removing the steering yoke.....................................................................0 Fitting the steering yoke......................................................................0 13.3 Tiller arm, E-man.................................................................................0 13.3.1 Overview, tiller arm E-man..................................................................0 13.3.2 Replacing the tiller arm cover (E-man)......................................................0 Removing the tiller arm cover (E-man)..........................................................0 Fitting the tiller arm cover (E-man)...........................................................0 13.3.3 Replacing the upper cover (E-man)...........................................................0 Removing the upper cover (E-man)...............................................................0 Fitting the upper cover (E-man)................................................................0 13.3.4 Replacing the tiller arm handle (E-man).....................................................0 Removing the tiller arm handle (E-man).........................................................0 Fitting the tiller arm handle (E-man)..........................................................0 13.3.5 Replacing the safety switch (E-man).........................................................0 Removing the safety switch (E-man).............................................................0 Fitting the safety switch (E-man)..............................................................0 13.3.6 Replacing the tiller arm (E-Man)............................................................0 Removing the tiller arm (E-man)................................................................0 Fitting the tiller arm (E-man).................................................................0 13.4 Power steering....................................................................................0 13.4.1 Safety......................................................................................0 13.4.2 Overview....................................................................................0 13.5 Steering angle sensor C4350.......................................................................0 13.5.1 Replacing the steering angle sensor servo unit..............................................0 Removing the steering angle sensor.............................................................0 Fitting the steering angle sensor..............................................................0 13.5.2 Replacing the steering damper...............................................................0 Removing the steering damper...................................................................0 Fitting the steering damper....................................................................0 13.5.3 Calibrating the steering damper/reference sensor............................................0 13.5.4 Steering adapter (power steering)...........................................................0 overview.......................................................................................0 13.5.5 Replacing the gas strut - height adjustment.................................................0 Removing the gas strut - height adjustment.....................................................0 Fitting the gas strut - height adjustment......................................................0 13.5.6 Replacing the lock - height adjustment......................................................0 Removing the lock - height adjustment..........................................................0 Fitting the lock - height adjustment...........................................................0 13.5.7 Checking the lock - height adjustment.......................................................0 13.5.8 Replacing the steering adapter (power steering).............................................0 Removing the steering adapter..................................................................0 Fitting the steering adapter...................................................................0 13.5.9 Replacing the steering bearing (power steering).............................................0 Removing the steering bearing..................................................................0 Fitting the steering bearing...................................................................0 13.5.10 Replacing the mechanical stop of the steer axle (power steering)...........................0 Removing the mechanical stop of the steer axle (power steering)................................0 Fitting the mechanical stop of the steer axle (power steering).................................0 13.6 Mechanical steering...............................................................................0 13.6.1 Overview....................................................................................0 13.6.2 Steering adapter, mech. steering............................................................0 13.6.3 Replacing the steering adapter (fixed)......................................................0 Removing the steering adapter..................................................................0 Fitting the steering adapter...................................................................0 13.6.4 Replacing the steering angle sensor.........................................................0 Removing the steering angle sensor.............................................................0 Fitting the steering angle sensor..............................................................0 13.6.5 Replacing the steering bearing - mechanical steering........................................0 Removing the steering bearing..................................................................0 Fitting the steering bearing...................................................................0 13.6.6 Replacing the mechanical stop of the steer axle.............................................0 Removing the mechanical stop of the steer axle.................................................0 Fitting the mechanical stop of the steer axle..................................................0 14. Electrical system C5000................................................................................0 14.1 General...........................................................................................0 14.1.1 Truck firmware applications.................................................................0 14.2 Menus.............................................................................................0 14.2.1 Menu navigation.............................................................................0 Menu overview..................................................................................0 14.2.2 Menu information............................................................................0 14.2.3 Display hour counter values.................................................................0 14.2.4 Show error codes............................................................................0 14.2.5 Show part numbers for software/hardware.....................................................0 14.2.6 Built-in test A5 (A5).......................................................................0 14.2.7 Show collisions.............................................................................0 14.2.8 Show/change parameters......................................................................0 14.2.9 Emergency driving mode......................................................................0 14.2.10 Calibration................................................................................0 14.2.11 Show/change PIN code.......................................................................0 14.3 Battery C5110.....................................................................................0 14.3.1 Battery replacement.........................................................................0 Replacement using a battery changing table.....................................................0 Replacement using lifting gear.................................................................0 14.3.2 Charging the battery........................................................................0 14.4 Electric panel:...................................................................................0 14.4.1 Overview....................................................................................0 14.5 Motor control [T1] (ACT)..........................................................................0 14.5.1 General.....................................................................................0 14.5.2 Replacing the motor control.................................................................0 Removing the motor control.....................................................................0 Fitting the motor control......................................................................0 14.5.3 Replacing the pump contactor................................................................0 Removing the pump contactor....................................................................0 Fitting the pump