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BT SWE140S,SWE150,SWE150L,SWE160,SWE160L,SWE200,SWE200L Repair Manual – PDF DOWNLOAD
BT SWE140S,SWE150,SWE150L,SWE160,SWE160L,SWE200,SWE200L Repair Manual – PDF DOWNLOAD
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BT SWE140S,SWE150,SWE150L,SWE160,SWE160L,SWE200,SWE200L Repair Manual – PDF DOWNLOAD
Language : English
Pages : 578
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
BT SWE140S,SWE150,SWE150L,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.............................................................................. 14 2.3.1 Electrostatic risks...................................................................... 14 2.3.2 Battery handling......................................................................... 14 2.4 Safe lifting................................................................................... 15 2.5 Product modification........................................................................... 16 2.6 Software....................................................................................... 16 2.7 Software....................................................................................... 16 2.8 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 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 Maintenance.......................................................................................... 69 6.1 Introduction................................................................................... 69 6.2 Maintenance instructions....................................................................... 69 6.2.1 Cleaning................................................................................. 69 6.2.2 High-pressure washers.................................................................... 69 6.2.3 Degreasing agents........................................................................ 70 6.2.4 Cleaning the exterior.................................................................... 70 6.2.5 Cleaning the chain....................................................................... 70 6.2.6 Cleaning the motor compartment........................................................... 70 6.2.7 Electric components...................................................................... 70 6.2.8 Hydraulic system......................................................................... 71 6.2.9 Signs, warnings and adhesive labels...................................................... 71 6.2.9.1 Placement of signs................................................................. 71 6.2.9.2 Placement of signs................................................................. 73 6.2.9.3 Placement of signs................................................................. 75 6.3 Lubricants specification....................................................................... 77 6.4 Periodic maintenance........................................................................... 77 7 Troubleshooting...................................................................................... 91 7.1 Auxiliary functions............................................................................ 91 7.1.1 Towing a defective truck................................................................. 91 7.1.1.1 Towing and transporting a defective truck.......................................... 91 7.1.1.2 Towing and transporting a defective truck.......................................... 91 7.1.2 Emergency driving mode................................................................... 92 7.1.2.1 Emergency driving mode............................................................. 92 7.1.3 Error code history....................................................................... 92 7.1.3.1 Error code history................................................................. 92 7.1.4 Extended error log....................................................................... 92 7.1.4.1 Extended error log................................................................. 92 7.1.5 Built-in test function for the tiller arm................................................ 93 7.1.5.1 General............................................................................ 93 7.1.5.2 Display test....................................................................... 93 7.1.5.3 Speed control...................................................................... 94 7.1.5.4 Safety reversing................................................................... 94 7.1.5.5 Controls for lifting/lowering...................................................... 94 7.1.5.6 Sensilift.......................................................................... 95 7.1.5.7 Keypad............................................................................. 95 7.1.6 Digital input/output status.............................................................. 96 7.1.6.1 Test mode "9"...................................................................... 96 7.1.6.2 Test mode “12” SEU expansion unit (option)......................................... 97 7.1.7 Service information...................................................................... 98 7.1.7.1 Service information................................................................ 98 7.2 Initial troubleshooting........................................................................100 7.3 Concluding troubleshooting.....................................................................101 7.4 Troubleshooting using error codes..............................................................102 7.4.1 List of error codes......................................................................102 8 Chassis C0000........................................................................................171 8.1 Overview.......................................................................................171 8.2 Inspection of the rear chassis.................................................................172 8.3 Frame, chassis C0300...........................................................................173 8.3.1 Inspection covers C0340..................................................................173 8.3.1.1 Motor compartment covers...........................................................173 8.3.1.1.1 Overview.....................................................................173 8.3.1.1.2 Replacing a service cover....................................................173 8.3.1.1.2.1 Removing the service cover.............................................173 8.3.1.1.2.2 Fitting the service cover..............................................174 8.3.1.1.3 Replacing an emblem cover....................................................175 8.3.1.1.3.1 Removing the emblem cover..............................................175 8.3.1.1.3.2 Fitting the emblem cover...............................................175 8.3.2 Support arms, stabilizers C0350..........................................................176 8.3.2.1 Overview...........................................................................176 8.3.2.2 Checking the linkage...............................................................177 8.3.2.3 Checking the wheel fork flexibility................................................177 8.3.2.4 Replacing the pressure rod.........................................................178 8.3.2.4.1 Removing a push rod..........................................................178 8.3.2.4.2 Installing a