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BT Forklift SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L Repair manual – PDF
BT Forklift SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D SPE200L Repair manual – PDF DOWNLOAD
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BT Forklift SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D SPE200L Repair manual – PDF DOWNLOAD
Language : English
Pages : 644
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D SPE200L Repair manual – PDF DOWNLOAD
1 General introduction.................................................................................. 9 1.1 How to use this manual.......................................................................... 9 1.2 Warning levels and symbols...................................................................... 9 1.3 Pictograms...................................................................................... 10 2 General safety rules.................................................................................. 13 2.1 Authorised personnel............................................................................ 13 2.2 Work safety..................................................................................... 13 2.3 Electrical system............................................................................... 13 2.3.1 Electrostatic risks....................................................................... 14 2.3.2 Battery handling.......................................................................... 14 2.4 Safe lifting.................................................................................... 15 2.5 Truck modifications............................................................................. 15 2.6 Software........................................................................................ 16 2.7 Hydraulic system................................................................................ 16 3 Operating principle................................................................................... 19 3.1 Description..................................................................................... 19 3.1.1 Battery is connected...................................................................... 19 3.1.2 Login via keypad.......................................................................... 19 3.1.3 Login via “ID key” option................................................................. 19 3.1.4 Tiller arm lowered for driving............................................................ 20 3.1.5 Driving in fork direction................................................................. 20 3.1.6 Driving in the drive wheel direction...................................................... 20 3.1.7 Braking in neutral........................................................................ 20 3.1.8 Reverse braking........................................................................... 21 3.1.9 Mechanical braking........................................................................ 21 3.1.10 Emergency reversal....................................................................... 21 3.1.11 Fork lowering............................................................................ 22 4 Parameters............................................................................................ 25 4.1 Display/change parameters....................................................................... 25 4.2 Parameters in general........................................................................... 25 4.3 Parameter list.................................................................................. 25 4.4 Parameter list.................................................................................. 57 5 Installation.......................................................................................... 61 5.1 Transport....................................................................................... 61 5.1.1 Transporting the truck.................................................................... 61 5.1.2 Transporting the mast..................................................................... 61 5.2 Lifting the truck............................................................................... 62 5.2.1 Lifting the truck......................................................................... 62 5.2.2 Lift using a jack......................................................................... 64 5.3 Commissioning................................................................................... 64 5.3.1 Parameters on commissioning............................................................... 64 5.3.1.1 Setting parameters.................................................................. 64 5.3.1.2 Setting collision sensor parameters (option)........................................ 64 5.3.1.3 Setting battery parameters.......................................................... 64 5.3.2 Battery................................................................................... 65 5.3.2.1 Battery installation................................................................ 65 6 ...................................................................................................... 69 6.1 ................................................................................................ 69 6.2 ................................................................................................ 69 6.2.1 .......................................................................................... 69 6.2.2 .......................................................................................... 69 6.2.3 .......................................................................................... 69 6.2.4 .......................................................................................... 69 6.2.5 .......................................................................................... 69 6.2.6 .......................................................................................... 69 6.2.7 .......................................................................................... 69 6.2.8 .......................................................................................... 69 6.2.9 .......................................................................................... 69 6.2.9.1 Placement of signs.................................................................. 69 6.2.9.2 Placement of signs.................................................................. 71 6.2.9.3 Placement of signs.................................................................. 73 6.2.9.4 Placement of signs.................................................................. 75 6.3 ................................................................................................ 77 6.4 ................................................................................................ 77 7 Troubleshooting....................................................................................... 81 7.1 Auxiliary functions............................................................................. 81 7.1.1 Towing a defective truck.................................................................. 81 7.1.1.1 Towing and transporting a defective truck........................................... 81 7.1.2 Emergency driving mode.................................................................... 81 7.1.2.1 Emergency driving mode.............................................................. 81 7.1.3 Error code history........................................................................ 82 7.1.3.1 Error code history.................................................................. 82 7.1.4 Extended error log........................................................................ 82 7.1.4.1 Extended error log.................................................................. 82 7.1.5 Built-in test function for the tiller arm................................................. 82 7.1.5.1 General............................................................................. 82 7.1.5.2 Display test........................................................................ 83 7.1.5.3 Speed control....................................................................... 83 7.1.5.4 Safety reversing.................................................................... 84 7.1.5.5 Controls for lifting/lowering....................................................... 84 7.1.5.6 Sensilift........................................................................... 85 7.1.5.7 Keypad.............................................................................. 85 7.2 Initial troubleshooting......................................................................... 86 7.3 Concluding troubleshooting...................................................................... 86 7.4 Troubleshooting using error codes............................................................... 86 7.4.1 List of error codes....................................................................... 