contactor.....................................................................0 14.5.4 Replacing the main contactor................................................................0 Removing the main contactor....................................................................0 Fitting the main contactor.....................................................................0 14.6 Horn C5160........................................................................................0 14.6.1 Horn [P4]...................................................................................0 14.7 Control system....................................................................................0 14.7.1 Direction selector/speed regulator..........................................................0 14.7.2 Safety reversing............................................................................0 14.7.3 Battery indicator...........................................................................0 14.7.4 Hour counter................................................................................0 14.7.5 Lifting and lowering control - support arm/fork lift........................................0 14.7.6 Signal buttons..............................................................................0 14.7.7 Option buttons..............................................................................0 14.7.8 Display.....................................................................................0 General........................................................................................0 Symbols on keypad and display..................................................................0 14.7.9 Keypad/ID unit..............................................................................0 14.7.10 Weighing system............................................................................0 14.7.11 Pressure equalization......................................................................0 14.7.12 Logic card (A5)............................................................................0 14.8 Work function harness/fuse........................................................................0 14.8.1 Fuse panel overview.........................................................................0 Fuses..........................................................................................0 14.9 Sending units and sensors C5800...................................................................0 14.9.1 Inductive sensors...........................................................................0 14.9.2 Position sensor.............................................................................0 14.9.3 Steering reference sensor...................................................................0 14.9.4 Pressure sensor.............................................................................0 14.9.5 Pulse transducer............................................................................0 14.10 Safety sensor....................................................................................0 14.10.1 Emergency switch off [S21].................................................................0 14.10.2 Photocell..................................................................................0 15. Hydraulic system C6000.................................................................................0 15.1 General...........................................................................................0 15.2 Hydraulic hygiene.................................................................................0 15.2.1 Washing.....................................................................................0 15.2.2 Packaging...................................................................................0 15.2.3 Handling....................................................................................0 15.2.4 Storage.....................................................................................0 15.2.5 Work procedures.............................................................................0 15.3 Hydraulic system..................................................................................0 15.3.1 Overview....................................................................................0 Description....................................................................................0 15.3.2 Hydraulic unit..............................................................................0 15.3.3 Tightening torques for hydraulic unit.......................................................0 15.3.4 Replacing the hydraulic unit................................................................0 Removing the hydraulic unit....................................................................0 Fitting the hydraulic unit.....................................................................0 15.3.5 Tank........................................................................................0 15.3.6 Changing oil................................................................................0 Draining oil...................................................................................0 Topping up with oil............................................................................0 15.3.7 Replacing the tank..........................................................................0 Removing the tank..............................................................................0 Fitting the tank...............................................................................0 15.3.8 Valve unit..................................................................................0 15.3.9 Hydraulic pump..............................................................................0 Description....................................................................................0 15.3.10 Replacing the hydraulic pump...............................................................0 Removing the hydraulic pump....................................................................0 Fitting the hydraulic pump.....................................................................0 15.3.11 Replacing the return filter................................................................0 Removing the return filter.....................................................................0 Fitting the return filter......................................................................0 15.3.12 Replacing the valve coil...................................................................0 Removing the valve coil........................................................................0 Fitting the valve coil.........................................................................0 15.3.13 Replacing the flow control valve...........................................................0 Removing the flow control valve................................................................0 Fitting the flow control valve.................................................................0 15.3.14 Pressure limitation........................................................................0 15.3.15 Replacing the pressure limiting valve......................................................0 Removing the pressure limiting valve...........................................................0 Fitting the pressure limiting valve............................................................0 15.3.16 Adjusting pressure limitation..............................................................0 15.3.17 Replacing the pressure sensor..............................................................0 Removing the pressure sensor...................................................................0 Fitting the pressure sensor....................................................................0 15.3.18 Lift cylinder..............................................................................0 15.3.19 Replacing lift cylinders...................................................................0 Removing the lift cylinder, right side.........................................................0 Fitting the lift cylinder, right side..........................................................0 Removing the lift cylinder, left side..........................................................0 Fitting the lift cylinder, left side...........................................................0 15.4 Hydraulic connections.............................................................................0 15.4.1 Quick change connector......................................................................0 Connecting the quick change connector..........................................................0 Dismantling the quick change connector.........................................................0 16. Mast C7000.............................................................................................0 17. Peripherals C8000......................................................................................0 18. Options/Extra equipment C9000..........................................................................0 18.1 Overview..........................................................................................0 