push rod........................................................181 8.3.2.5 Replacing torsion tubes............................................................183 8.3.2.5.1 Removing torsion tubes.......................................................183 8.3.2.5.2 Installing a torsion tube....................................................184 8.3.2.6 Replacing the roller on the torsion tube...........................................185 8.3.2.6.1 Removing the roller on the torsion tube......................................185 8.3.2.6.2 Fit the roller on the torsion tube...........................................187 8.3.2.7 Replacing a wheel fork.............................................................188 8.3.2.7.1 Removing wheel fork..........................................................188 8.3.2.7.2 Installing a wheel fork......................................................189 8.3.2.8 Replacing a bogie link, fork wheel.................................................191 8.3.2.8.1 Removing a bogie link, fork wheel............................................191 8.3.2.8.2 Fitting a bogie link, fork wheel.............................................192 8.3.2.9 Replacing a bogie link, support arm................................................192 8.3.2.9.1 Removing a bogie link, support arm...........................................192 8.3.2.9.2 Installing a bogie link, support arm.........................................193 8.3.2.10 Replacing the wheel fork bushing..................................................193 8.3.2.10.1 Removing the wheel fork bushing.............................................193 8.3.2.10.2 Fitting the wheel fork bushing..............................................194 8.3.2.11 Replacing the support arm bushing.................................................194 8.3.2.11.1 Removing the support arm bushing............................................194 8.3.2.11.2 Installing a support arm bushing............................................195 8.3.3 Fork structure (low-lifter) C0380........................................................195 8.3.3.1 Checking the fork lift height limitation...........................................195 8.3.3.2 Checking the support arm lift height limitation....................................195 8.3.4 Battery compartment parts C0390..........................................................196 8.3.4.1 Overview...........................................................................196 8.3.4.2 Overview...........................................................................197 8.3.4.3 Overview...........................................................................198 8.3.4.4 Description........................................................................198 8.3.4.4.1 Battery lock, fixed..........................................................198 8.3.4.4.2 Battery lock, quick..........................................................198 8.3.4.5 Checking the battery lock..........................................................199 8.3.4.6 Adjusting the battery lock.........................................................199 8.4 Frame/chassis components C0400.................................................................199 8.4.1 Safety equipment C0800...................................................................199 8.4.1.1 Signs, warnings, labels C0850......................................................199 8.4.1.1.1 Checking signs and labels....................................................199 8.4.1.1.2 Placement of signs...........................................................199 8.4.1.1.3 Placement of signs...........................................................201 8.4.1.1.4 Placement of signs...........................................................203 8.4.2 Motor mount/brackets C0450...............................................................205 8.4.2.1 Checking the motor mounts..........................................................205 8.4.2.2 Drive unit mountings...............................................................206 8.4.2.2.1 Drive unit mounting 6 km/h SWE...............................................206 8.4.2.2.1.1 Overview 6 km/h........................................................206 8.4.2.2.1.2 Description............................................................206 8.4.2.2.1.2.1 Technical data...................................................206 8.4.2.2.1.2.2 Technical data...................................................207 8.4.2.2.1.2.3 Technical data...................................................207 8.4.2.2.1.2.4 Technical data...................................................207 8.4.2.2.1.2.5 Technical data...................................................208 8.4.2.2.1.2.6 Technical data...................................................208 8.4.2.2.1.2.7 Technical data...................................................208 8.4.2.2.1.3 Replacing the drive unit mounting 6 km/h...............................209 8.4.2.2.1.3.1 Removing the drive unit mounting 6 km/h..........................209 8.4.2.2.1.3.2 Installing the drive unit mounting 6 km/h........................210 8.4.2.3 PowerTrak..........................................................................212 8.4.2.3.1 Description..................................................................212 8.4.2.3.1.1 Design.................................................................212 8.4.2.3.2 Increasing the spring tension................................................214 8.4.2.3.3 Releasing the spring tension.................................................216 8.4.2.3.4 Adjusting tool V08-18302.....................................................218 8.4.2.3.5 Replacing the initial pressure spring........................................219 8.4.2.3.5.1 Removing the initial pressure spring...................................219 8.4.2.3.5.2 Fitting the initial pressure spring....................................220 8.4.2.3.6 Replacing the PowerTrak spring...............................................221 8.4.2.3.6.1 Removing the PowerTrak spring..........................................221 8.4.2.3.6.2 Installing the PowerTrak spring........................................223 8.4.2.3.7 Replacing a spacer...........................................................225 8.4.2.3.7.1 Removing a spacer......................................................225 8.4.2.3.7.2 Installing a spacer....................................................226 8.4.2.4 Decompression locking..............................................................227 8.4.2.4.1 Overview.....................................................................227 8.4.2.4.2 Description..................................................................227 8.4.2.4.2.1 Design.................................................................227 8.4.2.4.3 Purging the decompression lock...............................................228 8.4.2.4.4 Checking the decompression lock..............................................230 8.4.2.4.5 Replacing the decompression lock.............................................230 8.4.2.4.5.1 Removing the decompression lock........................................230 8.4.2.4.5.2 Fitting the decompression lock.........................................232 8.5 Operator compartment, cab C0500................................................................234 8.5.1 Platform including fixing points C0560...................................................234 8.5.1.1 Replacing the