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BT Forklift Toyota LPE200 LPE220 LPE250 LPE340BE Repair Manual – PDF DOWNLOAD
BT Forklift Toyota LPE200 LPE220 LPE250 LPE340BE Repair Manual – PDF DOWNLOAD
FILE DETAILS:
BT Forklift Toyota LPE200 LPE220 LPE250 LPE340BE Repair Manual – PDF DOWNLOAD
Language : English
Pages : 670
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift Toyota LPE200 LPE220 LPE250 LPE340BE Repair Manual – PDF DOWNLOAD
1 General introduction.................................................................................. 9 1.1 Images and other information.................................................................... 9 1.2 Warning levels and symbols...................................................................... 9 1.3 Pictograms...................................................................................... 9 1.4 Abbreviations................................................................................... 10 2 General safety rules.................................................................................. 15 2.1 Authorised personnel............................................................................ 15 2.2 Product modification............................................................................ 15 2.2.1 Responsible............................................................................... 15 2.2.2 What is it permitted to modify?........................................................... 15 2.3 Work safety..................................................................................... 16 2.4 Electrical system............................................................................... 17 2.4.1 Electrostatic risks....................................................................... 17 2.4.2 Battery handling.......................................................................... 18 2.5 Safe lifting.................................................................................... 18 2.6 Software........................................................................................ 19 2.7 Hydraulic system................................................................................ 19 3 Operating principle................................................................................... 23 3.1 Description..................................................................................... 23 3.1.1 Battery is connected...................................................................... 23 3.1.2 Login via keypad.......................................................................... 23 3.1.3 Login via “ID key” option................................................................. 23 3.1.4 Tiller arm lowered for driving............................................................ 23 3.1.5 Driving in fork direction................................................................. 24 3.1.6 Driving in the drive wheel direction...................................................... 24 3.1.7 Braking in neutral........................................................................ 24 3.1.8 Reverse braking........................................................................... 25 3.1.9 Mechanical braking........................................................................ 25 3.1.10 Emergency reversal....................................................................... 25 3.1.11 Fork lifting............................................................................. 26 3.1.12 Fork lowering............................................................................ 26 4 Parameters............................................................................................ 29 4.1 Software........................................................................................ 29 4.2 Display/change parameters....................................................................... 29 4.3 Parameters on commissioning..................................................................... 29 4.3.1 Setting parameters........................................................................ 29 4.3.2 Setting collision sensor parameters (option).............................................. 29 4.3.3 Setting battery parameters................................................................ 30 4.4 Parameter list.................................................................................. 30 5 Installation.......................................................................................... 79 5.1 Transport....................................................................................... 79 5.1.1 Transporting the truck.................................................................... 79 5.1.2 Transporting the fork carriage............................................................ 79 5.2 Lifting the truck............................................................................... 80 5.2.1 Lifting the truck......................................................................... 80 5.2.2 Lift using a jack......................................................................... 80 5.3 Commissioning................................................................................... 81 5.3.1 Battery................................................................................... 81 5.3.1.1 Battery installation................................................................ 81 6 Maintenance........................................................................................... 85 6.1 Introduction.................................................................................... 85 6.2 Maintenance instructions........................................................................ 85 6.2.1 Cleaning.................................................................................. 85 6.2.2 High-pressure washers..................................................................... 85 6.2.3 Degreasing agents......................................................................... 86 6.2.4 Cleaning the exterior..................................................................... 86 6.2.5 Cleaning the chain........................................................................ 86 6.2.6 Cleaning the motor compartment............................................................ 86 6.2.7 Electric components....................................................................... 86 6.2.8 Optical sensors and reflectors............................................................ 86 6.2.9 Hydraulic system.......................................................................... 87 6.2.10 Signs, warnings and adhesive labels...................................................... 87 6.2.10.1 Placement of signs................................................................. 87 6.3 Lubricants specification........................................................................ 88 6.4 Periodic maintenance............................................................................ 89 7 Troubleshooting.......................................................................................105 7.1 Initial troubleshooting.........................................................................105 7.2 Concluding troubleshooting......................................................................106 7.3 Auxiliary functions.............................................................................107 7.3.1 Towing a defective truck..................................................................107 7.3.1.1 Towing and transporting a defective truck...........................................107 7.3.2 Emergency driving mode....................................................................107 7.3.2.1 Emergency driving mode..............................................................107 7.3.3 Error code history........................................................................107 7.3.3.1 Error code history..................................................................107 7.3.4 Extended error log........................................................................108 7.3.4.1 Extended error log..................................................................108 7.3.5 Built-in test function for the tiller arm.................................................108 7.3.5.1 General.............................................................................108 7.3.5.2 Display test........................................................................109 7.3.5.3 Speed control.......................................................................109 7.3.5.4 Safety reversing....................................................................109 7.3.5.5 Controls for lifting/lowering.......................................................110 7.3.5.6 Sensilift...........................................................................110 7.3.5.7 Keypad..............................................................................111 7.3.6 Digital input/output status...............................................................111 7.3.6.1 Test mode "9".......................................................................111 7.3.6.2 Test mode “12” SEU expansion unit (option)..........................................112 7.3.7 Service information.......................................................................113 7.3.7.1 Service information.................................................................113 7.3.8 Hydraulic pressure........................................................................114 7.3.8.1 Erroneous hydraulic system pressure.................................................114 7.4 Troubleshooting using error codes...............................................................114 7.4.1 First actions when an error code is displayed.............................................114 7.4.2 List of error codes.......................................................................115 8 Chassis C0000.........................................................................................183 8.1 Overview........................................................................................183 8.2 Frame, chassis C0300............................................................................183 8.2.1 Inspection of the rear chassis............................................................183 8.2.2 Inspection covers