86 8 Chassis C0000.........................................................................................155 8.1 Overview........................................................................................155 8.2 Frame, chassis C0300............................................................................156 8.2.1 Inspection covers C0340...................................................................156 8.2.1.1 Motor compartment covers............................................................156 8.2.1.1.1 Overview......................................................................156 8.2.1.1.2 Replacing a service cover.....................................................157 8.2.1.1.2.1 Removing a service cover................................................157 8.2.1.1.2.2 Installing a service cover..............................................157 8.2.1.1.3 Replacing a side cover........................................................157 8.2.1.1.3.1 Removing a side cover...................................................157 8.2.1.1.3.2 Installing a side cover.................................................158 8.2.1.1.4 Replacing an emblem cover.....................................................158 8.2.1.1.4.1 Removing an emblem cover................................................158 8.2.1.1.4.2 Installing an emblem cover..............................................159 8.2.1.1.5 Replacing an upper cover......................................................159 8.2.1.1.5.1 Removing an upper cover.................................................159 8.2.1.1.5.2 Installing an upper cover...............................................160 8.2.1.1.6 Replacing a cover.............................................................161 8.2.1.1.6.1 Removing a cover........................................................161 8.2.1.1.6.2 Installing a cover......................................................161 8.2.2 Support arms, stabilizers C0350...........................................................162 8.2.2.1 Overview............................................................................162 8.2.2.2 Checking the linkage................................................................163 8.2.2.3 Checking the wheel fork flexibility.................................................163 8.2.2.4 Replacing the pressure rod..........................................................163 8.2.2.4.1 Removing a push rod...........................................................163 8.2.2.4.2 Installing a push rod.........................................................166 8.2.2.5 Replacing torsion tubes.............................................................169 8.2.2.5.1 Removing torsion tubes........................................................169 8.2.2.5.2 Installing a torsion tube.....................................................170 8.2.2.6 Replacing the roller on the torsion tube............................................171 8.2.2.6.1 Removing the roller on the torsion tube.......................................171 8.2.2.6.2 Fit the roller on the torsion tube............................................172 8.2.2.7 Replacing a wheel fork..............................................................173 8.2.2.7.1 Removing wheel fork...........................................................173 8.2.2.7.2 Installing a wheel fork.......................................................175 8.2.2.8 Replacing a bogie link, fork wheel..................................................177 8.2.2.8.1 Removing a bogie link, fork wheel.............................................177 8.2.2.8.2 Fitting a bogie link, fork wheel..............................................177 8.2.2.9 Replacing a bogie link, support arm.................................................177 8.2.2.9.1 Removing a bogie link, support arm............................................177 8.2.2.9.2 Installing a bogie link, support arm..........................................178 8.2.2.10 Replacing the wheel fork bushing...................................................178 8.2.2.10.1 Removing the wheel fork bushing..............................................178 8.2.2.10.2 Fitting the wheel fork bushing...............................................179 8.2.2.11 Replacing the support arm bushing..................................................179 8.2.2.11.1 Removing the support arm bushing.............................................179 8.2.2.11.2 Installing a support arm bushing.............................................180 8.2.3 Fork structure (low-lifter) C0380.........................................................180 8.2.3.1 Checking the fork lift height limitation............................................180 8.2.4 Battery compartment parts C0390...........................................................181 8.2.4.1 Overview............................................................................181 8.2.4.2 Overview............................................................................182 8.2.4.3 Description.........................................................................182 8.2.4.3.1 Design........................................................................182 8.3 Frame/chassis components C0400..................................................................182 8.3.1 Motor mount/brackets C0450................................................................182 8.3.1.1 Checking the motor mounts...........................................................182 8.3.1.2 Drive unit mountings................................................................183 8.3.1.2.1 Drive unit mountings 6/8 km/h.................................................183 8.3.1.2.1.1 Overview 6/8 km/h.......................................................183 8.3.1.2.1.2 Description.............................................................183 8.3.1.2.1.2.1 Technical data....................................................183 8.3.1.2.1.2.2 Technical data....................................................184 8.3.1.2.1.2.3 Technical data....................................................184 8.3.1.2.1.2.4 Technical data....................................................184 8.3.1.2.1.2.5 Technical data....................................................185 8.3.1.2.1.2.6 Technical data....................................................185 8.3.1.2.1.2.7 Technical data....................................................185 8.3.1.2.1.2.8 Technical data....................................................186 8.3.1.2.1.2.9 Technical data....................................................186 8.3.1.2.1.3 Replacing the drive unit mountings 6/8 km/h.............................186 8.3.1.2.1.3.1 Removing the drive unit mountings 6/8 km/h........................186 8.3.1.2.1.3.2 Installing the drive unit mountings 6/8 km/h......................189 8.3.1.2.2 Drive unit mountings 10/12.5 km/h.............................................193 8.3.1.2.2.1 Overview 10/12.5 km/h..................................................193 8.3.1.2.2.2 Description.............................................................193 8.3.1.2.2.2.1 Technical data....................................................193 8.3.1.2.2.2.2 Technical data....................................................194 8.3.1.2.2.2.3 Technical data....................................................194 8.3.1.2.2.2.4 Technical data....................................................194 8.3.1.2.2.2.5 Technical data....................................................195 8.3.1.2.2.3 Replacing the drive unit mountings 10/12.5 km/h.........................195 8.3.1.2.2.3.1 Removing the drive unit mountings 10/12.5 km/h....................195 8.3.1.2.2.3.2 Installing the drive unit mountings 10/12.5 km/h..................198 8.3.1.3 PowerTrak...........................................................................201 8.3.1.3.1 Description...................................................................201 8.3.1.3.1.1 Design..................................................................201 8.3.1.3.2 Increasing the spring tension.................................................202 8.3.1.3.3 Releasing the spring tension..................................................204 8.3.1.3.4 Adjusting tool V08-18302......................................................206 8.3.1.3.5 Replacing the initial pressure spring.........................................207 8.3.1.3.5.1 Removing the initial pressure spring....................................207 8.3.1.3.5.2 Fitting the initial pressure spring.....................................208 8.3.1.3.6 Replacing the PowerTrak spring................................................209 8.3.1.3.6.1 Removing the PowerTrak spring...........................................209 8.3.1.3.6.2 Installing the PowerTrak spring.........................................211 8.3.1.3.7 Replacing a spacer............................................................213 8.3.1.3.7.1 Removing a spacer.......................................................213 8.3.1.3.7.2 Installing a spacer.....................................................214 8.3.1.4 Decompression locking...............................................................215 8.3.1.4.1 Overview......................................................................215 8.3.1.4.2 Description...................................................................215 8.3.1.4.2.1 Design..................................................................215 8.3.1.4.3 Purging the decompression lock................................................216 8.3.1.4.4 Checking the decompression lock...............................................218 8.3.1.4.5 Replacing the decompression lock..............................................218 8.3.1.4.5.1 Removing the decompression lock.........................................218 8.3.1.4.5.2 Fitting the decompression lock..........................................220 8.4 Operator compartment, cab C0500.................................................................222 8.4.1 Platform including fixing points C0560....................................................222 8.4.1.1 Overview............................................................................222 8.4.1.2 Overview............................................................................223 8.4.1.3 Overview............................................................................224 8.4.1.4 Checking the function of the platform switches......................................224 8.4.1.5 Adjusting the position sensor [B120]................................................225 8.4.1.6 Checking the platform...............................................................225 8.4.1.7 Inspection of the rear chassis......................................................225 8.4.1.8 Gas strut...........................................................................225 8.4.1.8.1 Checking the gas strut........................................................225 8.4.1.8.2 Replacing a gas strut.........................................................226 8.4.1.8.2.1 Removing a gas strut....................................................226 8.4.1.8.2.2 Installing a gas strut..................................................228 8.4.1.9 Platform suspension.................................................................230 8.4.1.9.1 Adjusting platform suspension.................................................230 8.4.1.9.2 Adjusting the platform suspension [Fixed side guards].........................230 8.4.1.9.3 Replacing the platform suspension.............................................231 8.4.1.9.3.1 Removing the platform suspension........................................231 8.4.1.9.3.2 Fitting the platform suspension.........................................232 8.4.1.10 Safety switch, platform [B119].....................................................233 8.4.1.10.1 Adjusting the position sensor play [B119]....................................233 8.4.1.10.2 Checking the position sensor [B119]..........................................234 8.4.1.11 