platform.............................................................234 8.5.1.1.1 Removing the platform........................................................234 8.5.1.1.2 Fitting the platform.........................................................234 9 Motors C1000.........................................................................................237 9.1 Electric motors C1700..........................................................................237 9.1.1 Electric pump motor C1710................................................................237 9.1.1.1 Overview...........................................................................237 9.1.1.2 Replacing the pump motor...........................................................237 9.1.1.2.1 Removing a pump motor........................................................237 9.1.1.2.2 Installing a pump motor......................................................238 9.1.2 Electric fan motor/fan C1740.............................................................239 9.1.2.1 Overview...........................................................................239 9.1.2.2 Description........................................................................239 9.1.2.2.1 Design.......................................................................239 9.1.2.3 Replacing the motor control fan....................................................240 9.1.2.3.1 Removing a motor control fan.................................................240 9.1.2.3.2 Installing a motor control fan...............................................241 9.1.3 Electric drive motor C1760...............................................................242 9.1.3.1 Overview 1.8, 2.5 kW...............................................................242 9.1.3.2 Description........................................................................242 9.1.3.2.1 Design.......................................................................242 9.1.3.3 Checking the electrical connections................................................243 9.1.3.4 Checking the drive motor...........................................................243 9.1.3.5 Listen for any abnormal noise in the drive motor bearings..........................243 9.1.3.6 Check the drive motor fitting (1.8 and 2.5 kW).....................................244 9.1.3.7 Checking the rotational speed sensor...............................................244 9.1.3.8 Check the rotational speed sensor fitting..........................................245 9.1.3.9 Replacing the drive motor..........................................................245 9.1.3.9.1 Removing the drive motor [M1]................................................245 9.1.3.9.2 Installing the drive motor [M1]..............................................248 9.1.3.10 Replacing the temperature sensor..................................................251 9.1.3.10.1 Installing the temperature sensor...........................................251 9.1.3.11 Replacing the rotational speed sensor.............................................252 9.1.3.11.1 Removing a rotational speed sensor..........................................252 9.1.3.11.2 Installing a rotational speed sensor........................................254 9.1.3.12 Replacing the toothed wheel.......................................................255 9.1.3.12.1 Removing a toothed wheel....................................................255 9.1.3.12.2 Installing a toothed wheel..................................................256 10 Transmission/Drive gear C2000.......................................................................259 10.1 Drive unit, final gear C2500..................................................................259 10.1.1 Drive unit/gear C2550 ..................................................................259 10.1.1.1 Overview..........................................................................259 10.1.1.2 Description ......................................................................259 10.1.1.2.1 Design......................................................................259 10.1.1.2.2 Technical data..............................................................260 10.1.1.3 Check the drive gear's attachment ................................................260 10.1.1.4 Checking for leaks in the drive gear..............................................260 10.1.1.5 Checking for noise in the drive gear..............................................260 10.1.1.6 Replacing the drive gear .........................................................261 10.1.1.6.1 Removing the drive gear.....................................................261 10.1.1.6.2 Installing the drive gear...................................................263 10.1.1.7 Replacing the wheel hub seal .....................................................265 10.1.1.7.1 Removing the wheel hub seal.................................................265 10.1.1.7.2 Installing the wheel hub seal...............................................266 10.1.1.8 Drive gear oil change.............................................................267 10.1.1.8.1 Empty the drive gear oil....................................................268 10.1.1.8.2 Filling oil in the drive gear...............................................269 10.1.1.9 Drive gear oil change.............................................................269 10.1.1.9.1 Empty the drive gear oil....................................................270 10.1.1.9.2 Filling oil in the drive gear...............................................271 10.1.1.10 Replacing the drive gear steering bearing .......................................271 10.1.1.10.1 Removing the drive gear steering bearing...................................271 10.1.1.10.2 Installing the drive gear steering bearing.................................272 10.1.1.11 Stud replacement ................................................................273 10.1.1.11.1 Removing a stud............................................................273 10.1.1.11.2 Installing a stud..........................................................274 11 Brake/wheel/track system C3000......................................................................277 11.1 Travel brake system C3100.....................................................................277 11.1.1 Description.............................................................................277 11.1.1.1 Brake types.......................................................................277 11.1.1.1.1 Travel brake................................................................277 11.1.1.1.2 Emergency brake.............................................................277 11.1.1.1.3 Parking brake...............................................................277 11.2 Parking brake details C3300...................................................................278 11.2.1 Electrical parking brake, magnet brake C3370............................................278 11.2.1.1 Overview..........................................................................278 11.2.1.2 Description.......................................................................279 11.2.1.2.1 Technical data..............................................................279 11.2.1.3 Cleaning the parking brake........................................................279 11.2.1.4 Adjusting the parking brake gap...................................................280 11.2.1.5 Adjusting the parking brake