C0340...................................................................184 8.2.2.1 Motor compartment covers............................................................184 8.2.2.1.1 Overview......................................................................184 8.2.2.1.2 Replacing a service cover.....................................................185 8.2.2.1.2.1 Removing a service cover................................................185 8.2.2.1.2.2 Installing a service cover..............................................185 8.2.2.1.3 Replacing a side cover........................................................185 8.2.2.1.3.1 Removing a side cover...................................................185 8.2.2.1.3.2 Installing a side cover.................................................186 8.2.2.1.4 Replacing an emblem cover.....................................................186 8.2.2.1.4.1 Removing an emblem cover................................................186 8.2.2.1.4.2 Installing an emblem cover..............................................187 8.2.2.1.5 Replacing an upper cover......................................................187 8.2.2.1.5.1 Removing an upper cover.................................................187 8.2.2.1.5.2 Installing an upper cover...............................................188 8.2.2.1.6 Replacing a cover.............................................................188 8.2.2.1.6.1 Removing a cover........................................................188 8.2.2.1.6.2 Installing a cover......................................................189 8.2.3 Support arms, stabilizers C0350...........................................................189 8.2.3.1 Replacing the roller on the torsion tube............................................189 8.2.3.1.1 Removing the roller on the torsion tube.......................................189 8.2.3.1.2 Fit the roller on the torsion tube............................................190 8.2.3.2 Replacing the wheel fork bushing....................................................191 8.2.3.2.1 Removing the bushing..........................................................191 8.2.3.2.2 Installing the bushing........................................................192 8.2.4 Fork structure (low-lifter) C0380.........................................................192 8.2.4.1 Overview............................................................................192 8.2.4.2 Replacing the fork carriage.........................................................193 8.2.4.2.1 Removing the fork carriage....................................................193 8.2.4.2.2 Installing the fork carriage..................................................196 8.2.4.3 Checking the fork carriage..........................................................199 8.2.4.4 Replacing the torsion tube-linkage-wheel fork.......................................200 8.2.4.4.1 Removing the torsion tube-linkage-wheel fork..................................200 8.2.4.4.2 Fitting the torsion tube-linkage-wheel fork...................................202 8.2.4.5 Checking the torsion tube-linkage-wheel fork........................................204 8.2.4.6 Push rod weld.......................................................................204 8.2.4.7 Checking the wheel fork flexibility.................................................208 8.2.4.8 Checking the linkage................................................................208 8.2.4.9 Checking the fork carriage..........................................................208 8.2.4.10 Lubricating the beams..............................................................209 8.2.4.11 Checking the fork lift height limitation...........................................209 8.2.4.12 Checking the fork carriage play....................................................209 8.2.5 Battery compartment parts C0390...........................................................210 8.2.5.1 Overview............................................................................210 8.2.5.2 Overview............................................................................211 8.2.5.3 Description.........................................................................211 8.2.5.3.1 Battery lock, quick...........................................................211 8.2.5.3.2 Battery lock, fixed...........................................................211 8.2.5.4 Checking the battery lock...........................................................212 8.2.5.5 Checking the battery lock...........................................................212 8.2.5.6 Adjusting the battery lock..........................................................212 8.3 Frame/chassis components C0400..................................................................212 8.3.1 ESD protection (anti-static braid)........................................................212 8.3.1.1 Replacing the ground strap..........................................................212 8.3.1.1.1 Removing the ground strap.....................................................212 8.3.1.1.2 Installing a ground strap.....................................................213 8.3.2 Motor mount/brackets C0450................................................................214 8.3.2.1 Checking the motor mounts...........................................................214 8.3.2.2 Drive unit mountings................................................................215 8.3.2.2.1 Drive unit mountings 6/8 km/h.................................................215 8.3.2.2.1.1 Overview 6/8 km/h.......................................................215 8.3.2.2.1.2 Description.............................................................215 8.3.2.2.1.2.1 Technical data....................................................215 8.3.2.2.1.2.2 Technical data....................................................216 8.3.2.2.1.3 Replacing the drive unit mountings 6/8 km/h.............................216 8.3.2.2.1.3.1 Removing the drive unit mountings 6/8 km/h........................216 8.3.2.2.1.3.2 Installing the drive unit mountings 6/8 km/h......................219 8.3.2.2.2 Drive unit mountings 10/12.5 km/h.............................................223 8.3.2.2.2.1 Overview 10/12.5 km/h..................................................223 8.3.2.2.2.2 Description.............................................................224 8.3.2.2.2.2.1 Technical data....................................................224 8.3.2.2.2.2.2 Technical data....................................................224 8.3.2.2.2.2.3 Technical data....................................................224 8.3.2.2.2.2.4 Technical data....................................................225 8.3.2.2.2.2.5 Technical data....................................................225 8.3.2.2.2.2.6 Technical data....................................................225 8.3.2.2.2.2.7 Technical data....................................................226 8.3.2.2.2.3 Replacing the drive unit mountings 10/12.5 km/h.........................226 8.3.2.2.2.3.1 Removing the drive unit mountings 10/12.5 km/h....................226 8.3.2.2.2.3.2 Installing the drive unit mountings 10/12.5 km/h..................229 8.3.2.3 PowerTrak...........................................................................234 8.3.2.3.1 Description...................................................................234 8.3.2.3.1.1 Design..................................................................234 8.3.2.3.2 Increasing the spring tension.................................................235 8.3.2.3.3 Increasing the spring tension.................................................237 8.3.2.3.4 Releasing the spring tension..................................................240 8.3.2.3.5 Releasing the spring tension..................................................241 8.3.2.3.6 Adjusting tool V08-18302......................................................243 8.3.2.3.7 Replacing the initial pressure spring.........................................244 8.3.2.3.7.1 Removing the initial pressure spring....................................244 8.3.2.3.7.2 Fitting the initial pressure spring.....................................245 8.3.2.3.8 Replacing the PowerTrak spring................................................246 8.3.2.3.8.1 Removing the PowerTrak spring...........................................246 8.3.2.3.8.2 Installing the PowerTrak spring.........................................247 8.4 Operator compartment, cab C0500.................................................................248 8.4.1 Platform including fixing points C0560....................................................248 8.4.1.1 Overview............................................................................248 8.4.1.2 Overview............................................................................249 8.4.1.3 Overview............................................................................250 8.4.1.4 Checking the function of the platform switches......................................251 8.4.1.5 Adjusting the position sensor [B120]................................................251 8.4.1.6 Checking the platform...............................................................252 8.4.1.7 Gas strut...........................................................................252 8.4.1.7.1 Checking the gas strut........................................................252 8.4.1.7.2 Replacing a gas strut.........................................................252 8.4.1.7.2.1 Removing a gas strut....................................................252 8.4.1.7.2.2 Installing a gas strut..................................................254 8.4.1.8 Platform suspension.................................................................255 8.4.1.8.1 Adjusting platform suspension.................................................255 8.4.1.8.2 Adjusting the platform suspension [Fixed side guards].........................255 8.4.1.8.3 Replacing the platform suspension.............................................256 8.4.1.8.3.1 Removing the platform suspension........................................256 8.4.1.8.3.2 Fitting the platform suspension.........................................256 8.4.1.9 Safety switch, platform [B119]......................................................257 8.4.1.9.1 Adjusting the position