Safety switch, platform [B119]/[B120]..............................................235 8.4.1.11.1 Measuring the detection distance [B120]......................................235 8.4.1.11.2 Replacing sensor [B119]......................................................235 8.4.1.11.2.1 Removing the platform position sensor [B119]...........................235 8.4.1.11.2.2 Fitting the platform position sensor [B119]............................236 8.4.1.11.3 Replacing sensor [B120]......................................................236 8.4.1.11.3.1 Removing the platform position sensor [B120]...........................236 8.4.1.11.3.2 Fitting the platform position sensor [B120]............................237 8.4.1.12 Replacing the platform.............................................................237 8.4.1.12.1 Removing the platform........................................................237 8.4.1.12.2 Removing the platform [Fixed side guards]....................................241 8.4.1.12.3 Installing the platform......................................................242 8.4.1.12.4 Fitting the platform [Fixed side guards].....................................244 8.5 Safety equipment C0800..........................................................................246 8.5.1 Operator protection C0840.................................................................246 8.5.1.1 Fixed side guard....................................................................246 8.5.1.1.1 Overview [Fixed side guards]..................................................246 8.5.1.1.2 Replacing the fixed side guard................................................247 8.5.1.1.2.1 Removing the fixed side guard...........................................247 8.5.1.1.2.2 Fitting fixed side guards...............................................248 8.5.1.1.3 Checking the position sensor [B119] [Fixed side guards].......................250 8.5.1.2 Gate................................................................................251 8.5.1.2.1 Overview [Gate]...............................................................251 8.5.1.2.2 Checking the gate bar.........................................................251 8.5.1.2.3 Replacing a gas strut.........................................................252 8.5.1.2.3.1 Removing the gate damper................................................252 8.5.1.2.3.2 Removing the gate damper................................................252 8.5.1.2.3.3 Fitting the gate damper.................................................253 8.5.1.2.3.4 Fitting the gate damper.................................................254 8.5.1.2.4 Replacing the pad.............................................................254 8.5.1.2.4.1 Removing the pad........................................................254 8.5.1.2.4.2 Fitting pads............................................................255 8.5.1.2.5 Replacing the gate............................................................256 8.5.1.2.5.1 Removing the gate.......................................................256 8.5.1.2.5.2 Installing the gate.....................................................258 8.5.1.2.6 Replacing the gate bar........................................................259 8.5.1.2.6.1 Removing the gate bar...................................................259 8.5.1.2.6.2 Installing the gate bar.................................................260 8.5.1.3 Back rest...........................................................................261 8.5.1.3.1 Overview [Back protection]....................................................261 8.5.1.3.2 Checking the position sensor [B119 back protection] ..........................261 8.5.1.3.3 Replacing the back guard......................................................262 8.5.1.3.3.1 Removing the back guard.................................................262 8.5.1.3.3.2 Installing the back guard...............................................263 8.5.2 Signs, warnings, labels C0850.............................................................263 8.5.2.1 Checking signs and labels...........................................................263 8.5.2.2 Placement of signs..................................................................263 8.5.2.3 Placement of signs..................................................................265 8.5.2.4 Placement of signs..................................................................267 8.5.2.5 Placement of signs..................................................................269 9 Motors C1000..........................................................................................275 9.1 Electric motors C1700...........................................................................275 9.1.1 Electric pump motor C1710.................................................................275 9.1.1.1 Overview............................................................................275 9.1.1.2 Replacing the pump motor............................................................275 9.1.1.2.1 Removing a pump motor.........................................................275 9.1.1.2.2 Installing a pump motor.......................................................276 9.1.2 Electric steering motor C1730.............................................................277 9.1.2.1 Overview............................................................................277 9.1.2.2 Description.........................................................................278 9.1.2.2.1 Design........................................................................278 9.1.2.3 Cleaning the ring gear..............................................................278 9.1.2.4 Checking the electrical connections.................................................278 9.1.2.5 Checking the steering motor gears...................................................278 9.1.2.6 Checking the steering motor.........................................................278 9.1.2.7 Lubricating the ring gear...........................................................278 9.1.2.8 Check the drive gear's attachment...................................................278 9.1.2.9 Replacing the steering motor........................................................279 9.1.2.9.1 Removing the steering motor [M6]..............................................279 9.1.2.9.2 Installing the steering motor [M6]............................................280 9.1.3 Electric fan motor/fan C1740..............................................................281 9.1.3.1 Overview............................................................................281 9.1.3.2 Description.........................................................................281 9.1.3.2.1 Design........................................................................281 9.1.3.3 Replacing the motor control fan.....................................................281 9.1.3.3.1 Removing a motor control fan..................................................281 9.1.3.3.2 Installing a motor control fan................................................283 9.1.4 Electric drive motor C1760................................................................284 9.1.4.1 Overview 1.8, 2.5 kW................................................................284 9.1.4.2 Overview............................................................................285 9.1.4.3 Description.........................................................................285 9.1.4.3.1 Design........................................................................285 9.1.4.4 Check the rotational speed sensor fitting...........................................286 9.1.4.5 Checking the electrical connections.................................................286 9.1.4.6 Checking the drive motor............................................................286 9.1.4.7 Listen for any abnormal noise in the drive motor bearings...........................286 9.1.4.8 Check the drive motor fitting (1.8 and 2.5 kW)......................................286 9.1.4.9 Check the drive motor fitting (2.8 kW)..............................................286 9.1.4.10 Checking the rotational speed sensor...............................................286 9.1.4.11 Replacing the drive motor..........................................................286 9.1.4.11.1 Removing the drive motor [M1]................................................286 9.1.4.11.2 Removing the drive motor [M1]................................................289 9.1.4.11.3 Removing the drive motor [M1]................................................291 9.1.4.11.4 Installing the drive motor [M1]..............................................295 9.1.4.11.5 Installing the drive motor [M1]..............................................299 9.1.4.11.6 Installing the drive motor [M1]..............................................302 9.1.4.12 Replacing the temperature sensor...................................................304 9.1.4.12.1 Installing the temperature sensor............................................304 9.1.4.13 Replacing the rotational speed sensor..............................................305 9.1.4.13.1 Removing a rotational speed sensor...........................................305 9.1.4.13.2 Installing a rotational speed sensor.........................................307 9.1.4.14 Replacing the toothed wheel........................................................309 9.1.4.14.1 Removing a toothed wheel.....................................................309 9.1.4.14.2 Installing a toothed wheel...................................................309 10 Transmission/Drive gear C2000........................................................................313 10.1 Drive unit, final gear C2500...................................................................313 10.1.1 Drive unit/gear C2550 ...................................................................313 10.1.1.1 Overview...........................................................................313 10.1.1.2 Overview...........................................................................314 10.1.1.3 Description .......................................................................314 10.1.1.3.1 Design.......................................................................314 10.1.1.3.2 Technical data...............................................................314 10.1.1.3.3 Technical data...............................................................315 10.1.1.4 Check the drive gear's attachment .................................................315 10.1.1.5 