gap...................................................280 11.2.1.6 Tighten the parking brake mounting bolts..........................................281 11.2.1.7 Emergency release of the parking brake............................................282 11.2.1.8 Checking the parking brake........................................................282 11.2.1.9 Replacing the brake hub...........................................................282 11.2.1.9.1 Disassembling the brake hub.................................................282 11.2.1.9.2 Installing a brake hub......................................................283 11.2.1.10 Replacing the friction disc......................................................283 11.2.1.10.1 Removing the friction disc.................................................283 11.2.1.10.2 Fitting the friction disc..................................................285 11.2.1.11 Replacing the parking brake......................................................286 11.2.1.11.1 Removing the parking brake.................................................286 11.2.1.11.2 Fitting the parking brake..................................................287 11.3 Wheels C3500..................................................................................288 11.3.1 Drive wheel C3530.......................................................................288 11.3.1.1 Overview..........................................................................288 11.3.1.2 Description.......................................................................289 11.3.1.2.1 Wheel wear..................................................................289 11.3.1.3 Measuring the drive wheel tread...................................................289 11.3.1.4 Replacing the drive wheel.........................................................289 11.3.1.4.1 Removing the drive wheel....................................................289 11.3.1.4.2 Fitting the drive wheel.....................................................291 11.3.2 Support arm wheels/castor wheels C3540..................................................292 11.3.2.1 Overview..........................................................................292 11.3.2.2 Description.......................................................................293 11.3.2.2.1 Wheel wear..................................................................293 11.3.2.3 Cleaning castor wheels............................................................293 11.3.2.4 Measuring the castor wheel tread..................................................294 11.3.2.5 Measuring the castor wheel tread..................................................294 11.3.2.6 Measuring the castor wheel tread..................................................294 11.3.2.7 Measuring the castor wheel tread..................................................295 11.3.2.8 Checking the castor wheels........................................................295 11.3.2.9 Replacing the castor wheel........................................................295 11.3.2.9.1 Removing the castor.........................................................295 11.3.2.9.2 Removing the castor.........................................................296 11.3.2.9.3 Installing a castor wheel...................................................297 11.3.2.9.4 Installing a castor wheel...................................................298 11.3.2.10 Replacing the castor wheel assembly..............................................299 11.3.2.10.1 Removing the castor wheel assembly.........................................299 11.3.2.10.2 Installing the castor wheel assembly.......................................300 11.3.3 Fork wheels/support arm wheels C3550....................................................301 11.3.3.1 Overview..........................................................................301 11.3.3.2 Description.......................................................................301 11.3.3.2.1 Wheel wear..................................................................301 11.3.3.3 Cleaning the fork wheels..........................................................302 11.3.3.4 Measuring the fork wheel tread....................................................302 11.3.3.5 Checking the fork wheel mounting..................................................302 11.3.3.6 Checking the fork wheel bushings..................................................303 11.3.3.7 Replacing a single wheel..........................................................303 11.3.3.7.1 Removing single wheels......................................................303 11.3.3.7.2 Single wheel installation...................................................304 11.3.3.8 Replacing bogie wheels............................................................305 11.3.3.8.1 Removing bogie wheels.......................................................305 11.3.3.8.2 Removing bogie wheels.......................................................307 11.3.3.8.3 Fitting the bogie wheel.....................................................308 11.3.3.8.4 Fitting the bogie wheel.....................................................310 11.3.3.9 Replacing a bogie link............................................................312 11.3.3.9.1 Removing a bogie link.......................................................312 11.3.3.9.2 Removing a bogie link.......................................................312 11.3.3.9.3 Installing a bogie link.....................................................313 11.3.3.9.4 Installing a bogie link.....................................................313 12 Steering system C4000...............................................................................317 12.1 Mechanical steering system C4100..............................................................317 12.1.1 Steering arm/wheel/lever C4110..........................................................317 12.1.1.1 Overview tiller arm...............................................................317 12.1.1.2 Operating panel...................................................................318 12.1.1.2.1 Overview operating panel....................................................318 12.1.1.2.2 Controls....................................................................319 12.1.1.2.2.1 Replacing the signal button/switch....................................319 12.1.1.2.2.1.1 Removing the signal button/switch...............................319 12.1.1.2.2.1.2 Fitting the signal button/switch................................320 12.1.1.2.2.2 Replacing the lift/lower button.......................................322 12.1.1.2.2.2.1 Removing the lift/lower button..................................322 12.1.1.2.2.2.2 Fitting the lift/lower button...................................323 12.1.1.2.2.2.3 Checking the hydraulic functions................................324 12.1.1.2.2.3 Replacing the stomach button..........................................324 12.1.1.2.2.3.1 Removing the stomach button.....................................324 12.1.1.2.2.3.2 Installing a stomach button.....................................325 12.1.1.2.2.3.3 Checking the stomach button.....................................326 12.1.1.2.2.4 Replacing the sensilift...............................................326 12.1.1.2.2.4.1 Removing the sensilift..........................................326 12.1.1.2.2.4.2 Installing sensilift............................................327 12.1.1.2.2.5 Changing the position of the controls - support arm lift/fork