sensor play [B119].....................................257 8.4.1.9.2 Checking the position sensor [B119]...........................................258 8.4.1.10 Safety switch, platform [B119]/[B120]..............................................259 8.4.1.10.1 Measuring the detection distance [B120]......................................259 8.4.1.10.2 Replacing sensor [B119]......................................................259 8.4.1.10.2.1 Removing the platform position sensor [B119]...........................259 8.4.1.10.2.2 Fitting the platform position sensor [B119]............................259 8.4.1.10.3 Replacing sensor [B120]......................................................260 8.4.1.10.3.1 Removing the platform position sensor [B120]...........................260 8.4.1.10.3.2 Fitting the platform position sensor [B120]............................260 8.4.1.11 Replacing the platform.............................................................260 8.4.1.11.1 Removing the platform........................................................260 8.4.1.11.2 Removing the platform [Fixed side guards]....................................263 8.4.1.11.3 Installing the platform......................................................263 8.4.1.11.4 Fitting the platform [Fixed side guards].....................................265 8.5 Safety equipment C0800..........................................................................267 8.5.1 Operator protection C0840.................................................................267 8.5.1.1 Fixed side guard....................................................................267 8.5.1.1.1 Overview [Fixed side guards]..................................................267 8.5.1.1.2 Replacing the fixed side guard................................................268 8.5.1.1.2.1 Removing the fixed side guard...........................................268 8.5.1.1.2.2 Fitting fixed side guards...............................................269 8.5.1.1.3 Checking the position sensor [B119] [Fixed side guards].......................271 8.5.1.2 Gate................................................................................272 8.5.1.2.1 ..............................................................................272 8.5.1.2.2 Checking the gate bar.........................................................273 8.5.1.2.3 Checking the function of the gate switches....................................273 8.5.1.2.4 Replacing a gas strut.........................................................273 8.5.1.2.4.1 Removing the gate damper................................................273 8.5.1.2.4.2 Removing the gate damper................................................274 8.5.1.2.4.3 Fitting the gate damper.................................................274 8.5.1.2.4.4 Fitting the gate damper.................................................275 8.5.1.2.5 Replacing the pad.............................................................275 8.5.1.2.5.1 Removing the pad........................................................275 8.5.1.2.5.2 ........................................................................276 8.5.1.2.5.3 Fitting pads............................................................277 8.5.1.2.5.4 ........................................................................278 8.5.1.2.6 Replacing the gate............................................................278 8.5.1.2.6.1 ........................................................................278 8.5.1.2.6.2 ........................................................................279 8.5.1.2.7 Replacing the gate bar........................................................281 8.5.1.2.7.1 Removing the gate bar...................................................281 8.5.1.2.7.2 ........................................................................281 8.5.1.2.7.3 Installing the gate bar.................................................282 8.5.1.2.7.4 ........................................................................282 8.5.1.3 Back rest...........................................................................283 8.5.1.3.1 Overview [Back protection]....................................................283 8.5.1.3.2 Checking the position sensor [B119 back protection]...........................283 8.5.1.3.3 Replacing the back guard......................................................284 8.5.1.3.3.1 Removing the back guard.................................................284 8.5.1.3.3.2 Installing the back guard...............................................285 8.5.2 Signs, warnings, labels C0850.............................................................285 8.5.2.1 Checking signs and labels...........................................................285 8.5.2.2 Placement of signs..................................................................285 9 Motors C1000..........................................................................................289 9.1 Lubrication / cooling system C1300..............................................................289 9.1.1 Mechanical cooling fan C1380..............................................................289 9.1.1.1 Checking the cooling system.........................................................289 9.2 Electric motors C1700...........................................................................289 9.2.1 Electric pump motor C1710.................................................................289 9.2.1.1 Overview............................................................................289 9.2.1.2 Description.........................................................................290 9.2.1.2.1 Construction..................................................................290 9.2.1.3 Replacing the carbon brushes........................................................290 9.2.1.3.1 Removing the carbon brushes...................................................290 9.2.1.3.2 Fitting carbon brushes........................................................291 9.2.1.4 Replacing the pump motor............................................................292 9.2.1.4.1 Removing the pump motor [M3]..................................................292 9.2.1.4.2 Installing the pump motor [M3]................................................293 9.2.2 Electric steering motor C1730.............................................................295 9.2.2.1 Overview............................................................................295 9.2.2.2 Description.........................................................................295 9.2.2.2.1 Technical data................................................................295 9.2.2.3 Cleaning the ring gear..............................................................295 9.2.2.4 Checking the electrical connections.................................................296 9.2.2.5 Checking the steering motor gears...................................................296 9.2.2.6 Checking the steering motor.........................................................296 9.2.2.7 Lubricating the ring gear...........................................................296 9.2.2.8 Check the drive gear's attachment...................................................296 9.2.2.9 Replacing the steering motor........................................................296 9.2.2.9.1 Removing the steering motor [M6]..............................................296 9.2.2.9.2 Installing the steering motor [M6]............................................297 9.2.2.10 Replacing the control unit.........................................................298 9.2.2.10.1 Removing the control unit....................................................298 9.2.2.10.2 Installing the control unit..................................................299 9.2.3 Electric fan motor/fan C1740..............................................................300 9.2.3.1 Overview............................................................................300 9.2.3.2 Replacing the motor control fan.....................................................300 9.2.3.2.1 Removing a motor control fan..................................................300 9.2.3.2.2 Installing a motor control fan................................................302 9.2.4 Electric drive motor C1760................................................................303 9.2.4.1 Overview 1.8, 2.5 kW................................................................303 9.2.4.2 Overview............................................................................304 9.2.4.3 Checking the electrical connections.................................................305 9.2.4.4 Checking the drive motor............................................................305 9.2.4.5 Listen for any abnormal noise in the drive motor bearings...........................305 9.2.4.6 Check the drive motor fitting (1.8 and 2.5 kW)......................................306 9.2.4.7 Check the drive motor fitting (2.8 kW)..............................................306 9.2.4.8 Checking the rotational speed sensor................................................306 9.2.4.9 Check the rotational speed sensor fitting...........................................307 9.2.4.10 Replacing the drive motor..........................................................307 9.2.4.10.1 Removing the drive motor [M1]................................................307 9.2.4.10.2 Removing the drive motor [M1]................................................309 9.2.4.10.3 Removing the drive motor [M1]................................................311 9.2.4.10.4 Installing the drive motor [M1]..............................................313 9.2.4.10.5 Installing the drive motor [M1]..............................................315 9.2.4.10.6 Installing the drive motor [M1]..............................................317 9.2.4.11 Replacing the temperature sensor...................................................319 9.2.4.11.1 Installing the temperature sensor............................................319 9.2.4.12 Replacing the rotational speed sensor..............................................320 9.2.4.12.1 Removing a rotational speed sensor...........................................320 9.2.4.12.2 Installing a rotational speed sensor.........................................322 9.2.4.13 Replacing the toothed