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BT Forklift SWE140S SWE145 SWE145L SWE160 SWE160L SWE200 SWE200L Repair Manual
BT Forklift SWE140S SWE145 SWE145L SWE160 SWE160L SWE200 SWE200L Repair Manual – PDF DOWNLOAD
FILE DETAILS:
BT Forklift SWE140S SWE145 SWE145L SWE160 SWE160L SWE200 SWE200L Repair Manual – PDF DOWNLOAD
Language : English
Pages : 532
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift SWE140S SWE145 SWE145L SWE160 SWE160L SWE200 SWE200L 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................................................................................. 26 4.4 Parameter list................................................................................. 26 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 6.3 ............................................................................................... 75 6.4 ............................................................................................... 75 7 Troubleshooting...................................................................................... 79 7.1 Auxiliary functions............................................................................ 79 7.1.1 Towing a defective truck................................................................. 79 7.1.1.1 Towing and transporting a defective truck.......................................... 79 7.1.2 Emergency driving mode................................................................... 79 7.1.2.1 Emergency driving mode............................................................. 79 7.1.3 Error code history....................................................................... 80 7.1.3.1 Error code history................................................................. 80 7.1.4 Extended error log....................................................................... 80 7.1.4.1 Extended error log................................................................. 80 7.1.5 Built-in test function for the tiller arm................................................ 80 7.1.5.1 General............................................................................ 80 7.1.5.2 Display test....................................................................... 81 7.1.5.3 Speed control...................................................................... 81 7.1.5.4 Safety reversing................................................................... 82 7.1.5.5 Controls for lifting/lowering...................................................... 82 7.1.5.6 Sensilift.......................................................................... 83 7.1.5.7 Keypad............................................................................. 83 7.2 Initial troubleshooting........................................................................ 84 7.3 Concluding troubleshooting..................................................................... 84 7.4 Troubleshooting using error codes.............................................................. 84 7.4.1 List of error codes...................................................................... 84 8 Chassis C0000........................................................................................153 8.1 Overview.......................................................................................153 8.2 Frame, chassis C0300...........................................................................154 8.2.1 Inspection covers C0340..................................................................154 8.2.1.1 Motor compartment covers...........................................................154 8.2.1.1.1 Overview.....................................................................154 8.2.1.1.2 Replacing a service cover....................................................154 8.2.1.1.2.1 Removing the service cover.............................................154 8.2.1.1.2.2 Fitting the service cover..............................................155 8.2.1.1.3 Replacing an emblem cover....................................................156 8.2.1.1.3.1 Removing the emblem cover..............................................156 8.2.1.1.3.2 Fitting the emblem cover...............................................156 8.2.2 Support arms, stabilizers C0350..........................................................157 8.2.2.1 Overview...........................................................................157 8.2.2.2 Checking the linkage...............................................................158 8.2.2.3 Checking the wheel fork flexibility................................................158 8.2.2.4 Replacing the pressure rod.........................................................159 8.2.2.4.1 Removing a push rod..........................................................159 8.2.2.4.2 Installing a push rod........................................................162 8.2.2.5 Replacing torsion tubes............................................................164 8.2.2.5.1 Removing torsion tubes.......................................................164 8.2.2.5.2 Installing a torsion tube....................................................165 8.2.2.6 Replacing the roller on the torsion tube...........................................166 8.2.2.6.1 Removing the roller on the torsion tube......................................166 8.2.2.6.2 Fit the roller on the torsion tube...........................................168 8.2.2.7 Replacing a wheel fork.............................................................169 8.2.2.7.1 Removing wheel fork..........................................................169 8.2.2.7.2 Installing a wheel fork......................................................170 8.2.2.8 Replacing a bogie link, fork wheel.................................................172 8.2.2.8.1 Removing a bogie link, fork wheel............................................172 8.2.2.8.2 Fitting a bogie link, fork wheel.............................................173 8.2.2.9 Replacing a bogie link, support arm................................................173 8.2.2.9.1 Removing a bogie link, support arm...........................................173 8.2.2.9.2 Installing a bogie link, support arm.........................................174 8.2.2.10 Replacing the wheel fork bushing..................................................174 8.2.2.10.1 Removing the wheel fork bushing.............................................174 8.2.2.10.2 Fitting the wheel fork bushing..............................................175 8.2.2.11 Replacing the support arm bushing.................................................175 8.2.2.11.1 Removing the support arm bushing............................................175 8.2.2.11.2 Installing a support arm bushing............................................176 8.2.3 Fork structure (low-lifter) C0380........................................................176 8.2.3.1 Checking the fork lift height limitation...........................................176 8.2.4 Battery compartment parts C0390..........................................................177 8.2.4.1 Overview...........................................................................177 8.2.4.2 Overview...........................................................................178 8.2.4.3 Description........................................................................178 8.2.4.3.1 Design.......................................................................178 8.3 Frame/chassis components C0400.................................................................178 8.3.1 Motor mount/brackets C0450...............................................................178 8.3.1.1 Checking the motor mounts..........................................................178 8.3.1.2 Drive unit mountings...............................................................179 