lift....327 12.1.1.2.2.6 Replacing the keypad..................................................328 12.1.1.2.2.6.1 Removing the keypad.............................................328 12.1.1.2.2.6.2 Installing a keypad.............................................328 12.1.1.2.3 Replacing the operating panel...............................................328 12.1.1.2.3.1 Removing the operating panel..........................................328 12.1.1.2.3.2 Installing an operating panel.........................................329 12.1.1.2.3.3 Checking the speed control............................................331 12.1.1.2.4 Replacing the logic card....................................................331 12.1.1.2.4.1 Removing the logic card...............................................331 12.1.1.2.4.2 Installing a logic card...............................................332 12.1.1.2.4.3 Logic card [A5].......................................................334 12.1.1.3 Tiller arm handle.................................................................334 12.1.1.3.1 Replacing the handle to the tiller arm......................................334 12.1.1.3.1.1 Removing the tiller arm handle........................................334 12.1.1.3.1.2 Fitting the handle to the tiller arm..................................335 12.1.1.4 Tiller arm........................................................................336 12.1.1.4.1 Replacing the tiller arm....................................................336 12.1.1.4.1.1 Removing the tiller arm...............................................336 12.1.1.4.1.2 Fitting tiller arm....................................................338 12.1.1.4.2 Replacing the tiller arm assembly...........................................340 12.1.1.4.2.1 Removing the tiller arm assembly......................................340 12.1.1.4.2.2 Fitting the tiller arm assembly.......................................341 12.1.1.4.3 Checking the brake microswitches............................................342 12.1.1.4.4 Checking the play and the return travel.....................................343 12.1.1.4.5 Replacing the tiller arm cover..............................................343 12.1.1.4.5.1 Removing the tiller arm cover.........................................343 12.1.1.4.5.2 Fitting the tiller arm cover..........................................344 12.1.1.4.6 Replacing the tiller arm housing............................................344 12.1.1.4.6.1 Removing the tiller arm housing.......................................344 12.1.1.4.6.2 Fitting the tiller arm housing........................................345 12.1.1.5 Steering yoke.....................................................................346 12.1.1.5.1 Overview steering servo.....................................................346 12.1.1.5.2 Replacing the steering yoke.................................................346 12.1.1.5.2.1 Removing the steering yoke............................................346 12.1.1.5.2.2 Fitting the steering yoke.............................................348 12.1.1.5.3 Replacing the steering yoke cover...........................................349 12.1.1.5.3.1 Removing the steering yoke cover......................................349 12.1.1.5.3.2 Fitting the steering yoke cover.......................................350 12.1.1.5.4 Changing the tiller arm damper..............................................350 12.1.1.5.4.1 Removing the tiller arm damper........................................350 12.1.1.5.4.2 Installing the tiller arm damper......................................352 12.1.1.5.5 Adjusting the tiller arm damper.............................................353 12.1.1.5.6 Replacing the safety switch.................................................354 12.1.1.5.6.1 Removing the safety switch [B60]......................................354 12.1.1.5.6.2 Installing the safety switch [B60]....................................355 12.1.1.6 Tiller arm wiring harness.........................................................356 12.1.1.6.1 Replacing the tiller arm wiring harness.....................................356 12.1.1.6.1.1 Removing the tiller arm wiring harness................................356 12.1.1.6.1.2 Fitting the tiller arm wiring harness.................................356 12.2 Electric steering system C4300................................................................357 12.2.1 Steering angle sensor C4350.............................................................357 12.2.1.1 Replacing the steering angle sensor mech. ........................................357 12.2.1.1.1 Removing the steering angle sensor mech.....................................357 12.2.1.1.2 Installing the steering angle sensor mech...................................359 13 Electrical system C5000.............................................................................365 13.1 Description...................................................................................365 13.1.1 General.................................................................................365 13.1.2 Truck firmware applications.............................................................365 13.2 Programming tools.............................................................................365 13.2.1 TruckCom................................................................................365 13.2.1.1 Connect the CAN interface to the truck............................................365 13.2.2 Software................................................................................365 13.2.2.1 Software update...................................................................365 13.3 General electric equipment C5100..............................................................366 13.3.1 Battery C5110...........................................................................366 13.3.1.1 Description.......................................................................366 13.3.1.1.1 Mast dimensions.............................................................366 13.3.1.2 Cleaning the battery..............................................................366 13.3.1.3 Checking the connections..........................................................366 13.3.1.4 Checking the battery cables.......................................................366 13.3.1.5 Checking the battery..............................................................367 13.3.1.6 Checking cell and terminal protectors.............................................367 13.3.1.7 Checking the level of the electrolyte.............................................368 13.3.1.8 Checking the electrolyte density..................................................368 13.3.1.9 Checking the battery parameters...................................................368 13.3.1.10 Checking the battery voltage.....................................................368 13.3.1.11 Resetting/restarting the battery.................................................368 13.3.1.12 Charging the battery.............................................................370 13.3.1.13 Replacing a battery using a lifting device.......................................371 13.3.1.13.1 Removing a battery using a lifting device..................................371 13.3.1.13.2 Installing a battery using a lifting device................................371 13.3.1.14 Replacing a battery using a battery changing table...............................373 13.3.1.14.1 Removing a battery using a