Checking for leaks in the drive gear...............................................315 10.1.1.6 Checking for noise in the drive gear...............................................315 10.1.1.7 Replacing the drive gear ..........................................................315 10.1.1.7.1 Removing the drive gear......................................................315 10.1.1.7.2 Installing the drive gear....................................................318 10.1.1.8 Replacing the wheel hub seal ......................................................320 10.1.1.8.1 Removing the wheel hub seal..................................................320 10.1.1.8.2 Installing the wheel hub seal................................................321 10.1.1.9 Drive gear oil change..............................................................322 10.1.1.9.1 Empty the drive gear oil.....................................................322 10.1.1.9.2 Empty the drive gear oil.....................................................323 10.1.1.9.3 Filling oil in the drive gear................................................324 10.1.1.9.4 Filling oil in the drive gear................................................325 10.1.1.10 Replacing the drive gear steering bearing ........................................326 10.1.1.10.1 Removing the drive gear steering bearing....................................326 10.1.1.10.2 Removing the drive gear steering bearing....................................327 10.1.1.10.3 Installing the drive gear steering bearing..................................327 10.1.1.10.4 Installing the drive gear steering bearing..................................328 10.1.1.11 Stud replacement .................................................................329 10.1.1.11.1 Removing a stud.............................................................329 10.1.1.11.2 Installing a stud...........................................................329 11 Brake/wheel/track system C3000.......................................................................333 11.1 Travel brake system C3100......................................................................333 11.1.1 Description..............................................................................333 11.1.1.1 Brake types........................................................................333 11.1.1.1.1 Travel brake.................................................................333 11.1.1.1.2 Emergency brake..............................................................333 11.1.1.1.3 Parking brake................................................................333 11.2 Parking brake details C3300....................................................................334 11.2.1 Electrical parking brake, magnet brake C3370.............................................334 11.2.1.1 Overview...........................................................................334 11.2.1.2 Description........................................................................335 11.2.1.2.1 Technical data...............................................................335 11.2.1.2.2 Technical data...............................................................335 11.2.1.2.3 Technical data...............................................................335 11.2.1.3 Cleaning the parking brake.........................................................336 11.2.1.4 Adjusting the parking brake gap....................................................336 11.2.1.5 Adjusting the parking brake gap....................................................337 11.2.1.6 Adjusting the parking brake gap....................................................337 11.2.1.7 Adjusting the parking brake gap....................................................338 11.2.1.8 Tighten the parking brake mounting bolts...........................................339 11.2.1.9 Emergency release of the parking brake.............................................339 11.2.1.10 Checking the parking brake........................................................339 11.2.1.11 Replacing the brake hub...........................................................340 11.2.1.11.1 Disassembling the brake hub.................................................340 11.2.1.11.2 Installing a brake hub......................................................340 11.2.1.12 Replacing the friction disc.......................................................341 11.2.1.12.1 Removing the friction disc..................................................341 11.2.1.12.2 Fitting the friction disc...................................................342 11.2.1.13 Replacing the parking brake.......................................................343 11.2.1.13.1 Removing the parking brake..................................................343 11.2.1.13.2 Fitting the parking brake...................................................344 11.3 Wheels C3500...................................................................................345 11.3.1 Drive wheel C3530........................................................................345 11.3.1.1 Overview...........................................................................345 11.3.1.2 Description........................................................................346 11.3.1.2.1 Wheel wear...................................................................346 11.3.1.3 Measuring the drive wheel tread....................................................346 11.3.1.4 Measuring the drive wheel tread....................................................346 11.3.1.5 Replacing the drive wheel..........................................................346 11.3.1.5.1 Disassembling the drive wheel................................................346 11.3.1.5.2 Installing a drive wheel.....................................................348 11.3.2 Support arm wheels/castor wheels C3540...................................................350 11.3.2.1 Overview...........................................................................350 11.3.2.2 Description........................................................................350 11.3.2.2.1 Wheel wear...................................................................350 11.3.2.3 Cleaning castor wheels.............................................................351 11.3.2.4 Measuring the castor wheel tread...................................................351 11.3.2.5 Measuring the castor wheel tread...................................................351 11.3.2.6 Measuring the castor wheel tread...................................................351 11.3.2.7 Measuring the castor wheel tread...................................................352 11.3.2.8 Checking the castor wheels.........................................................352 11.3.2.9 Replacing the castor wheel.........................................................352 11.3.2.9.1 Removing the castor..........................................................352 11.3.2.9.2 Removing the castor..........................................................353 11.3.2.9.3 Installing a castor wheel....................................................354 11.3.2.9.4 Installing a castor wheel....................................................355 11.3.2.10 Replacing the castor wheel assembly...............................................356 11.3.2.10.1 Removing the castor wheel assembly..........................................356 11.3.2.10.2 Installing the castor wheel assembly........................................357 11.3.3 Fork wheels/support arm wheels C3550.....................................................358 11.3.3.1 Overview...........................................................................358 11.3.3.2 Description........................................................................358 11.3.3.2.1 Wheel wear...................................................................358 11.3.3.3 Cleaning the fork wheels...........................................................359 11.3.3.4 Measuring the fork wheel tread.....................................................359 11.3.3.5 Checking the fork wheel mounting...................................................359 11.3.3.6 Checking the fork wheel bushings...................................................359 11.3.3.7 Replacing a single wheel...........................................................359 11.3.3.7.1 Removing single wheels.......................................................359 11.3.3.7.2 Single wheel installation....................................................360 11.3.3.8 Replacing bogie wheels.............................................................361 11.3.3.8.1 Removing bogie wheels........................................................361 11.3.3.8.2 Removing bogie wheels........................................................363 11.3.3.8.3 Fitting the bogie wheel......................................................365 11.3.3.8.4 Fitting the bogie wheel......................................................366 11.3.3.9 Replacing a bogie link.............................................................368 11.3.3.9.1 Removing a bogie link........................................................368 11.3.3.9.2 Removing a bogie link........................................................368 11.3.3.9.3 Installing a bogie link......................................................369 11.3.3.9.4 Installing a bogie link......................................................369 12 Steering system C4000................................................................................373 12.1 Description....................................................................................373 12.1.1 Power steering...........................................................................373 12.2 Mechanical steering system C4100...............................................................373 12.2.1 Steering arm/wheel/lever C4110...........................................................373 12.2.1.1 Overview tiller arm................................................................373 12.2.1.2 Operating panel....................................................................375 12.2.1.2.1 Overview operating panel.....................................................375 12.2.1.2.2 Controls.....................................................................376 12.2.1.2.2.1 Replacing the signal button/switch.....................................376 12.2.1.2.2.1.1 Removing the signal button/switch................................376 12.2.1.2.2.1.2 Fitting the signal button/switch.................................377 12.2.1.2.2.2 