wheel........................................................323 9.2.4.13.1 Removing a toothed wheel.....................................................323 9.2.4.13.2 Installing a toothed wheel...................................................324 10 Transmission/Drive gear C2000........................................................................327 10.1 Drive unit, final gear C2500...................................................................327 10.1.1 Drive unit/gear C2550 ...................................................................327 10.1.1.1 Overview...........................................................................327 10.1.1.2 Overview...........................................................................328 10.1.1.3 Description .......................................................................328 10.1.1.3.1 Design.......................................................................328 10.1.1.3.2 Technical data...............................................................328 10.1.1.3.3 Technical data...............................................................329 10.1.1.4 Check the drive gear's attachment .................................................329 10.1.1.5 Checking for leaks in the drive gear...............................................329 10.1.1.6 Checking for noise in the drive gear...............................................330 10.1.1.7 Replacing the drive gear ..........................................................330 10.1.1.7.1 Removing the drive gear......................................................330 10.1.1.7.2 Installing the drive gear....................................................332 10.1.1.8 Replacing the wheel hub seal ......................................................333 10.1.1.8.1 Removing the wheel hub seal..................................................333 10.1.1.8.2 Installing the wheel hub seal................................................334 10.1.1.9 Drive gear oil change..............................................................335 10.1.1.9.1 Empty the drive gear oil.....................................................336 10.1.1.9.2 Empty the drive gear oil.....................................................337 10.1.1.9.3 Filling oil in the drive gear................................................338 10.1.1.9.4 Filling oil in the drive gear................................................339 10.1.1.10 Replacing the drive gear steering bearing ........................................339 10.1.1.10.1 Removing the drive gear steering bearing....................................339 10.1.1.10.2 Removing the drive gear steering bearing....................................340 10.1.1.10.3 Installing the drive gear steering bearing..................................341 10.1.1.10.4 Installing the drive gear steering bearing..................................342 10.1.1.11 Stud replacement..................................................................342 10.1.1.11.1 Removing a stud.............................................................342 10.1.1.11.2 Installing a stud...........................................................343 11 Brake/wheel/track system C3000.......................................................................347 11.1 Travel brake system C3100......................................................................347 11.1.1 Description..............................................................................347 11.1.1.1 Brake types........................................................................347 11.1.1.1.1 Travel brake.................................................................347 11.1.1.1.2 Emergency brake..............................................................347 11.1.1.1.3 Parking brake................................................................347 11.2 Parking brake details C3300....................................................................348 11.2.1 Electrical parking brake, magnet brake C3370.............................................348 11.2.1.1 Overview...........................................................................348 11.2.1.2 Description........................................................................349 11.2.1.2.1 Technical data...............................................................349 11.2.1.2.2 Technical data...............................................................349 11.2.1.3 Cleaning the parking brake.........................................................349 11.2.1.4 Adjusting the parking brake gap....................................................350 11.2.1.5 Adjusting the parking brake gap....................................................351 11.2.1.6 Adjusting the parking brake gap....................................................351 11.2.1.7 Tighten the parking brake mounting bolts...........................................352 11.2.1.8 Emergency release of the parking brake.............................................352 11.2.1.9 Checking the parking brake.........................................................353 11.2.1.10 Replacing the brake hub...........................................................353 11.2.1.10.1 Disassembling the brake hub.................................................353 11.2.1.10.2 Installing a brake hub......................................................354 11.2.1.11 Replacing the friction disc.......................................................354 11.2.1.11.1 Removing the friction disc..................................................354 11.2.1.11.2 Fitting the friction disc...................................................355 11.2.1.11.3 Fitting the friction disc...................................................356 11.2.1.12 Replacing the parking brake.......................................................357 11.2.1.12.1 Removing the parking brake..................................................357 11.2.1.12.2 Fitting the parking brake...................................................359 11.3 Wheels C3500...................................................................................361 11.3.1 Drive wheel C3530........................................................................361 11.3.1.1 Overview...........................................................................361 11.3.1.2 Measuring the drive wheel tread....................................................361 11.3.1.3 Measuring the drive wheel tread....................................................362 11.3.1.4 Check the drive wheel mountings....................................................362 11.3.1.5 Check the drive wheel mountings....................................................363 11.3.1.6 Replacing the drive wheel..........................................................363 11.3.1.6.1 Disassembling the drive wheel................................................363 11.3.1.6.2 Installing a drive wheel.....................................................364 11.3.2 Support arm wheels/castor wheels C3540...................................................365 11.3.2.1 Overview...........................................................................365 11.3.2.2 Cleaning castor wheels.............................................................366 11.3.2.3 Measuring the castor wheel tread...................................................366 11.3.2.4 Measuring the castor wheel tread...................................................366 11.3.2.5 Measuring the castor wheel tread...................................................367 11.3.2.6 Measuring the castor wheel tread...................................................367 11.3.2.7 Checking the castor wheels.........................................................367 11.3.2.8 Replacing the castor wheel.........................................................367 11.3.2.8.1 Removing the castor..........................................................367 11.3.2.8.2 Removing the castor..........................................................368 11.3.2.8.3 Installing a castor wheel....................................................370 11.3.2.8.4 Installing a castor wheel....................................................371 11.3.2.9 Replacing the castor wheel assembly................................................371 11.3.2.9.1 Removing the castor wheel assembly...........................................371 11.3.2.9.2 Installing the castor wheel assembly.........................................372 11.3.3 Fork wheels/support arm wheels C3550.....................................................373 11.3.3.1 Overview...........................................................................373 11.3.3.2 Description........................................................................374 11.3.3.2.1 Wheel wear...................................................................374 11.3.3.3 Cleaning the fork wheels...........................................................374 11.3.3.4 Measuring the fork wheel tread.....................................................375 11.3.3.5 Checking the fork wheel mounting...................................................375 11.3.3.6 Checking the fork wheel bushings...................................................375 11.3.3.7 Replacing a single wheel...........................................................376 11.3.3.7.1 Removing single wheels.......................................................376 11.3.3.7.2 Removing single wheels.......................................................377 11.3.3.7.3 Single wheel installation....................................................378 11.3.3.7.4 Single wheel installation....................................................379 11.3.3.8 Replacing bogie wheels.............................................................380 11.3.3.8.1 Removing bogie wheels........................................................380 11.3.3.8.2 Fitting the bogie wheel......................................................381 11.3.3.9 Replacing a bogie link.............................................................382 11.3.3.9.1 Removing a bogie link........................................................382 11.3.3.9.2 Installing a bogie link......................................................383 12 Steering system C4000................................................................................387 12.1 Description....................................................................................387 