battery changing table..........................373 13.3.1.14.2 Installing a battery using a battery changing table........................373 13.3.2 General alarm signals (audible/visual) C5160............................................376 13.3.2.1 Horn..............................................................................376 13.3.2.1.1 Overview....................................................................376 13.3.2.1.2 Checking the horn function..................................................376 13.3.3 Battery charger (built-in) C5170........................................................376 13.3.3.1 Checking the battery charger cables...............................................376 13.3.3.2 Checking the battery charger parameters...........................................376 13.3.4 Battery cut out switch, main contactor C5190............................................377 13.3.4.1 Main contactor....................................................................377 13.3.4.1.1 Replacing the main contactor................................................377 13.3.4.1.1.1 Removing the main contactor...........................................377 13.3.4.1.1.2 Fitting the main contactor............................................380 13.4 Instrument panel, display C5200...............................................................382 13.4.1 Menu....................................................................................382 13.4.1.1 Menus.............................................................................382 13.4.1.2 Menu navigation...................................................................382 13.4.1.3 Menu list.........................................................................383 13.4.1.4 Menu information..................................................................383 13.4.1.5 Show hour meter values............................................................383 13.4.1.6 Show error codes..................................................................384 13.4.1.7 Show part numbers for software/hardware...........................................384 13.4.1.8 Built-in test ICH.................................................................384 13.4.1.9 Show collisions...................................................................385 13.4.1.10 Show/change parameters...........................................................385 13.4.1.11 Emergency driving mode...........................................................385 13.4.1.12 Calibration......................................................................385 13.4.1.13 Show/change PIN code.............................................................385 13.4.1.14 PIN codes........................................................................386 13.4.1.14.1 General....................................................................386 13.4.1.14.2 PIN code for resetting the truck...........................................386 13.4.1.14.3 Programming PIN codes......................................................386 13.4.1.14.4 PIN code defaults..........................................................388 13.4.2 Hour counter, tachograph C5290..........................................................388 13.4.2.1 Checking error log and operating hours............................................388 13.5 Control system travel function C5300..........................................................389 13.5.1 Direction selector/speed regulator......................................................389 13.5.2 Pressure equalization...................................................................389 13.5.3 Weighing system.........................................................................389 13.5.4 Display.................................................................................389 13.5.5 Symbols on keypad and display...........................................................389 13.5.6 Option buttons..........................................................................389 13.5.7 Signal buttons..........................................................................389 13.5.8 Lifting and lowering control............................................................390 13.5.9 Hour meter..............................................................................390 13.5.10 Battery indicator......................................................................390 13.5.11 Safety reversing.......................................................................390 13.5.12 Travel function wiring/fuse C5390......................................................390 13.5.12.1 Description......................................................................390 13.5.12.1.1 Fuses......................................................................390 13.6 Power system travel function C5400............................................................391 13.6.1 Overview................................................................................391 13.6.2 Transistor panel C5460..................................................................391 13.6.2.1 Description.......................................................................391 13.6.2.1.1 General.....................................................................391 13.6.2.2 Checking the contactors...........................................................392 13.6.2.3 Checking the cable connections....................................................392 13.6.2.4 Checking the electric panel mounting..............................................392 13.6.2.5 Cleaning the electric panel heatsink..............................................393 13.6.2.6 Replacing the motor control panel.................................................393 13.6.2.6.1 Removing the motor control panel............................................393 13.6.2.6.2 Installing the motor control panel..........................................394 13.7 Control system, working function C5500........................................................395 13.7.1 Work function harnesses/fuse C5590......................................................395 13.7.1.1 Checking the wiring harnesses.....................................................395 13.8 Protective sensors, position sensors C5800....................................................395 13.8.1 Description.............................................................................395 13.8.1.1 Inductive sensors.................................................................395 13.8.1.1.1 Position sensors............................................................395 13.8.1.1.2 Steering reference sensor...................................................396 13.8.1.2 Pressure sensor...................................................................396 13.8.1.3 Pulse transducer..................................................................397 13.8.2 Safety probes/sensors C5830.............................................................397 13.8.2.1 Emergency switch off..............................................................397 13.8.2.1.1 Description.................................................................397 13.8.2.1.1.1 Task and function.....................................................397 13.8.2.1.2 Checking the emergency switch function......................................398 13.9 Calibrations..................................................................................398 13.9.1 Steering angle calibration..............................................................398 