Replacing the lift/lower button........................................379 12.2.1.2.2.2.1 Removing the lift/lower button...................................379 12.2.1.2.2.2.2 Fitting the lift/lower button....................................380 12.2.1.2.2.2.3 Checking the hydraulic functions.................................381 12.2.1.2.2.3 Replacing the stomach button...........................................381 12.2.1.2.2.3.1 Removing the stomach button......................................381 12.2.1.2.2.3.2 Installing a stomach button......................................382 12.2.1.2.2.3.3 Checking the stomach button......................................383 12.2.1.2.2.4 Replacing the sensilift................................................383 12.2.1.2.2.4.1 Removing the sensilift...........................................383 12.2.1.2.2.4.2 Installing sensilift.............................................384 12.2.1.2.2.5 Changing the position of the controls - support arm lift/fork lift.....384 12.2.1.2.2.6 Replacing the keypad...................................................385 12.2.1.2.2.6.1 Removing the keypad..............................................385 12.2.1.2.2.6.2 Installing a keypad..............................................385 12.2.1.2.3 Replacing the operating panel................................................385 12.2.1.2.3.1 Removing the operating panel...........................................385 12.2.1.2.3.2 Installing an operating panel..........................................386 12.2.1.2.3.3 Checking the speed control.............................................388 12.2.1.2.4 Replacing the operating panel "Built-in".....................................388 12.2.1.2.4.1 Removing the operating panel "Built-in"................................388 12.2.1.2.4.2 Installing the operating panel "Built-in"..............................389 12.2.1.2.4.3 Checking the speed control.............................................390 12.2.1.2.5 Replacing the logic card.....................................................391 12.2.1.2.5.1 Removing the logic card................................................391 12.2.1.2.5.2 Installing a logic card................................................392 12.2.1.2.5.3 Logic card [A5]........................................................393 12.2.1.3 Tiller arm handle..................................................................394 12.2.1.3.1 Replacing the handle to the tiller arm.......................................394 12.2.1.3.1.1 Removing the tiller arm handle.........................................394 12.2.1.3.1.2 Fitting the handle to the tiller arm...................................395 12.2.1.3.2 Replacing the tiller arm handle "Built-in"...................................395 12.2.1.3.2.1 Removing the tiller arm handle "Built-in"..............................395 12.2.1.3.2.2 Installing the tiller arm handle "Built-in"............................396 12.2.1.4 Tiller arm.........................................................................396 12.2.1.4.1 Replacing the tiller arm.....................................................396 12.2.1.4.1.1 Removing the tiller arm................................................396 12.2.1.4.1.2 Fitting tiller arm.....................................................398 12.2.1.4.2 Replacing the tiller arm "Built-in"..........................................400 12.2.1.4.2.1 Removing the tiller arm "Built-in".....................................400 12.2.1.4.2.2 Installing the tiller arm "Built-in"...................................401 12.2.1.4.3 Checking the brake microswitches.............................................403 12.2.1.4.4 Checking the play and the return travel......................................403 12.2.1.4.5 Replacing the tiller arm cover...............................................404 12.2.1.4.5.1 Removing the tiller arm cover..........................................404 12.2.1.4.5.2 Installing the tiller arm cover........................................404 12.2.1.4.6 Replacing the tiller arm cover "Built-in"....................................405 12.2.1.4.6.1 Removing the tiller arm cover "Built-in"...............................405 12.2.1.4.6.2 Installing the tiller arm cover "Built-in".............................405 12.2.1.5 Steering yoke......................................................................407 12.2.1.5.1 Overview steering servo......................................................407 12.2.1.5.2 Overview Ergo................................................................408 12.2.1.5.3 Replacing the steering yoke..................................................409 12.2.1.5.3.1 Removing the steering yoke.............................................409 12.2.1.5.3.2 Installing a steering yoke.............................................410 12.2.1.5.4 Changing the tiller arm spring...............................................410 12.2.1.5.4.1 Removing the tiller arm spring.........................................410 12.2.1.5.4.2 Installing the tiller arm spring.......................................411 12.2.1.5.5 Replacing the safety switch..................................................411 12.2.1.5.5.1 Removing the safety switch [B60].......................................411 12.2.1.5.5.2 Installing the safety switch [B60].....................................413 12.2.1.5.6 Replacing the safety switch "Built-in".......................................413 12.2.1.5.6.1 Removing the safety switch "Built-in"..................................413 12.2.1.5.6.2 Installing the safety switch "Built-in"................................414 12.2.1.6 Steering adapter...................................................................416 12.2.1.6.1 Overview steering servo......................................................416 12.2.1.6.2 Replacing the steering adapter...............................................417 12.2.1.6.2.1 Removing the steering adapter..........................................417 12.2.1.6.2.2 Installing a steering adapter..........................................418 12.2.1.6.3 Replacing the steering adapter cover.........................................420 12.2.1.6.3.1 Removing the steering adapter cover....................................420 12.2.1.6.3.2 Installing the steering adapter cover..................................421 12.2.1.6.4 Replacing a gas strut - height adjuster......................................421 12.2.1.6.4.1 Removing a gas strut - height adjuster.................................421 12.2.1.6.4.2 Installing a gas strut - height adjuster...............................422 12.2.1.6.4.3 Checking the height adjuster...........................................422 12.2.1.6.5 Replacing the height adjustment lock.........................................422 12.2.1.6.5.1 Removing the height adjustment lock....................................422 12.2.1.6.5.2 Installing the height adjustment lock..................................423 12.2.1.6.5.3 Checking the height adjustment lock....................................423 12.2.1.6.6 Replacing the mechanical stop of the steering shaft..........................424 12.2.1.6.6.1 Removing the mechanical stop of the steering shaft (power steering)....424 12.2.1.6.6.2 Fitting the mechanical stop of the steering shaft (power steering).....425 12.2.1.7 Tiller arm wiring harness..........................................................427 12.2.1.7.1 Replacing the tiller arm wiring harness......................................427 12.2.1.7.1.1 Removing the tiller arm wiring harness.................................427 12.2.1.8 Replacing the steering bearing.....................................................430 12.2.1.8.1 Removing the steering bearing................................................430 12.2.1.8.2 Fitting the steering bearing.................................................432 12.2.1.9 Replacing the rubber seals.........................................................433 12.2.1.9.1 Removing rubber seals........................................................433 12.2.1.9.2 Installing rubber seals......................................................434 12.3 Electric steering system C4300.................................................................436 12.3.1 Overview.................................................................................436 12.3.2 Steering angle sensor C4350..............................................................437 12.3.2.1 Description........................................................................437 12.3.2.1.1 Design.......................................................................437 12.3.2.2 Replacing the steering angle sensor servo unit.....................................437 12.3.2.2.1 Removing the steering angle sensor...........................................437 12.3.2.2.2 Installing steering angle sensor.............................................438 12.3.2.3 Checking the reference sensor......................................................439 12.3.2.4 Replacing the steering damper......................................................440 12.3.2.4.1 Removing the steering damper [A83]...........................................440 12.3.2.4.2 Installing the steering damper [A83].........................................440 13 Electrical system C5000..............................................................................447 13.1 Description....................................................................................447 13.1.1 General..................................................................................447 13.1.2 Truck firmware applications..............................................................447 13.2 Software update................................................................................447 13.3 Programming tools..............................................................................447 13.3.1 TruckCom.................................................................................447 13.3.1.1 Connect the CAN interface to the truck.............................................447 13.3.2 Software.................................................................................448 13.3.2.1 Software update....................................................................448 13.4 General electric equipment C5100...............................................................448 13.4.1 Battery C5110............................................................................448 13.4.1.1 Cleaning the battery...............................................................448 13.4.1.2 Checking the