18.2 Spider expansion unit.............................................................................0 18.3 DC/DC converter...................................................................................0 18.4 Impact sensor.....................................................................................0 18.5 Integrated battery charger C5170..................................................................0 18.5.1 Overview....................................................................................0 18.5.2 Description.................................................................................0 18.5.3 Connecting the battery charger..............................................................0 18.6 E-bar.............................................................................................0 18.6.1 Overview....................................................................................0 18.6.2 E-bar options...............................................................................0 18.6.3 Fire extinguisher...........................................................................0 19. Instructions for disposal..............................................................................0 19.1 General...........................................................................................0 19.2 Marking of plastics...............................................................................0 19.2.1 General marking of products and packaging...................................................0 19.2.2 Marking according to the manufacturer’s standards...........................................0 Abbreviations..................................................................................0 Marking examples...............................................................................0 19.3 Pressure vessels..................................................................................0 19.3.1 Gas dampers.................................................................................0 19.4 Sorting categories................................................................................0 20. Electrical components and wiring diagrams..............................................................0 20.1 Electric components...............................................................................0 20.2 Component location................................................................................0 Picture 1..........................................................................................0 Picture 2..........................................................................................0 Picture 3..........................................................................................0 Picture 4..........................................................................................0 Picture 5..........................................................................................0 Picture 6..........................................................................................0 Picture 7..........................................................................................0 Picture 8..........................................................................................0 Picture 9..........................................................................................0 Picture 10.........................................................................................0 Picture 11.........................................................................................0 Picture 12.........................................................................................0 Picture 13.........................................................................................0 Picture 14.........................................................................................0 Picture 15.........................................................................................0 20.3 Wiring diagrams...................................................................................0 20.3.1 List of symbols.............................................................................0 20.3.2 Wiring diagram P300 overview - std platform.................................................0 20.3.3 Wiring diagram P300 overview - fixed platform...............................................0 20.3.4 Wiring diagram P300 overview - options......................................................0 20.3.5 Wiring diagram..............................................................................0 20.4 Electrical components and wiring diagrams.........................................................0 20.5 Electric components...............................................................................0 20.6 Component location................................................................................0 Picture 1..........................................................................................0 Picture 2..........................................................................................0 Picture 3..........................................................................................0 Picture 4..........................................................................................0 Picture 5..........................................................................................0 Picture 6..........................................................................................0 Picture 7..........................................................................................0 Picture 8..........................................................................................0 Picture 9..........................................................................................0 Picture 10.........................................................................................0 Picture 11.........................................................................................0 Picture 12.........................................................................................0 Picture 13.........................................................................................0 Picture 14.........................................................................................0 Picture 15.........................................................................................0 20.7 Wiring diagrams...................................................................................0 20.7.1 List of symbols.............................................................................0 20.7.2 Wiring diagram P300 overview - std platform.................................................0 20.7.3 Wiring diagram P300 overview - fixed platform...............................................0 20.7.4 Wiring diagram P300 overview - options......................................................0 20.7.5 Wiring diagram..............................................................................0 21. Hydraulics schematics..................................................................................0 21.1 Component list....................................................................................0 21.2 Component location................................................................................0 Picture 1..........................................................................................0 Picture 2..........................................................................................0 Picture 3..........................................................................................0 21.2.1 Valve unit..................................................................................0 21.3 Hydraulics schematics.............................................................................0 21.3.1 P320, 322...................................................................................0 22. Tools..................................................................................................0 22.1 AMP contacts......................................................................................0 22.2 MQS contacts......................................................................................0 22.3 CPC contacts......................................................................................0 22.4 Other tools.......................................................................................0 23. Service data and grease specifications.................................................................0 23.1 General tightening torques........................................................................0 23.2 Oil and grease specification......................................................................0 24. Technical data.........................................................................................0 24.1 Basic data........................................................................................0 Battery dimensions.................................................................................0 Service data.......................................................................................0
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