8.3.1.2.1 Drive unit mounting 6 km/h SWE...............................................179 8.3.1.2.1.1 Overview 6 km/h........................................................179 8.3.1.2.1.2 Description............................................................179 8.3.1.2.1.2.1 Technical data...................................................179 8.3.1.2.1.2.2 Technical data...................................................180 8.3.1.2.1.2.3 Technical data...................................................180 8.3.1.2.1.2.4 Technical data...................................................180 8.3.1.2.1.2.5 Technical data...................................................181 8.3.1.2.1.2.6 Technical data...................................................181 8.3.1.2.1.2.7 Technical data...................................................181 8.3.1.2.1.3 Replacing the drive unit mounting 6 km/h...............................182 8.3.1.2.1.3.1 Removing the drive unit mounting 6 km/h..........................182 8.3.1.2.1.3.2 Installing the drive unit mounting 6 km/h........................183 8.3.1.3 PowerTrak..........................................................................185 8.3.1.3.1 Description..................................................................185 8.3.1.3.1.1 Design.................................................................185 8.3.1.3.2 Increasing the spring tension................................................187 8.3.1.3.3 Releasing the spring tension.................................................189 8.3.1.3.4 Adjusting tool V08-18302.....................................................191 8.3.1.3.5 Replacing the initial pressure spring........................................192 8.3.1.3.5.1 Removing the initial pressure spring...................................192 8.3.1.3.5.2 Fitting the initial pressure spring....................................193 8.3.1.3.6 Replacing the PowerTrak spring...............................................194 8.3.1.3.6.1 Removing the PowerTrak spring..........................................194 8.3.1.3.6.2 Installing the PowerTrak spring........................................196 8.3.1.3.7 Replacing a spacer...........................................................198 8.3.1.3.7.1 Removing a spacer......................................................198 8.3.1.3.7.2 Installing a spacer....................................................199 8.3.1.4 Decompression locking..............................................................200 8.3.1.4.1 Overview.....................................................................200 8.3.1.4.2 Description..................................................................200 8.3.1.4.2.1 Design.................................................................200 8.3.1.4.3 Purging the decompression lock...............................................201 8.3.1.4.4 Checking the decompression lock..............................................203 8.3.1.4.5 Replacing the decompression lock.............................................203 8.3.1.4.5.1 Removing the decompression lock........................................203 8.3.1.4.5.2 Fitting the decompression lock.........................................205 8.4 Operator compartment, cab C0500................................................................207 8.4.1 Platform including fixing points C0560...................................................207 8.4.1.1 Replacing the platform.............................................................207 8.4.1.1.1 Removing the platform........................................................207 8.4.1.1.2 Fitting the platform.........................................................207 8.5 Safety equipment C0800.........................................................................208 8.5.1 Signs, warnings, labels C0850............................................................208 8.5.1.1 Checking signs and labels..........................................................208 8.5.1.2 Placement of signs.................................................................208 8.5.1.3 Placement of signs.................................................................210 8.5.1.4 Placement of signs.................................................................212 9 Motors C1000.........................................................................................217 9.1 Electric motors C1700..........................................................................217 9.1.1 Electric pump motor C1710................................................................217 9.1.1.1 Overview...........................................................................217 9.1.1.2 Replacing the pump motor...........................................................217 9.1.1.2.1 Removing a pump motor........................................................217 9.1.1.2.2 Installing a pump motor......................................................218 9.1.2 Electric fan motor/fan C1740.............................................................219 9.1.2.1 Overview...........................................................................219 9.1.2.2 Description........................................................................219 9.1.2.2.1 Design.......................................................................219 9.1.2.3 Replacing the motor control fan....................................................220 9.1.2.3.1 Removing a motor control fan.................................................220 9.1.2.3.2 Installing a motor control fan...............................................221 9.1.3 Electric drive motor C1760...............................................................222 9.1.3.1 Overview 1.8, 2.5 kW...............................................................222 9.1.3.2 Description........................................................................222 9.1.3.2.1 Design.......................................................................222 9.1.3.3 Check the rotational speed sensor fitting..........................................223 9.1.3.4 Checking the electrical connections................................................223 9.1.3.5 Checking the drive motor...........................................................223 9.1.3.6 Listen for any abnormal noise in the drive motor bearings..........................223 9.1.3.7 Check the drive motor fitting (1.8 and 2.5 kW).....................................223 9.1.3.8 Checking the rotational speed sensor...............................................223 9.1.3.9 Replacing the drive motor..........................................................223 9.1.3.9.1 Removing the drive motor [M1]................................................223 9.1.3.9.2 Installing the drive motor [M1]..............................................227 9.1.3.10 Replacing the temperature sensor..................................................230 9.1.3.10.1 Installing the temperature sensor...........................................230 9.1.3.11 Replacing the rotational speed sensor.............................................231 9.1.3.11.1 Removing a rotational speed sensor..........................................231 9.1.3.11.2 Installing a rotational speed sensor........................................233 9.1.3.12 Replacing the toothed wheel.......................................................234 9.1.3.12.1 Removing a toothed wheel....................................................234 9.1.3.12.2 Installing a toothed wheel..................................................235 10 Transmission/Drive gear C2000.......................................................................239 10.1 Drive unit, final gear C2500..................................................................239 10.1.1 Drive unit/gear C2550 ..................................................................239 10.1.1.1 Overview..........................................................................239 10.1.1.2 Description ......................................................................239 10.1.1.2.1 Design......................................................................239 10.1.1.2.2 Technical data..............................................................240 10.1.1.3 Check the drive gear's attachment ................................................240 10.1.1.4 Checking for leaks in the drive gear..............................................240 10.1.1.5 Checking for noise in the drive gear..............................................240 10.1.1.6 Replacing the drive gear .........................................................240 10.1.1.6.1 Removing the drive gear.....................................................240 10.1.1.6.2 Installing the drive gear...................................................243 10.1.1.7 Replacing the wheel hub seal .....................................................244 10.1.1.7.1 Removing the wheel hub seal.................................................244 10.1.1.7.2 Installing the wheel hub seal...............................................246 10.1.1.8 Drive gear oil change.............................................................246 10.1.1.8.1 Empty the drive gear oil....................................................247 10.1.1.8.2 Filling oil in the drive gear...............................................248 10.1.1.9 Replacing the drive gear steering bearing ........................................248 10.1.1.9.1 Removing the drive gear steering bearing....................................248 10.1.1.9.2 Installing the drive gear steering bearing..................................249 10.1.1.10 Stud replacement ................................................................250 10.1.1.10.1 Removing a stud............................................................250 10.1.1.10.2 Installing a stud..........................................................251 11 Brake/wheel/track system C3000......................................................................255 11.1 Travel brake system C3100.....................................................................255 11.1.1 Description.............................................................................255 11.1.1.1 Brake types.......................................................................255 11.1.1.1.1 Travel brake................................................................255 11.1.1.1.2 Emergency brake.............................................................255 11.1.1.1.3 Parking brake...............................................................255 11.2 Parking brake details C3300...................................................................256 11.2.1 Electrical parking brake, magnet brake C3370............................................256 11.2.1.1 Overview..........................................................................256 11.2.1.2 Description.......................................................................257 11.2.1.2.1 Technical data..............................................................257 11.2.1.3 Cleaning the parking brake........................................................257 11.2.1.4 Adjusting the parking brake gap...................................................258 11.2.1.5 Adjusting the parking brake gap...................................................258 11.2.1.6 Tighten the parking brake mounting bolts..........................................259 11.2.1.7 Emergency release of the parking brake............................................259 11.2.1.8 Checking the parking brake........................................................260 11.2.1.9 Replacing the brake hub...........................................................260 11.2.1.9.1 Disassembling the brake hub.................................................260 11.2.1.9.2 Installing a brake hub......................................................261 11.2.1.10 Replacing the friction disc......................................................261 11.2.1.10.1 Removing the friction disc.................................................261 11.2.1.10.2 Fitting the friction disc..................................................262 11.2.1.11 Replacing the parking brake......................................................263 11.2.1.11.1 Removing the parking brake.................................................263 11.2.1.11.2 Fitting the parking brake..................................................264 11.3 Wheels C3500..................................................................................266 11.3.1 Drive wheel C3530.......................................................................266 11.3.1.1 Overview..........................................................................266 11.3.1.2 Description.......................................................................267 11.3.1.2.1 Wheel wear..................................................................267 11.3.1.3 Measuring the drive wheel tread...................................................267 11.3.1.4 Replacing the drive wheel.........................................................267 11.3.1.4.1 Removing the drive wheel....................................................267 11.3.1.4.2 Fitting the drive wheel.....................................................269 11.3.2 Support arm wheels/castor wheels C3540..................................................270 11.3.2.1 Overview..........................................................................270 11.3.2.2 Description.......................................................................271 11.3.2.2.1 Wheel wear..................................................................271 11.3.2.3 Cleaning castor wheels............................................................271 11.3.2.4 Measuring the castor wheel tread..................................................271 11.3.2.5 Measuring the castor wheel tread..................................................272 11.3.2.6 Measuring the castor wheel tread..................................................272 11.3.2.7 Measuring the castor wheel tread..................................................272 11.3.2.8 Checking the castor wheels........................................................272 11.3.2.9 Replacing the castor wheel........................................................272 11.3.2.9.1 Removing the castor.........................................................272 11.3.2.9.2 Removing the castor.........................................................273 11.3.2.9.3 Installing a castor wheel...................................................274 11.3.2.9.4 Installing a castor wheel...................................................275 11.3.2.10 Replacing the castor wheel assembly..............................................276 11.3.2.10.1 Removing the castor wheel assembly.........................................276 11.3.2.10.2 Installing the castor wheel assembly.......................................277 11.3.3 Fork wheels/support arm wheels C3550....................................................278 11.3.3.1 Overview..........................................................................278 11.3.3.2 Description.......................................................................278 11.3.3.2.1 Wheel wear..................................................................278 11.3.3.3 Cleaning the fork wheels..........................................................279 11.3.3.4 Measuring the fork wheel tread....................................................279 11.3.3.5 Checking the fork wheel mounting..................................................279 11.3.3.6 Checking the fork wheel