connections...........................................................448 13.4.1.3 Checking the battery cables........................................................449 13.4.1.4 Checking the battery...............................................................449 13.4.1.5 Checking cell and terminal protectors..............................................449 13.4.1.6 Checking the level of the electrolyte..............................................449 13.4.1.7 Checking the electrolyte density...................................................450 13.4.1.8 Checking the battery parameters....................................................450 13.4.1.9 Checking the battery voltage.......................................................450 13.4.1.10 Resetting/restarting the battery..................................................450 13.4.1.11 Charging the battery..............................................................451 13.4.1.12 Replacing a battery using a lifting device........................................452 13.4.1.12.1 Removing a battery using a lifting device...................................452 13.4.1.12.2 Installing a battery using a lifting device.................................452 13.4.1.13 Replacing a battery using a battery changing table................................455 13.4.1.13.1 Removing a battery using a battery changing table...........................455 13.4.1.13.2 Installing a battery using a battery changing table.........................455 13.4.2 General alarm signals (audible/visual) C5160.............................................458 13.4.2.1 Horn...............................................................................458 13.4.2.1.1 Overview.....................................................................458 13.4.2.1.2 Checking the horn function...................................................458 13.4.3 Battery charger (built-in) C5170.........................................................458 13.4.3.1 Checking the battery charger cables................................................458 13.4.3.2 Checking the battery charger parameters............................................458 13.4.4 Battery cut out switch, main contactor C5190.............................................459 13.4.4.1 Main contactor.....................................................................459 13.4.4.1.1 Replacing the main contactor.................................................459 13.4.4.1.1.1 Removing the main contactor............................................459 13.4.4.1.1.2 Fitting the main contactor.............................................462 13.5 Instrument panel, display C5200................................................................464 13.5.1 Menu.....................................................................................464 13.5.1.1 Menus..............................................................................464 13.5.1.2 Menu navigation....................................................................464 13.5.1.3 Menu list..........................................................................465 13.5.1.4 Menu information...................................................................465 13.5.1.5 Show hour meter values.............................................................465 13.5.1.6 Show error codes...................................................................466 13.5.1.7 Show part numbers for software/hardware............................................466 13.5.1.8 Built-in test ICH..................................................................466 13.5.1.9 Show collisions....................................................................467 13.5.1.10 Show/change parameters............................................................467 13.5.1.11 Emergency driving mode............................................................467 13.5.1.12 Calibration.......................................................................467 13.5.1.13 Show/change PIN code..............................................................467 13.5.1.14 PIN codes.........................................................................468 13.5.1.14.1 General.....................................................................468 13.5.1.14.2 PIN code for resetting the truck............................................468 13.5.1.14.3 Programming PIN codes.......................................................468 13.5.1.14.4 PIN code defaults...........................................................470 13.5.2 Hour counter, tachograph C5290...........................................................470 13.5.2.1 Checking error log and operating hours.............................................470 13.6 Control system travel function C5300...........................................................470 13.6.1 Direction selector/speed regulator.......................................................470 13.6.2 Pressure equalization....................................................................471 13.6.3 Weighing system..........................................................................471 13.6.4 Display..................................................................................471 13.6.5 Symbols on keypad and display............................................................471 13.6.6 Option buttons...........................................................................471 13.6.7 Signal buttons...........................................................................471 13.6.8 Lifting and lowering control.............................................................471 13.6.9 Hour meter...............................................................................472 13.6.10 Battery indicator.......................................................................472 13.6.11 Safety reversing........................................................................472 13.6.12 Travel function wiring/fuse C5390.......................................................472 13.6.12.1 Description.......................................................................472 13.6.12.1.1 Fuses.......................................................................472 13.7 Power system travel function C5400.............................................................473 13.7.1 Overview.................................................................................473 13.7.2 Transistor panel C5460...................................................................473 13.7.2.1 Description........................................................................473 13.7.2.1.1 General......................................................................473 13.7.2.2 Checking the contactors............................................................474 13.7.2.3 Checking the cable connections.....................................................474 13.7.2.4 Checking the electric panel mounting...............................................474 13.7.2.5 Cleaning the electric panel heatsink...............................................474 13.7.2.6 Replacing the motor control panel..................................................474 13.7.2.6.1 Removing the motor control panel.............................................474 13.7.2.6.2 Installing the motor control panel...........................................475 13.8 Control system, working function C5500.........................................................476 13.8.1 Work function harnesses/fuse C5590.......................................................476 13.8.1.1 Checking the wiring harnesses......................................................476 13.9 Protective sensors, position sensors C5800.....................................................476 13.9.1 Description..............................................................................476 13.9.1.1 Inductive sensors..................................................................476 13.9.1.1.1 Position sensors.............................................................476 13.9.1.1.2 Steering reference sensor....................................................477 13.9.1.2 Pressure sensor....................................................................478 13.9.1.3 Pulse transducer...................................................................478 13.9.2 Safety probes/sensors C5830..............................................................479 13.9.2.1 Emergency switch off...............................................................479 13.9.2.1.1 Description..................................................................479 13.9.2.1.1.1 Task and function......................................................479 13.9.2.1.2 Checking the emergency switch function.......................................479 13.9.2.2 Gate switches [B121]/[B122]........................................................479 13.9.2.2.1 Replacing the gate switch [B120].............................................479 13.9.2.2.1.1 Removing the position sensor [B121]....................................479 13.9.2.2.1.2 Installing the position sensor [B121]..................................480 13.9.2.2.2 Replacing the gate switch [B122].............................................481 13.9.2.2.2.1 Removing the position sensor [B122]....................................481 13.9.2.2.2.2 Installing the position sensor [B122]..................................481 13.9.2.3 Photocell..........................................................................482 13.9.2.3.1 Overview [Photocells for fixed side guards]..................................482 13.9.2.3.2 Description..................................................................482 13.9.2.3.2.1 Function...............................................................482 13.9.2.3.3 Checking the photocell.......................................................482 13.10 Calibrations..................................................................................483 13.10.1 Steering angle calibration..............................................................483 13.10.2 Hydraulic valve calibration.............................................................483 13.10.2.1 Proportional valve calibration....................................................483 13.10.2.2 Tilt angle calibration............................................................484 13.10.3 Pressure sensor calibration.............................................................484 13.10.3.1 Weight measuring calibration......................................................484 13.10.3.2 Overload calibration..............................................................485 14 