12.1.1 Power steering...........................................................................387 12.2 Mechanical steering system C4100...............................................................387 12.2.1 Steering arm/wheel/lever C4110...........................................................387 12.2.1.1 Overview tiller arm................................................................387 12.2.1.2 Operating panel....................................................................389 12.2.1.2.1 Overview operating panel.....................................................389 12.2.1.2.2 Controls.....................................................................390 12.2.1.2.2.1 Checking the hydraulic functions.......................................390 12.2.1.2.2.2 Checking the stomach button............................................390 12.2.1.2.2.3 Replacing the signal button/switch.....................................390 12.2.1.2.2.3.1 Removing the signal button/switch................................390 12.2.1.2.2.3.2 Fitting the signal button/switch.................................391 12.2.1.2.2.4 Replacing the lift/lower button........................................391 12.2.1.2.2.4.1 Removing the lift/lower button...................................391 12.2.1.2.2.4.2 Fitting the lift/lower button....................................392 12.2.1.2.2.5 Replacing a switch button..............................................394 12.2.1.2.2.5.1 Removing a switch button.........................................394 12.2.1.2.2.5.2 Fitting a switch button..........................................394 12.2.1.2.2.6 Changing the position of the controls - support arm lift/fork lift.....395 12.2.1.2.2.7 Replacing the safety reversing switch..................................395 12.2.1.2.2.7.1 Removing the safety reversing switch.............................395 12.2.1.2.2.7.2 Fitting the safety reversing switch..............................396 12.2.1.2.2.8 Replacing the keypad...................................................397 12.2.1.2.2.8.1 Removing the keypad..............................................397 12.2.1.2.2.8.2 Installing a keypad..............................................397 12.2.1.2.3 Replacing the operating panel................................................398 12.2.1.2.3.1 Removing the operating panel...........................................398 12.2.1.2.3.2 Installing an operating panel..........................................398 12.2.1.2.3.3 Checking the speed control.............................................399 12.2.1.2.4 Replacing the operating panel "Built-in".....................................400 12.2.1.2.4.1 Removing the operating panel "Built-in"................................400 12.2.1.2.4.2 Installing the operating panel "Built-in"..............................401 12.2.1.2.5 Replacing the logic card.....................................................402 12.2.1.2.5.1 Removing the logic card................................................402 12.2.1.2.5.2 Installing a logic card................................................403 12.2.1.2.5.3 Logic card [A5]........................................................404 12.2.1.3 Tiller arm handle..................................................................405 12.2.1.3.1 Replacing the handle to the tiller arm.......................................405 12.2.1.3.1.1 Removing the tiller arm handle.........................................405 12.2.1.3.1.2 Fitting the handle to the tiller arm...................................405 12.2.1.3.2 Replacing the tiller arm handle "Built-in"...................................406 12.2.1.3.2.1 Removing the tiller arm handle "Built-in"..............................406 12.2.1.3.2.2 Installing the tiller arm handle "Built-in"............................407 12.2.1.4 Tiller arm.........................................................................407 12.2.1.4.1 Replacing the tiller arm.....................................................407 12.2.1.4.1.1 Removing the tiller arm................................................407 12.2.1.4.1.2 Fitting tiller arm.....................................................409 12.2.1.4.2 Replacing the tiller arm "Built-in"..........................................411 12.2.1.4.2.1 Removing the tiller arm "Built-in".....................................411 12.2.1.4.2.2 Installing the tiller arm "Built-in"...................................413 12.2.1.4.3 Checking the brake microswitches.............................................414 12.2.1.4.4 Checking the play and the return travel......................................415 12.2.1.4.5 Replacing the tiller arm cover...............................................415 12.2.1.4.5.1 Removing the tiller arm cover..........................................415 12.2.1.4.5.2 Installing the tiller arm cover........................................416 12.2.1.4.6 Replacing the tiller arm cover "Built-in"....................................416 12.2.1.4.6.1 Removing the tiller arm cover "Built-in"...............................416 12.2.1.4.6.2 Installing the tiller arm cover "Built-in".............................417 12.2.1.5 Steering yoke......................................................................418 12.2.1.5.1 Overview.....................................................................418 12.2.1.5.2 Overview steering servo......................................................419 12.2.1.5.3 Overview Ergo................................................................420 12.2.1.5.4 Replacing the steering yoke..................................................421 12.2.1.5.4.1 Removing the steering yoke.............................................421 12.2.1.5.4.2 Installing a steering yoke.............................................422 12.2.1.5.5 Changing the tiller arm spring...............................................422 12.2.1.5.5.1 Removing the tiller arm spring.........................................422 12.2.1.5.5.2 Installing the tiller arm spring.......................................423 12.2.1.5.6 Replacing the safety switch..................................................423 12.2.1.5.6.1 Removing the safety switch [B60].......................................423 12.2.1.5.6.2 Installing the safety switch [B60].....................................425 12.2.1.5.7 Replacing the safety switch "Built-in".......................................425 12.2.1.5.7.1 Removing the safety switch "Built-in"..................................425 12.2.1.5.7.2 Installing the safety switch "Built-in"................................426 12.2.1.6 Steering adapter...................................................................428 12.2.1.6.1 Overview steering servo......................................................428 12.2.1.6.2 Overview Mechanical steering.................................................429 12.2.1.6.3 Overview steering servo......................................................431 12.2.1.6.4 Overview Mechanical steering.................................................432 12.2.1.6.5 Replacing the steering adapter...............................................433 12.2.1.6.5.1 Removing the steering adapter..........................................433 12.2.1.6.5.2 Removing the steering adapter..........................................434 12.2.1.6.5.3 Removing the steering adapter..........................................435 12.2.1.6.5.4 Removing the steering adapter..........................................436 12.2.1.6.5.5 Installing a steering adapter..........................................437 12.2.1.6.5.6 Installing a steering adapter..........................................439 12.2.1.6.5.7 Installing a steering adapter..........................................440 12.2.1.6.5.8 Installing a steering adapter..........................................442 12.2.1.6.6 Replacing the steering adapter cover.........................................443 12.2.1.6.6.1 Removing the steering adapter cover....................................443 12.2.1.6.6.2 Installing the steering adapter cover..................................444 12.2.1.6.7 Replacing a gas strut - height adjuster......................................444 12.2.1.6.7.1 Removing a gas strut - height adjuster.................................444 12.2.1.6.7.2 Installing a gas strut - height adjuster...............................444 12.2.1.6.7.3 Checking the height adjuster...........................................445 12.2.1.6.8 Replacing the height adjustment lock.........................................445 12.2.1.6.8.1 Removing the height adjustment lock....................................445 12.2.1.6.8.2 Removing the height adjustment lock....................................445 12.2.1.6.8.3 Installing the height adjustment lock..................................447 12.2.1.6.8.4 Installing the height adjustment lock..................................447 12.2.1.6.8.5 Checking the height adjustment lock....................................448 12.2.1.6.9 Replacing the mechanical stop of the steering shaft..........................448 12.2.1.6.9.1 Removing the mechanical stop of the steering shaft (power steering)....448 12.2.1.6.9.2 Fitting the mechanical stop of the steering shaft (power steering).....450 12.2.1.7 Tiller arm wiring harness..........................................................452 12.2.1.7.1 Replacing the tiller arm wiring harness......................................452 12.2.1.7.1.1 Removing the tiller arm wiring harness.................................452 12.2.1.7.1.2 Fitting the tiller arm wiring harness..................................455 12.2.1.8 Replacing the steering bearing.....................................................461 12.2.1.8.1 Removing the steering bearing................................................461 12.2.1.8.2 Removing the steering bearing................................................462 12.2.1.8.3 Fitting the steering bearing.................................................464 12.2.1.8.4 Fitting the steering bearing.................................................465 12.2.1.9 Replacing the rubber seals.........................................................467 12.2.1.9.1 Removing rubber seals........................................................467 12.2.1.9.2 Installing rubber seals......................................................467 12.3 Electric steering system