13.9.2 Hydraulic valve calibration.............................................................399 13.9.2.1 Proportional valve calibration....................................................399 13.9.2.2 Tilt angle calibration............................................................399 13.9.3 Pressure sensor calibration.............................................................400 13.9.3.1 Steering angle manual steering....................................................400 13.9.3.2 Weight measuring calibration......................................................401 13.9.3.3 Overload calibration..............................................................401 14 Hydraulics/Pneumatics C6000.........................................................................405 14.1 Overview......................................................................................405 14.2 Description...................................................................................405 14.2.1 Hydraulic hygiene.......................................................................405 14.2.1.1 Washing...........................................................................405 14.2.1.2 Packaging.........................................................................406 14.2.1.3 Handling..........................................................................406 14.2.1.4 Storage...........................................................................406 14.2.1.5 Work procedures...................................................................406 14.2.1.6 General rules.....................................................................406 14.2.1.7 Measures..........................................................................407 14.2.2 Design..................................................................................408 14.3 Quick change connectors.......................................................................408 14.3.1 Overview quick change connectors........................................................408 14.3.2 Removing quick change connectors (female)...............................................408 14.3.3 Installing quick change connector (female)..............................................409 14.3.4 Removing a quick change connector (male)................................................410 14.3.5 Installing a quick change connector (male)..............................................411 14.4 Hydraulic unit C6100..........................................................................412 14.4.1 Hydraulic unit..........................................................................412 14.4.2 Description.............................................................................412 14.4.2.1 Pressure limiting valve...........................................................412 14.4.3 Hydraulic oil tank C6110................................................................413 14.4.3.1 Tank..............................................................................413 14.4.3.2 Description.......................................................................413 14.4.3.2.1 Design......................................................................413 14.4.3.3 Cleaning the tank.................................................................413 14.4.3.4 Checking the tank.................................................................414 14.4.3.5 Oil change........................................................................414 14.4.3.5.1 Draining oil................................................................414 14.4.3.5.2 Topping up with oil.........................................................415 14.4.3.6 Replacing the tank................................................................415 14.4.3.6.1 Removing the tank...........................................................415 14.4.3.6.2 Fitting the tank............................................................416 14.4.4 Filter, filter housing C6130............................................................416 14.4.4.1 Cleaning the suction filter.......................................................416 14.4.4.2 Oil filter replacement............................................................416 14.4.4.2.1 Removing oil filter.........................................................416 14.4.4.2.2 Installing the oil filter...................................................417 14.4.4.3 Replacing the suction filter......................................................418 14.4.4.3.1 Removing suction filter.....................................................418 14.4.4.3.2 Installing the suction filter...............................................419 14.4.5 Hydraulic pump C6140....................................................................420 14.4.5.1 Hydraulic pump....................................................................420 14.4.5.2 Description.......................................................................420 14.4.5.2.1 Design......................................................................420 14.4.6 Pressure/flow control valve C6170.......................................................420 14.4.6.1 Description.......................................................................420 14.4.6.1.1 Checking the pressure limiting valve........................................420 14.4.6.2 Replacing the flow control valve..................................................421 14.4.6.2.1 Removing the flow control valve.............................................421 14.4.6.2.2 Fitting the flow control valve..............................................422 14.4.6.3 Replacing the pressure limiting valve.............................................422 14.4.6.3.1 Removing the pressure limiting valve........................................422 14.4.6.3.2 Fitting the pressure limiting valve.........................................423 14.4.7 Replacing the hydraulic unit............................................................423 14.4.7.1 Removing the hydraulic unit.......................................................423 14.4.7.2 Fitting the hydraulic unit........................................................424 14.4.8 Replacing the valve coil................................................................425 14.4.8.1 Removing the valve coil...........................................................425 14.4.8.2 Fitting the valve coil............................................................426 14.4.9 Replacing the pressure sensor...........................................................426 14.4.9.1 Removing the pressure sensor......................................................426 14.4.9.2 Fitting the pressure sensor.......................................................427 14.5 Hydraulic system, fitted on the mast C6300....................................................427 14.5.1 Mast hydraulic conduits C6320...........................................................427 14.5.