bushings..................................................279 11.3.3.7 Replacing a single wheel..........................................................279 11.3.3.7.1 Removing single wheels......................................................279 11.3.3.7.2 Single wheel installation...................................................280 11.3.3.8 Replacing bogie wheels............................................................281 11.3.3.8.1 Removing bogie wheels.......................................................281 11.3.3.8.2 Removing bogie wheels.......................................................283 11.3.3.8.3 Fitting the bogie wheel.....................................................285 11.3.3.8.4 Fitting the bogie wheel.....................................................286 11.3.3.9 Replacing a bogie link............................................................288 11.3.3.9.1 Removing a bogie link.......................................................288 11.3.3.9.2 Removing a bogie link.......................................................288 11.3.3.9.3 Installing a bogie link.....................................................289 11.3.3.9.4 Installing a bogie link.....................................................289 12 Steering system C4000...............................................................................293 12.1 Mechanical steering system C4100..............................................................293 12.1.1 Steering arm/wheel/lever C4110..........................................................293 12.1.1.1 Overview tiller arm...............................................................293 12.1.1.2 Operating panel...................................................................294 12.1.1.2.1 Overview operating panel....................................................294 12.1.1.2.2 Controls....................................................................295 12.1.1.2.2.1 Replacing the signal button/switch....................................295 12.1.1.2.2.1.1 Removing the signal button/switch...............................295 12.1.1.2.2.1.2 Fitting the signal button/switch................................296 12.1.1.2.2.2 Replacing the lift/lower button.......................................298 12.1.1.2.2.2.1 Removing the lift/lower button..................................298 12.1.1.2.2.2.2 Fitting the lift/lower button...................................299 12.1.1.2.2.2.3 Checking the hydraulic functions................................300 12.1.1.2.2.3 Replacing the stomach button..........................................300 12.1.1.2.2.3.1 Removing the stomach button.....................................300 12.1.1.2.2.3.2 Installing a stomach button.....................................301 12.1.1.2.2.3.3 Checking the stomach button.....................................302 12.1.1.2.2.4 Replacing the sensilift...............................................302 12.1.1.2.2.4.1 Removing the sensilift..........................................302 12.1.1.2.2.4.2 Installing sensilift............................................303 12.1.1.2.2.5 Changing the position of the controls - support arm lift/fork lift....303 12.1.1.2.2.6 Replacing the keypad..................................................304 12.1.1.2.2.6.1 Removing the keypad.............................................304 12.1.1.2.2.6.2 Installing a keypad.............................................304 12.1.1.2.3 Replacing the operating panel...............................................304 12.1.1.2.3.1 Removing the operating panel..........................................304 12.1.1.2.3.2 Installing an operating panel.........................................305 12.1.1.2.3.3 Checking the speed control............................................307 12.1.1.2.4 Replacing the logic card....................................................307 12.1.1.2.4.1 Removing the logic card...............................................307 12.1.1.2.4.2 Installing a logic card...............................................308 12.1.1.2.4.3 Logic card [A5].......................................................310 12.1.1.3 Tiller arm handle.................................................................310 12.1.1.3.1 Replacing the handle to the tiller arm......................................310 12.1.1.3.1.1 Removing the tiller arm handle........................................310 12.1.1.3.1.2 Fitting the handle to the tiller arm..................................311 12.1.1.4 Tiller arm........................................................................312 12.1.1.4.1 Replacing the tiller arm....................................................312 12.1.1.4.1.1 Removing the tiller arm...............................................312 12.1.1.4.1.2 Fitting tiller arm....................................................314 12.1.1.4.2 Replacing the tiller arm assembly...........................................316 12.1.1.4.2.1 Removing the tiller arm assembly......................................316 12.1.1.4.2.2 Fitting the tiller arm assembly.......................................317 12.1.1.4.3 Checking the brake microswitches............................................318 12.1.1.4.4 Checking the play and the return travel.....................................318 12.1.1.4.5 Replacing the tiller arm cover..............................................319 12.1.1.4.5.1 Removing the tiller arm cover.........................................319 12.1.1.4.5.2 Fitting the tiller arm cover..........................................319 12.1.1.4.6 Replacing the tiller arm housing............................................320 12.1.1.4.6.1 Removing the tiller arm housing.......................................320 12.1.1.4.6.2 Fitting the tiller arm housing........................................321 12.1.1.5 Steering yoke.....................................................................322 12.1.1.5.1 Overview steering servo.....................................................322 12.1.1.5.2 Replacing the steering yoke.................................................322 12.1.1.5.2.1 Removing the steering yoke............................................322 12.1.1.5.2.2 Fitting the steering yoke.............................................324 12.1.1.5.3 Replacing the steering yoke cover...........................................325 12.1.1.5.3.1 Removing the steering yoke cover......................................325 12.1.1.5.3.2 Fitting the steering yoke cover.......................................326 12.1.1.5.4 Changing the tiller arm damper..............................................326 12.1.1.5.4.1 Removing the tiller arm damper........................................326 12.1.1.5.4.2 Installing the tiller arm damper......................................328 12.1.1.5.5 Replacing the safety switch.................................................329 12.1.1.5.5.1 Removing the safety switch [B60]......................................329 12.1.1.5.5.2 Installing the safety switch [B60]....................................330 12.1.1.6 Tiller arm wiring harness.........................................................331 12.1.1.6.1 Replacing the tiller arm wiring harness.....................................331 12.1.1.6.1.1 Removing the tiller arm wiring harness................................331 12.1.1.6.1.2 Fitting the tiller arm wiring harness.................................332 12.2 Electric steering system C4300................................................................333 12.2.1 Steering angle sensor C4350.............................................................333 12.2.1.1 Replacing the steering angle sensor mech. ........................................333 12.2.1.1.1 Removing the steering angle sensor mech.....................................333 12.2.1.1.2 Installing the steering angle sensor