C4300.................................................................469 12.3.1 Overview.................................................................................469 12.3.2 Overview.................................................................................470 12.3.3 Steering angle sensor C4350..............................................................470 12.3.3.1 Description........................................................................470 12.3.3.1.1 Design.......................................................................470 12.3.3.2 Replacing the steering angle sensor servo unit.....................................471 12.3.3.2.1 Removing the steering angle sensor...........................................471 12.3.3.2.2 Installing steering angle sensor.............................................472 12.3.3.3 Checking the reference sensor......................................................473 12.3.3.4 Replacing the steering angle sensor mech. .........................................474 12.3.3.4.1 Removing the steering angle sensor mech......................................474 12.3.3.4.2 Installing the steering angle sensor mech....................................475 12.3.3.5 Replacing the steering damper......................................................476 12.3.3.5.1 Removing the steering damper [A83]...........................................476 12.3.3.5.2 Removing the steering damper [A83]...........................................477 12.3.3.5.3 Installing the steering damper [A83].........................................477 12.3.3.5.4 Installing the steering damper [A83].........................................479 13 Electrical system C5000..............................................................................485 13.1 Description....................................................................................485 13.1.1 General..................................................................................485 13.2 Using the anti-static carpet...................................................................485 13.3 Programming tools..............................................................................485 13.3.1 TruckCom.................................................................................485 13.3.1.1 Connect the CAN interface to the truck.............................................485 13.3.2 Software.................................................................................486 13.3.2.1 Software update....................................................................486 13.4 General electric equipment C5100...............................................................486 13.4.1 Battery C5110............................................................................486 13.4.1.1 Cleaning the battery...............................................................486 13.4.1.2 Checking the connections...........................................................487 13.4.1.3 Checking the battery cables........................................................487 13.4.1.4 Checking the battery...............................................................487 13.4.1.5 Checking cell and terminal protectors..............................................488 13.4.1.6 Checking the level of the electrolyte..............................................488 13.4.1.7 Checking the electrolyte density...................................................488 13.4.1.8 Battery replacement................................................................488 13.4.1.8.1 Replacing a battery using a lifting device...................................488 13.4.1.8.1.1 Removing a battery using a lifting device..............................488 13.4.1.8.1.2 Installing a battery using a lifting device............................489 13.4.1.8.2 Replacing a battery using a battery changing table...........................491 13.4.1.8.2.1 Removing a battery using a battery changing table......................491 13.4.1.8.2.2 Installing a battery using a battery changing table....................491 13.4.2 Battery Li-ion C5110.....................................................................493 13.4.2.1 Battery module.....................................................................493 13.4.2.1.1 Disconnection/connection.....................................................493 13.4.2.1.1.1 Resetting/restarting the battery.......................................493 13.4.3 General alarm signals (audible/visual) C5160.............................................494 13.4.3.1 Horn...............................................................................494 13.4.3.1.1 Overview.....................................................................494 13.4.3.1.2 Checking the horn function...................................................495 13.4.4 Battery charger (built-in) C5170.........................................................495 13.4.4.1 Checking the battery charger cables................................................495 13.4.4.2 Checking the battery charger parameters............................................495 13.4.5 Battery cut out switch, main contactor C5190.............................................495 13.4.5.1 Main contactor.....................................................................495 13.4.5.1.1 Replacing the main contactor.................................................495 13.4.5.1.1.1 Removing the main contactor............................................495 13.4.5.1.1.2 Removing the main contactor............................................498 13.4.5.1.1.3 Fitting the main contactor.............................................499 13.4.5.1.1.4 Fitting the main contactor.............................................502 13.5 Instrument panel, display C5200................................................................502 13.5.1 Menu.....................................................................................502 13.5.1.1 Menus..............................................................................502 13.5.1.2 Menu navigation....................................................................503 13.5.1.3 Menu overview......................................................................504 13.5.1.4 Menu list..........................................................................504 13.5.1.5 Menu information...................................................................505 13.5.1.6 Show hour meter values.............................................................505 13.5.1.7 Show error codes...................................................................506 13.5.1.8 Show part numbers for software/hardware............................................506 13.5.1.9 Built-in test ICH..................................................................506 13.5.1.10 Show collisions...................................................................506 13.5.1.11 Show/change parameters............................................................507 13.5.1.12 Emergency driving mode............................................................507 13.5.1.13 Calibration.......................................................................507 13.5.1.14 Show/change PIN code..............................................................507 13.5.1.15 PIN codes.........................................................................507 13.5.1.15.1 General.....................................................................507 13.5.1.15.2 PIN code for resetting the truck............................................508 13.5.1.15.3 Programming PIN codes.......................................................508 13.5.1.15.4 PIN code at delivery........................................................509 13.5.1.15.5 PIN code defaults...........................................................510 13.5.2 Hour counter, tachograph C5290...........................................................511 13.5.2.1 Checking error log and operating hours.............................................511 13.6 Control system travel function C5300...........................................................511 13.6.1 Direction selector/speed regulator.......................................................511 13.6.2 Safety reversing.........................................................................511 13.6.3 Battery indicator........................................................................511 13.6.4 Hour meter...............................................................................511 13.6.5 Lifting and lowering control.............................................................511 13.6.6 Signal buttons...........................................................................511 13.6.7 Option buttons...........................................................................512 13.6.8 Display..................................................................................512 13.6.9 Symbols on keypad and display............................................................512 13.6.10 Weighing system.........................................................................512 13.6.11 Pressure equalization...................................................................512 13.7 Power system travel function C5400.............................................................513 13.7.1 Transistor panel C5460...................................................................513 13.7.1.1 Overview ACT.......................................................................513 13.7.1.2 Overview ACC.......................................................................514 13.7.1.3 Description........................................................................514 13.7.1.3.1 General......................................................................514 13.7.1.4 Checking the contactors............................................................515 13.7.1.5 Checking the cable connections.....................................................515 13.7.1.6 Checking the electric panel mounting...............................................515 13.7.1.7 Cleaning the electric panel heatsink...............................................516 13.7.1.8 Replacing the motor control panel..................................................516 13.7.1.8.1 Removing the motor control panel.............................................516 13.7.1.8.2 Installing the motor control panel...........................................517 