Hydraulics/Pneumatics C6000..........................................................................489 14.1 Overview.......................................................................................489 14.2 Description....................................................................................489 14.2.1 Hydraulic hygiene........................................................................489 14.2.1.1 Washing............................................................................489 14.2.1.2 Packaging..........................................................................490 14.2.1.3 Handling...........................................................................490 14.2.1.4 Storage............................................................................490 14.2.1.5 Work procedures....................................................................490 14.2.1.6 General rules......................................................................490 14.2.1.7 Measures...........................................................................491 14.2.2 Design...................................................................................492 14.3 Quick change connectors........................................................................492 14.3.1 Overview quick change connectors.........................................................492 14.3.2 Removing quick change connectors (female)................................................492 14.3.3 Installing quick change connector (female)...............................................493 14.3.4 Removing a quick change connector (male).................................................494 14.3.5 Installing a quick change connector (male)...............................................495 14.4 Hydraulic unit C6100...........................................................................496 14.4.1 Hydraulic unit...........................................................................496 14.4.2 Description..............................................................................496 14.4.2.1 Pressure limiting valve............................................................496 14.4.3 Hydraulic oil tank C6110.................................................................497 14.4.3.1 Tank...............................................................................497 14.4.3.2 Description........................................................................497 14.4.3.2.1 Design.......................................................................497 14.4.3.3 Cleaning the tank..................................................................497 14.4.3.4 Checking the tank..................................................................497 14.4.3.5 Oil change.........................................................................498 14.4.3.5.1 Draining oil.................................................................498 14.4.3.5.2 Topping up with oil..........................................................498 14.4.3.6 Replacing the tank.................................................................499 14.4.3.6.1 Removing the tank............................................................499 14.4.3.6.2 Fitting the tank.............................................................500 14.4.4 Filter, filter housing C6130.............................................................500 14.4.4.1 Cleaning the suction filter........................................................500 14.4.4.2 Oil filter replacement.............................................................500 14.4.4.2.1 Removing oil filter..........................................................500 14.4.4.2.2 Installing the oil filter....................................................501 14.4.4.3 Replacing the suction filter.......................................................502 14.4.4.3.1 Removing suction filter......................................................502 14.4.4.3.2 Installing the suction filter................................................502 14.4.5 Hydraulic pump C6140.....................................................................503 14.4.5.1 Hydraulic pump.....................................................................503 14.4.5.2 Description........................................................................503 14.4.5.2.1 Design.......................................................................503 14.4.6 Pressure/flow control valve C6170........................................................503 14.4.6.1 Description........................................................................503 14.4.6.1.1 Checking the pressure limiting valve.........................................503 14.4.6.2 Replacing the flow control valve...................................................504 14.4.6.2.1 Removing the flow control valve..............................................504 14.4.6.2.2 Fitting the flow control valve...............................................505 14.4.6.3 Replacing the pressure limiting valve..............................................505 14.4.6.3.1 Removing the pressure limiting valve.........................................505 14.4.6.3.2 Fitting the pressure limiting valve..........................................506 14.4.7 Replacing the hydraulic unit.............................................................506 14.4.7.1 Removing the hydraulic unit........................................................506 14.4.7.2 Installing the hydraulic unit......................................................507 14.4.8 Replacing the valve coil.................................................................508 14.4.8.1 Removing the valve coil............................................................508 14.4.8.2 Fitting the valve coil.............................................................509 14.4.9 Replacing the pressure sensor............................................................510 14.4.9.1 Removing the pressure sensor.......................................................510 14.4.9.2 Fitting the pressure sensor........................................................510 14.5 Hydraulic system, fitted on the mast C6300.....................................................510 14.5.1 Mast hydraulic conduits C6320............................................................510 14.5.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit...........510 14.5.1.2 Checks for leaks from hydraulic conduits and connections, mast.....................511 14.6 Hydraulic cylinder C6600.......................................................................511 14.6.1 Main lift cylinders C6610................................................................511 14.6.1.1 Checking for leaks in the lift cylinder............................................511 14.6.1.2 Replacing the main lift cylinders..................................................511 14.6.1.2.1 Removing the lift cylinder...................................................511 14.6.1.2.2 Fitting the lift cylinder....................................................513 14.6.2 Support arm/initial lift cylinder C6630..................................................515 14.6.2.1 Replacing the main initial lift cylinder...........................................515 14.6.2.1.1 Removing the initial lift cylinder...........................................515 14.6.2.1.2 Installing the initial lift cylinder.........................................516 14.6.3 PowerTrak cylinder C6680.................................................................517 14.6.3.1 Replacing the PowerTrak cylinder...................................................517 14.6.3.1.1 Removing the PowerTrak cylinder..............................................517 14.6.3.1.2 Installing the PowerTrak cylinder............................................519 15 Work function - lifting masts C7000..................................................................523 15.1 Description....................................................................................523 15.1.1 Ordering a replacement mast..............................................................523 15.2 Chain system, general..........................................................................523 15.2.1 General..................................................................................523 15.2.2 Adjusting the chain......................................................................523 15.2.3 Lubrication..............................................................................523 15.2.4 Checking the chains......................................................................524 15.2.4.1 Noise..............................................................................524 15.2.4.2 Surface rust.......................................................................524 15.2.4.3 Rusty links........................................................................524 15.2.4.4 Stiff links........................................................................524 15.2.4.5 Bolt rotation......................................................................524 15.2.4.6 Loose bolts........................................................................525 15.2.4.7 Outline wear.......................................................................525 15.2.4.8 Chain gauge........................................................................526 15.2.4.9 Stretching.........................................................................526 15.2.4.10 Damaged plates....................................................................527 15.2.4.11 Damaged bolts.....................................................................527 15.2.4.12 Other damage......................................................................527 15.2.4.13 Dirty chain.......................................................................527 15.3 Checking the chains............................................................................528 15.4 Lubricating the chains.........................................................................528 15.5 Checking the split pins........................................................................529 15.6 Check-tighten the locking nuts.................................................................529 15.7 Main mast C7100................................................................................529 15.7.1 Check the position of the mast guide.....................................................529 15.7.2 Check for cracks/damages to the mast.....................................................530 15.7.3 Lubrication of the