mech...................................335 13 Electrical system C5000.............................................................................341 13.1 Description...................................................................................341 13.1.1 General.................................................................................341 13.1.2 Truck firmware applications.............................................................341 13.2 Software update...............................................................................341 13.3 Programming tools.............................................................................341 13.3.1 TruckCom................................................................................341 13.3.1.1 Connect the CAN interface to the truck............................................341 13.3.2 Software................................................................................342 13.3.2.1 Software update...................................................................342 13.4 General electric equipment C5100..............................................................342 13.4.1 Battery C5110...........................................................................342 13.4.1.1 Cleaning the battery..............................................................342 13.4.1.2 Checking the connections..........................................................342 13.4.1.3 Checking the battery cables.......................................................343 13.4.1.4 Checking the battery..............................................................343 13.4.1.5 Checking cell and terminal protectors.............................................343 13.4.1.6 Checking the level of the electrolyte.............................................343 13.4.1.7 Checking the electrolyte density..................................................344 13.4.1.8 Checking the battery parameters...................................................344 13.4.1.9 Checking the battery voltage......................................................344 13.4.1.10 Resetting/restarting the battery.................................................344 13.4.1.11 Charging the battery.............................................................345 13.4.1.12 Replacing a battery using a lifting device.......................................346 13.4.1.12.1 Removing a battery using a lifting device..................................346 13.4.1.12.2 Installing a battery using a lifting device................................346 13.4.1.13 Replacing a battery using a battery changing table...............................349 13.4.1.13.1 Removing a battery using a battery changing table..........................349 13.4.1.13.2 Installing a battery using a battery changing table........................349 13.4.2 General alarm signals (audible/visual) C5160............................................352 13.4.2.1 Horn..............................................................................352 13.4.2.1.1 Overview....................................................................352 13.4.2.1.2 Checking the horn function..................................................352 13.4.3 Battery charger (built-in) C5170........................................................352 13.4.3.1 Checking the battery charger cables...............................................352 13.4.3.2 Checking the battery charger parameters...........................................352 13.4.4 Battery cut out switch, main contactor C5190............................................353 13.4.4.1 Main contactor....................................................................353 13.4.4.1.1 Replacing the main contactor................................................353 13.4.4.1.1.1 Removing the main contactor...........................................353 13.4.4.1.1.2 Fitting the main contactor............................................356 13.5 Instrument panel, display C5200...............................................................358 13.5.1 Menu....................................................................................358 13.5.1.1 Menus.............................................................................358 13.5.1.2 Menu navigation...................................................................358 13.5.1.3 Menu list.........................................................................359 13.5.1.4 Menu information..................................................................359 13.5.1.5 Show hour meter values............................................................359 13.5.1.6 Show error codes..................................................................360 13.5.1.7 Show part numbers for software/hardware...........................................360 13.5.1.8 Built-in test ICH.................................................................360 13.5.1.9 Show collisions...................................................................361 13.5.1.10 Show/change parameters...........................................................361 13.5.1.11 Emergency driving mode...........................................................361 13.5.1.12 Calibration......................................................................361 13.5.1.13 Show/change PIN code.............................................................361 13.5.1.14 PIN codes........................................................................362 13.5.1.14.1 General....................................................................362 13.5.1.14.2 PIN code for resetting the truck...........................................362 13.5.1.14.3 Programming PIN codes......................................................362 13.5.1.14.4 PIN code defaults..........................................................364 13.5.2 Hour counter, tachograph C5290..........................................................364 13.5.2.1 Checking error log and operating hours............................................364 13.6 Control system travel function C5300..........................................................364 13.6.1 Direction selector/speed regulator......................................................364 13.6.2 Pressure equalization...................................................................365 13.6.3 Weighing system.........................................................................365 13.6.4 Display.................................................................................365 13.6.5 Symbols on keypad and display...........................................................365 13.6.6 Option buttons..........................................................................365 13.6.7 Signal buttons..........................................................................365 13.6.8 Lifting and lowering control............................................................365 13.6.9 Hour meter..............................................................................366 13.6.10 Battery indicator......................................................................366 13.6.11 Safety reversing.......................................................................366 13.6.12 Travel function wiring/fuse C5390......................................................366 13.6.12.1 Description......................................................................366 13.6.12.1.1 Fuses......................................................................366 13.7 Power system travel function C5400............................................................367 13.7.1 Overview................................................................................367 13.7.2 Transistor panel C5460..................................................................367 13.7.2.1 Description.......................................................................367 