13.7.1.8.3 Installing the motor control panel...........................................518 13.8 Control system, working function C5500.........................................................519 13.8.1 Work function harnesses/fuse C5590.......................................................519 13.8.1.1 Checking the wiring harnesses......................................................519 13.9 Power system working function C5600............................................................519 13.9.1 Pump contactor C5610.....................................................................519 13.9.1.1 Replacing the pump contactor.......................................................519 13.9.1.1.1 Removing the pump contactor..................................................519 13.9.1.1.2 Fitting the pump contactor...................................................521 13.10 Control/protection electronics C5700..........................................................523 13.10.1 Protective electronics wiring harness and fuse C5790....................................523 13.10.1.1 Check the CAN bus.................................................................523 13.10.1.2 Check the CAN node................................................................523 13.11 Protective sensors, position sensors C5800....................................................523 13.11.1 Description.............................................................................523 13.11.1.1 Pressure sensor...................................................................523 13.11.2 Safety probes/sensors C5830.............................................................524 13.11.2.1 Emergency switch off..............................................................524 13.11.2.1.1 Description.................................................................524 13.11.2.1.1.1 Task and function.....................................................524 13.11.2.1.2 Checking the emergency switch function......................................524 13.11.2.2 Gate switches [B121]/[B122].......................................................524 13.11.2.2.1 Replacing the gate switch [B120]............................................524 13.11.2.2.1.1 Removing the position sensor [B121]...................................524 13.11.2.2.1.2 ......................................................................525 13.11.2.2.1.3 Installing the position sensor [B121].................................526 13.11.2.2.1.4 ......................................................................527 13.11.2.2.2 Replacing the gate switch [B122]............................................527 13.11.2.2.2.1 Removing the position sensor [B122]...................................527 13.11.2.2.2.2 ......................................................................528 13.11.2.2.2.3 Installing the position sensor [B122].................................529 13.11.2.2.2.4 ......................................................................529 13.11.2.3 Photocell.........................................................................530 13.11.2.3.1 Overview [Photocells for fixed side guards].................................530 13.11.2.3.2 Description.................................................................530 13.11.2.3.2.1 Function..............................................................530 13.11.2.3.3 Checking the photocell......................................................531 13.12 Calibrations..................................................................................531 13.12.1 Steering angle calibration..............................................................531 13.12.2 Weight measuring calibration............................................................532 13.12.3 Weight measuring calibration............................................................532 13.12.4 Steering angle manual steering..........................................................533 13.12.5 Weight measuring calibration............................................................533 14 Hydraulics/Pneumatics C6000..........................................................................537 14.1 Overview.......................................................................................537 14.2 Description....................................................................................537 14.2.1 Hydraulic hygiene........................................................................537 14.2.1.1 Definitions – hydraulic parts......................................................537 14.2.1.2 Inside cleaning....................................................................538 14.2.1.3 Packaging..........................................................................538 14.2.1.4 Handling...........................................................................538 14.2.1.5 Storage............................................................................538 14.2.1.6 Work procedures....................................................................538 14.2.2 Construction.............................................................................539 14.3 Quick change connectors........................................................................539 14.3.1 Overview quick change connectors.........................................................539 14.3.2 Removing female quick change connectors..................................................539 14.3.3 Installing female quick change connectors................................................540 14.3.4 Removing a quick change connector (male).................................................541 14.3.5 Installing a quick change connector (male)...............................................542 14.4 Hydraulic unit C6100...........................................................................543 14.4.1 Overview.................................................................................543 14.4.2 Hydraulic oil tank C6110.................................................................544 14.4.2.1 Overview...........................................................................544 14.4.2.2 Cleaning the tank..................................................................544 14.4.2.3 Checking the tank..................................................................544 14.4.2.4 Oil change.........................................................................545 14.4.2.4.1 Draining oil.................................................................545 14.4.2.4.2 Topping up with oil..........................................................545 14.4.2.5 Replacing the tank.................................................................546 14.4.2.5.1 Removing the tank............................................................546 14.4.2.5.2 Fitting the tank.............................................................547 14.4.3 Filter, filter housing C6130.............................................................547 14.4.3.1 Air filter.........................................................................547 14.4.3.1.1 Cleaning the air filter......................................................547 14.4.3.2 ...................................................................................548 14.4.3.2.1 Replacing the suction filter.................................................548 14.4.3.2.1.1 Removing suction filter................................................548 14.4.3.2.1.2 Installing the suction filter..........................................548 14.4.3.3 Oil filter replacement.............................................................548 14.4.3.3.1 Oil filter replacement.......................................................548 14.4.3.4 Replacing the return filter........................................................549 14.4.3.4.1 Removing the return filter...................................................549 14.4.3.4.2 Fitting the return filter....................................................550 14.4.4 Hydraulic pump C6140.....................................................................551 14.4.4.1 Overview...........................................................................551 14.4.4.2 Description........................................................................551 14.4.4.2.1 Construction.................................................................551 14.4.4.3 Replacing the hydraulic pump.......................................................551 14.4.4.3.1 Removing the hydraulic pump..................................................551 14.4.4.3.2 Removing the hydraulic pump..................................................552 14.4.4.3.3 Installing the hydraulic pump................................................553 14.4.4.3.4 Installing the hydraulic pump................................................554 14.4.5 .........................................................................................555 14.4.5.1 Checking the pressure limiting valve...............................................555 14.4.5.2 Replacing the flow control valve...................................................556 14.4.5.2.1 Removing the flow control valve..............................................556 14.4.5.2.2 Fitting the flow control valve...............................................557 14.4.5.3 Replacing the pressure limiting valve..............................................557 14.4.5.3.1 Removing the pressure limiting valve.........................................557 14.4.5.3.2 Fitting the pressure limiting valve..........................................558 14.4.5.4 Adjusting the lifting capacity.....................................................558 14.4.5.4.1 Adjusting the lifting capacity, reducing.....................................558 14.4.5.4.2 Adjusting the lifting capacity, increasing...................................559 14.4.6 Replacing the hydraulic unit.............................................................559 14.4.6.1 Removing the hydraulic unit........................................................559 14.4.6.2 Installing the hydraulic unit......................................................560 14.4.7 Replacing the valve coil.................................................................561 14.4.7.1 Removing the valve coil............................................................561 14.4.7.2 Removing the valve coil............................................................562 14.4.7.3 Fitting a solenoid valve...........................................................563 14.4.7.4 Fitting a solenoid valve...........................................................564 14.4.8 Replacing the pressure sensor............................................................564 14.4.8.1 Removing the pressure sensor [B4]..................................................564 14.4.8.2 Fitting the pressure sensor [B4]...................................................565 14.5 Hydraulic system, fitted to chassis C6200......................................................566 14.5.1 Main valve lift/reach/tilt C6210.........................................................566 14.5.1.1 Overview...........................................................................566 14.6 Hydraulic system, fitted on the mast C6300.....................................................566 14.6.1 Mast hydraulic conduits C6320............................................................566 14.6.