mast roller guides ...................................................530 15.7.4 Measuring the mast inclination...........................................................530 15.7.5 Adjusting the mast inclination...........................................................531 15.7.6 Replacing the roller.....................................................................532 15.7.6.1 Installing a roller................................................................532 15.7.7 Replacement of the mast..................................................................532 15.7.7.1 Disassembling the mast.............................................................532 15.7.7.2 Removing a roller..................................................................534 15.7.7.3 Assembling the mast................................................................535 15.7.7.4 Installing a roller................................................................537 15.7.8 Main mast fork carriage C7130............................................................537 15.7.8.1 Replacing the idler roller.........................................................537 15.7.8.1.1 Removing a roller............................................................537 15.7.9 Initial lift of frame/mast C7160.........................................................538 15.7.9.1 Replacing the main initial lift cylinder...........................................538 15.7.9.1.1 Disassembling the fork carriage..............................................538 15.7.9.1.2 Installing a fork carriage...................................................539 15.7.10 Main mast suspension C7190..............................................................540 15.7.10.1 Mast mount........................................................................540 15.7.10.1.1 Tightening the upper mast fixing points.....................................540 15.7.10.1.2 Check-tighten the locking nuts..............................................541 15.7.10.1.3 Tightening the lower mast fixing points.....................................541 15.8 Lifting/carrying/clamping devices C7400........................................................541 15.8.1 Fork carriage unit/with integrated sideshift/fork spread C7420...........................541 15.8.1.1 Checking the fork carriage.........................................................541 15.8.1.2 Check the play of the fork carriage................................................541 15.8.1.3 Lubricating the beams..............................................................542 15.8.1.4 Measuring the fork-to-floor distance...............................................542 15.8.1.5 Replacing the fork carriage........................................................542 15.8.1.5.1 Disassembling the fork carriage..............................................542 15.8.1.5.2 Installing a fork carriage...................................................544 16 Auxiliary equipment, installation equipment C8000....................................................549 17 Optional equipment/Extra equipment C9000.............................................................553 17.1 Overview.......................................................................................553 17.2 Extra electrical equipment C9400...............................................................554 17.2.1 Extra power socket.......................................................................554 17.2.1.1 Overview...........................................................................554 17.2.1.2 Description........................................................................554 17.2.1.2.1 DC/DC converter..............................................................554 17.2.2 Truck log equipment, code lock C9420.....................................................555 17.2.2.1 Overview...........................................................................555 17.2.2.2 I_Site.............................................................................555 17.2.2.2.1 Description..................................................................555 17.2.2.2.1.1 I_Site.................................................................555 17.2.2.3 Impact Manager.....................................................................556 17.2.2.3.1 Description..................................................................556 17.2.2.3.1.1 Collision sensor.......................................................556 17.2.2.3.2 Checking the reference sensor parameters.....................................556 17.2.2.3.3 Checking DHU/TWIS [K110].....................................................556 17.3 Other extra equipment C9500....................................................................556 17.3.1 Ground strap.............................................................................556 17.3.1.1 Replacing the ground strap.........................................................556 17.3.1.1.1 Removing the ground strap....................................................556 17.3.1.1.2 Installing a ground strap....................................................557 17.3.2 Fire extinguisher........................................................................558 17.3.2.1 Description........................................................................558 17.3.2.1.1 Fire extinguisher............................................................558 17.3.3 Horizontal E-bar.........................................................................559 17.3.3.1 Description........................................................................559 17.3.3.1.1 E-bar........................................................................559 17.3.3.2 Checking the E-bar lock............................................................559 17.3.4 Spider expansion unit....................................................................560 17.3.4.1 Description........................................................................560 17.3.4.1.1 Spider expansion unit........................................................560 18 Instructions for disposal............................................................................563 18.1 General........................................................................................563 18.2 Marking of plastics............................................................................563 18.2.1 General marking of products and packaging................................................563 18.2.2 Marking according to the manufacturer’s standards........................................563 18.2.2.1 Abbreviations......................................................................563 18.2.2.2 Marking examples...................................................................564 18.3 Pressure vessels...............................................................................564 18.3.1 Gas struts...............................................................................564 18.4 Sorting categories.............................................................................565 19 Wiring diagram.......................................................................................569 19.1 Colour code table..............................................................................569 19.2 Diagram........................................................................................569 19.2.1 Component list...........................................................................569 19.2.2 Component placement......................................................................573 19.2.3 Detailed diagrams........................................................................587 20 Hydraulics schematics................................................................................615 20.1 Component list.................................................................................615 20.2 Component location.............................................................................616 20.2.1 Picture 1................................................................................616 20.2.2 Picture 2................................................................................617 20.2.3 Picture 3................................................................................618 20.2.4 Picture 4................................................................................618 20.3 Valve unit.....................................................................................620 20.3.1 Valve unit 1-function....................................................................620 20.3.2 Valve unit 2-functions...................................................................621 20.3.3 Valve unit 1-function + AUX..............................................................622 20.4 Diagram........................................................................................623 20.5 Diagram........................................................................................623 20.6 Diagram........................................................................................625 21 Tools................................................................................................629 21.1 Tools for electric connectors..................................................................629 21.1.1 AMP connectors...........................................................................629 21.1.2 MQS connectors...........................................................................629 21.1.3 CPC connectors...........................................................................630 21.1.4 AMP Seal connectors......................................................................631 21.2 Special tools..................................................................................631 22 Service data and grease specifications...............................................................635 22.1 General tightening torques.....................................................................635 22.1.1 Galvanised, non-oiled screws.............................................................635 22.1.2 Untreated, oiled screws..................................................................635 22.2 Lubricants specification.......................................................................636 23 Technical data.......................................................................................639 24 .....................................................................................................641
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