13.7.2.1.1 General.....................................................................367 13.7.2.2 Checking the contactors...........................................................368 13.7.2.3 Checking the cable connections....................................................368 13.7.2.4 Checking the electric panel mounting..............................................368 13.7.2.5 Cleaning the electric panel heatsink..............................................368 13.7.2.6 Replacing the motor control panel.................................................368 13.7.2.6.1 Removing the motor control panel............................................368 13.7.2.6.2 Installing the motor control panel..........................................369 13.8 Control system, working function C5500........................................................370 13.8.1 Work function harnesses/fuse C5590......................................................370 13.8.1.1 Checking the wiring harnesses.....................................................370 13.9 Protective sensors, position sensors C5800....................................................370 13.9.1 Description.............................................................................370 13.9.1.1 Inductive sensors.................................................................370 13.9.1.1.1 Position sensors............................................................370 13.9.1.1.2 Steering reference sensor...................................................371 13.9.1.2 Pressure sensor...................................................................372 13.9.1.3 Pulse transducer..................................................................372 13.9.2 Safety probes/sensors C5830.............................................................373 13.9.2.1 Emergency switch off..............................................................373 13.9.2.1.1 Description.................................................................373 13.9.2.1.1.1 Task and function.....................................................373 13.9.2.1.2 Checking the emergency switch function......................................373 13.10 Calibrations.................................................................................373 13.10.1 Steering angle calibration.............................................................373 13.10.2 Hydraulic valve calibration............................................................374 13.10.2.1 Proportional valve calibration...................................................374 13.10.2.2 Tilt angle calibration...........................................................375 13.10.3 Pressure sensor calibration............................................................375 13.10.3.1 Weight measuring calibration.....................................................375 13.10.3.2 Overload calibration.............................................................376 14 Hydraulics/Pneumatics C6000.........................................................................379 14.1 Overview......................................................................................379 14.2 Description...................................................................................379 14.2.1 Hydraulic hygiene.......................................................................379 14.2.1.1 Washing...........................................................................379 14.2.1.2 Packaging.........................................................................380 14.2.1.3 Handling..........................................................................380 14.2.1.4 Storage...........................................................................380 14.2.1.5 Work procedures...................................................................380 14.2.1.6 General rules.....................................................................380 14.2.1.7 Measures..........................................................................381 14.2.2 Design..................................................................................382 14.3 Quick change connectors.......................................................................382 14.3.1 Overview quick change connectors........................................................382 14.3.2 Removing quick change connectors (female)...............................................382 14.3.3 Installing quick change connector (female)..............................................383 14.3.4 Removing a quick change connector (male)................................................384 14.3.5 Installing a quick change connector (male)..............................................385 14.4 Hydraulic unit C6100..........................................................................386 14.4.1 Hydraulic unit..........................................................................386 14.4.2 Description.............................................................................386 14.4.2.1 Pressure limiting valve...........................................................386 14.4.3 Hydraulic oil tank C6110................................................................387 14.4.3.1 Tank..............................................................................387 14.4.3.2 Description.......................................................................387 14.4.3.2.1 Design......................................................................387 14.4.3.3 Cleaning the tank.................................................................387 14.4.3.4 Checking the tank.................................................................387 14.4.3.5 Oil change........................................................................387 14.4.3.5.1 Draining oil................................................................387 14.4.3.5.2 Topping up with oil.........................................................388 14.4.3.6 Replacing the tank................................................................389 14.4.3.6.1 Removing the tank...........................................................389 14.4.3.6.2 Fitting the tank............................................................389 14.4.4 Filter, filter housing C6130............................................................389 14.4.4.1 Cleaning the suction filter.......................................................389 14.4.4.2 Oil filter replacement............................................................390 14.4.4.2.1 Removing oil filter.........................................................390 14.4.4.2.2 Installing the oil filter...................................................390 14.4.4.3 Replacing the suction filter......................................................391 14.4.4.3.1 Removing suction filter.....................................................391 14.4.4.3.2 Installing the suction filter...............................................392 14.4.5 Hydraulic pump C6140....................................................................393 14.4.5.1 Hydraulic pump....................................................................393 14.4.5.2 Description.......................................................................393 14.4.5.2.1 Design......................................................................393 14.4.6 Pressure/flow control valve C6170.......................................................393 14.4.6.1 Description.......................................................................393 14.4.6.1.1 Checking the pressure limiting valve........................................393 14.4.6.2 Replacing the flow control valve..................................................394 14.4.6.2.1 Removing the flow control valve.............................................394 14.4.6.2.2 Fitting the flow control