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit...........566 14.7 Hydraulic cylinder C6600.......................................................................567 14.7.1 Main lift cylinders C6610................................................................567 14.7.1.1 Description........................................................................567 14.7.1.1.1 Construction.................................................................567 14.7.1.2 Checking the attachment of the lift cylinders......................................567 14.7.1.3 Checking for leaks in the lift cylinder............................................567 14.7.1.4 Replacing the main lift cylinders..................................................567 14.7.1.4.1 Removing the lift cylinder, right side.......................................567 14.7.1.4.2 Removing the lift cylinder, left side........................................568 14.7.1.4.3 Fitting the lift cylinder, right side........................................570 14.7.1.4.4 Fitting the lift cylinder, left side.........................................571 14.7.2 PowerTrak cylinder C6680.................................................................572 14.7.2.1 Replacing the PowerTrak cylinder...................................................572 14.7.2.1.1 Removing the PowerTrak cylinder..............................................572 14.7.2.1.2 Installing the PowerTrak cylinder............................................573 15 Work function - lifting masts C7000..................................................................577 16 Auxiliary equipment, installation equipment C8000....................................................581 17 Optional equipment/Extra equipment C9000.............................................................585 17.1 Overview.......................................................................................585 17.2 Extra electrical equipment C9400...............................................................586 17.2.1 Extra power socket.......................................................................586 17.2.1.1 Overview...........................................................................586 17.2.1.2 Description........................................................................586 17.2.1.2.1 DC/DC converter..............................................................586 17.2.2 Truck log equipment, code lock C9420.....................................................587 17.2.2.1 Overview...........................................................................587 17.2.2.2 I_Site.............................................................................587 17.2.2.2.1 Description..................................................................587 17.2.2.2.1.1 I_Site.................................................................587 17.2.2.3 Impact Manager.....................................................................588 17.2.2.3.1 Impact sensor................................................................588 17.2.2.3.2 Description..................................................................588 17.2.2.3.2.1 Impact sensor..........................................................588 17.2.2.3.3 Checking the impact sensor parameters........................................588 17.2.2.3.4 Checking DHU/I-site [K110]...................................................588 17.2.2.4 PreOpCheck.........................................................................588 17.3 Other extra equipment C9500....................................................................590 17.3.1 Fire extinguisher........................................................................590 17.3.1.1 Description........................................................................590 17.3.1.1.1 Fire extinguisher............................................................590 17.3.1.2 Inspection of fire extinguisher....................................................591 17.3.2 Horizontal E-bar.........................................................................592 17.3.2.1 Overview...........................................................................592 17.3.2.2 E-bar..............................................................................592 17.3.2.3 Description........................................................................593 17.3.2.3.1 E-bar........................................................................593 17.3.2.4 Checking the E-bar lock............................................................594 17.3.3 Spider expansion unit....................................................................594 17.3.3.1 Description........................................................................594 17.3.3.1.1 Spider expansion unit........................................................594 18 Instructions for disposal............................................................................597 18.1 General........................................................................................597 18.2 Marking of plastics............................................................................597 18.2.1 General marking of products and packaging................................................597 18.2.2 Marking according to the manufacturer’s standards........................................597 18.2.2.1 Abbreviations......................................................................597 18.2.2.2 Marking examples...................................................................598 18.3 Pressure vessels...............................................................................598 18.3.1 Gas struts...............................................................................598 18.4 Sorting categories.............................................................................599 19 Wiring diagram.......................................................................................603 19.1 Colour code table..............................................................................603 19.2 List of fuses..................................................................................603 19.3 Diagram........................................................................................604 19.3.1 Component list...........................................................................604 19.3.2 Component placement......................................................................607 19.3.3 Detailed diagrams........................................................................621 20 Hydraulics schematics................................................................................639 20.1 List of symbols................................................................................639 20.2 Component list.................................................................................641 20.3 Component location.............................................................................642 20.3.1 Picture 1................................................................................642 20.3.2 Picture 2................................................................................643 20.3.3 Picture 3................................................................................644 20.4 Diagram........................................................................................645 21 Tools................................................................................................649 21.1 Tools for electric connectors..................................................................649 21.1.1 AMP connectors...........................................................................649 21.1.2 MQS connectors...........................................................................649 21.1.3 CPC connectors...........................................................................650 21.1.4 AMP Seal connectors......................................................................651 21.1.5 Super Seal connectors....................................................................651 21.1.6 Molex connectors.........................................................................652 21.2 Lubricating tool...............................................................................653 21.3 Special tools..................................................................................654 22 Service data and grease specifications...............................................................661 22.1 General tightening torques.....................................................................661 22.1.1 Galvanised, non-oiled screws.............................................................661 22.1.2 Untreated, oiled screws..................................................................661 22.2 Lubricants specification.......................................................................662 23 Technical data.......................................................................................665 23.1 Truck Dimensions...............................................................................665 23.2 Truck data.....................................................................................665 24 Index................................................................................................667
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