valve..............................................395 14.4.6.3 Replacing the pressure limiting valve.............................................395 14.4.6.3.1 Removing the pressure limiting valve........................................395 14.4.6.3.2 Fitting the pressure limiting valve.........................................396 14.4.7 Replacing the hydraulic unit............................................................396 14.4.7.1 Removing the hydraulic unit.......................................................396 14.4.7.2 Fitting the hydraulic unit........................................................397 14.4.8 Replacing the valve coil................................................................398 14.4.8.1 Removing the valve coil...........................................................398 14.4.8.2 Fitting the valve coil............................................................399 14.4.9 Replacing the pressure sensor...........................................................399 14.4.9.1 Removing the pressure sensor......................................................399 14.4.9.2 Fitting the pressure sensor.......................................................400 14.5 Hydraulic system, fitted on the mast C6300....................................................400 14.5.1 Mast hydraulic conduits C6320...........................................................400 14.5.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit..........400 14.5.1.2 Checks for leaks from hydraulic conduits and connections, mast....................400 14.6 Hydraulic cylinder C6600......................................................................401 14.6.1 Main lift cylinders C6610...............................................................401 14.6.1.1 Checking for leaks in the lift cylinder...........................................401 14.6.1.2 Replacing the main lift cylinders.................................................401 14.6.1.2.1 Removing the lift cylinder..................................................401 14.6.1.2.2 Fitting the lift cylinder...................................................403 14.6.2 Support arm/initial lift cylinder C6630.................................................404 14.6.2.1 Replacing the main initial lift cylinder..........................................404 14.6.2.1.1 Removing the initial lift cylinder..........................................404 14.6.2.1.2 Installing the initial lift cylinder........................................406 14.6.3 PowerTrak cylinder C6680................................................................407 14.6.3.1 Replacing the PowerTrak cylinder..................................................407 14.6.3.1.1 Removing the PowerTrak cylinder.............................................407 14.6.3.1.2 Installing the PowerTrak cylinder...........................................408 15 Work function - lifting masts C7000.................................................................413 15.1 Description...................................................................................413 15.1.1 Ordering a replacement mast.............................................................413 15.2 Chain system, general.........................................................................413 15.2.1 General.................................................................................413 15.2.2 Adjusting the chain.....................................................................413 15.2.3 Lubrication.............................................................................413 15.2.4 Checking the chains.....................................................................414 15.2.4.1 Noise.............................................................................414 15.2.4.2 Surface rust......................................................................414 15.2.4.3 Rusty links.......................................................................414 15.2.4.4 Stiff links.......................................................................414 15.2.4.5 Bolt rotation.....................................................................414 15.2.4.6 Loose bolts.......................................................................415 15.2.4.7 Outline wear......................................................................415 15.2.4.8 Chain gauge.......................................................................416 15.2.4.9 Stretching........................................................................416 15.2.4.10 Damaged plates...................................................................417 15.2.4.11 Damaged bolts....................................................................417 15.2.4.12 Other damage.....................................................................417 15.2.4.13 Dirty chain......................................................................417 15.3 Checking the chains...........................................................................418 15.4 Lubricating the chains........................................................................418 15.5 Checking the split pins.......................................................................419 15.6 Check-tighten the locking nuts................................................................419 15.7 Main mast C7100...............................................................................419 15.7.1 Check the position of the mast guide....................................................419 15.7.2 Check for cracks/damages to the mast....................................................420 15.7.3 Lubrication of the mast roller guides ..................................................420 15.7.4 Measuring the mast inclination..........................................................420 15.7.5 Adjusting the mast inclination..........................................................421 15.7.6 Replacing the roller....................................................................422 15.7.6.1 Installing a roller...............................................................422 15.7.7 Replacement of the mast.................................................................422 15.7.7.1 Disassembling the mast............................................................422 15.7.7.2 Removing a roller.................................................................424 15.7.7.3 Assembling the mast...............................................................425 15.7.7.4 Installing a roller...............................................................427 15.7.8 Main mast fork carriage C7130...........................................................427 15.7.8.1 Replacing the idler roller........................................................427 15.7.8.1.1 Removing a roller...........................................................427 15.7.9 Initial lift of frame/mast C7160........................................................428 15.7.9.1 Replacing the main initial lift cylinder..........................................428 15.7.9.1.1 Disassembling the fork carriage.............................................428 15.7.9.1.2 Installing a fork carriage..................................................429 15.7.10 Main mast suspension C7190.............................................................430 15.7.10.1 Mast mount.......................................................................430 15.7.10.1.1 Tightening the upper mast fixing points....................................430 15.7.10.1.2 Check-tighten the locking nuts.............................................431 15.7.10.1.3 Tightening the lower mast fixing points....................................431 15.8 Lifting/carrying/clamping devices C7400.......................................................431 15.8.1 Fork carriage unit/with integrated sideshift/fork spread C7420..........................431 15.8.1.1 Checking the fork carriage........................................................431 15.8.1.2 Check the play of the fork carriage...............................................431 15.8.1.3 Lubricating the beams.............................................................432 15.8.1.4 Measuring the fork-to-floor distance..............................................432 15.8.1.5 Replacing the fork carriage.......................................................432 15.8.1.5.1 Disassembling the fork carriage.............................................432 15.8.1.5.2 Installing a fork carriage..................................................434 16 Auxiliary equipment, installation equipment C8000...................................................439 17 Optional equipment/Extra equipment C9000............................................................443 17.1 Overview......................................................................................443 17.2 Extra electrical equipment C9400..............................................................444 17.2.1 Extra power socket......................................................................444 17.2.1.1 Overview..........................................................................444 17.2.1.2 Description.......................................................................444 17.2.1.2.1 DC/DC converter.............................................................444 17.2.2 Truck log equipment, code lock C9420....................................................445 17.2.2.1 Overview..........................................................................445 17.2.2.2 I_Site............................................................................445 17.2.2.2.1 Description.................................................................445 17.2.2.2.1.1 I_Site................................................................445 17.2.2.3 Impact Manager....................................................................446 17.2.2.3.1 Description.................................................................446 17.2.2.3.1.1 Collision sensor......................................................446 17.2.2.3.2 Checking the reference sensor parameters....................................446 17.2.2.3.3 Checking DHU/TWIS [K110]....................................................446 17.3 Other extra equipment C9500...................................................................446 17.3.1 Fire extinguisher.......................................................................446 17.3.1.1 Description.......................................................................446 17.3.1.1.1 Fire extinguisher...........................................................446 17.3.2 Horizontal E-bar........................................................................447 17.3.2.1 Description.......................................................................447 17.3.2.1.1 E-bar.......................................................................447 17.3.2.2 Checking the E-bar lock...........................................................448 17.3.3 Spider expansion unit...................................................................448 17.3.3.1 Description.......................................................................448 17.3.3.1.1 Spider expansion unit.......................................................448 18 Instructions for disposal...........................................................................453 18.1 General.......................................................................................453 18.2 Marking of plastics...........................................................................453 18.2.1 General marking of products and packaging...............................................453 18.2.2 Marking according to the manufacturer’s standards.......................................453 18.2.2.1 Abbreviations.....................................................................453 18.2.2.2 Marking examples..................................................................454 18.3 Pressure vessels..............................................................................454 18.3.1 Gas struts..............................................................................454 18.4 Sorting categories............................................................................455 19 Wiring diagram......................................................................................459 19.1 Colour code table.............................................................................459 19.2 Diagram.......................................................................................459 19.2.1 Component list..........................................................................459 19.2.2 Component placement.....................................................................463 19.2.3 Detailed diagrams.......................................................................477 20 Hydraulics schematics...............................................................................505 20.1 Component list................................................................................505 20.2 Component location............................................................................506 20.2.1 Picture 1...............................................................................506 20.2.2 Picture 2...............................................................................507 20.2.3 Picture 3...............................................................................508 20.2.4 Picture 4...............................................................................508 20.3 Valve unit....................................................................................510 20.3.1 Valve unit 1-function...................................................................510 20.3.2 Valve unit 2-functions..................................................................511 20.4 Diagram.......................................................................................512 20.5 Diagram.......................................................................................513 20.6 Diagram.......................................................................................514 21 Tools...............................................................................................517 21.1 Tools for electric connectors.................................................................517 21.1.1 AMP connectors..........................................................................517 21.1.2 MQS connectors..........................................................................517 21.1.3 CPC connectors..........................................................................518 21.1.4 AMP Seal connectors.....................................................................519 21.2 Special tools.................................................................................519 22 Service data and grease specifications..............................................................523 22.1 General tightening torques....................................................................523 22.1.1 Galvanised, non-oiled screws............................................................523 22.1.2 Untreated, oiled screws.................................................................523 22.2 Lubricants specification......................................................................524 23 Technical data......................................................................................527 24 ....................................................................................................529
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