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit..........427 14.5.1.2 Checks for leaks from hydraulic conduits and connections, mast....................428 14.6 Hydraulic cylinder C6600......................................................................428 14.6.1 Main lift cylinders C6610...............................................................428 14.6.1.1 Checking for leaks in the lift cylinder...........................................428 14.6.1.2 Replacing the main lift cylinders.................................................428 14.6.1.2.1 Removing the lift cylinder..................................................428 14.6.1.2.2 Fitting the lift cylinder...................................................430 14.6.2 Support arm/initial lift cylinder C6630.................................................432 14.6.2.1 Replacing the main initial lift cylinder..........................................432 14.6.2.1.1 Removing the initial lift cylinder..........................................432 14.6.2.1.2 Installing the initial lift cylinder........................................434 14.6.3 PowerTrak cylinder C6680................................................................435 14.6.3.1 Replacing the PowerTrak cylinder..................................................435 14.6.3.1.1 Removing the PowerTrak cylinder.............................................435 14.6.3.1.2 Installing the PowerTrak cylinder...........................................436 15 Work function - lifting masts C7000.................................................................441 15.1 Description...................................................................................441 15.1.1 Ordering a replacement mast.............................................................441 15.2 Chain system, general.........................................................................441 15.2.1 General.................................................................................441 15.2.2 Adjusting the chain.....................................................................441 15.2.3 Lubrication.............................................................................441 15.2.4 Checking the chains.....................................................................442 15.2.4.1 Noise.............................................................................442 15.2.4.2 Surface rust......................................................................442 15.2.4.3 Rusty links.......................................................................442 15.2.4.4 Stiff links.......................................................................442 15.2.4.5 Bolt rotation.....................................................................442 15.2.4.6 Loose bolts.......................................................................443 15.2.4.7 Outline wear......................................................................443 15.2.4.8 Chain gauge.......................................................................444 15.2.4.9 Stretching........................................................................444 15.2.4.10 Damaged plates...................................................................445 15.2.4.11 Damaged bolts....................................................................445 15.2.4.12 Other damage.....................................................................445 15.2.4.13 Dirty chain......................................................................445 15.3 Checking the chains...........................................................................446 15.4 Lubricating the chains........................................................................446 15.5 Checking the split pins.......................................................................447 15.6 Check-tighten the locking nuts................................................................447 15.7 Main mast C7100...............................................................................448 15.7.1 Check the position of the mast guide....................................................448 15.7.2 Check for cracks/damages to the mast....................................................448 15.7.3 Lubrication of the mast roller guides ..................................................448 15.7.4 Measuring the mast inclination..........................................................449 15.7.5 Adjusting the mast inclination..........................................................449 15.7.6 Replacing the roller....................................................................450 15.7.6.1 Installing a roller...............................................................450 15.7.7 Replacement of the mast.................................................................451 15.7.7.1 Disassembling the mast............................................................451 15.7.7.2 Removing a roller.................................................................452 15.7.7.3 Assembling the mast...............................................................453 15.7.8 Main mast fork carriage C7130...........................................................455 15.7.8.1 Fork yoke.........................................................................455 15.7.8.1.1 Replacing the fork yoke.....................................................455 15.7.8.1.1.1 Removing the fork yoke................................................455 15.7.8.1.1.2 Fitting the fork yoke.................................................457 15.7.8.1.2 Replacing the idler roller..................................................458 15.7.8.1.2.1 ......................................................................458 15.7.8.1.2.2 Removing a roller.....................................................458 15.7.8.1.2.3 ......................................................................459 15.7.8.1.2.4 Installing a roller...................................................460 15.7.8.1.3 Replacing forks.............................................................460 15.7.8.1.3.1 Removing the forks....................................................460 15.7.8.1.3.2 Fitting the forks.....................................................461 15.7.9 Initial lift of frame/mast C7160........................................................462 15.7.9.1 Replacing the main initial lift cylinder..........................................462 15.7.9.1.1 Disassembling the fork carriage.............................................462 15.7.9.1.2 Installing a fork carriage..................................................463 15.7.10 Main mast suspension C7190.............................................................465 15.7.10.1 Mast mount.......................................................................465 15.7.10.1.1 Tightening the upper mast fixing points....................................465 15.7.10.1.2 Tightening the lower mast fixing points....................................465 15.7.10.1.3 Replacing the mast dampers.................................................465 15.7.10.1.3.1 Removing the mast dampers............................................465 15.7.10.1.3.2 Installing the mast dampers..........................................466 15.7.10.1.4 Checking the mast dampers..................................................466 15.8 Lifting/carrying/clamping devices C7400.......................................................467 15.8.1 Fork carriage unit/with integrated sideshift/fork spread C7420..........................467 15.8.1.1 Checking the fork carriage........................................................467 15.8.1.2 Check the play of the fork carriage...............................................467 15.8.1.3 ..................................................................................467 15.8.1.4 Measuring the fork-to-floor distance..............................................468 15.8.1.5 Replacing the fork carriage.......................................................469 15.8.1.5.1 Disassembling the fork carriage.............................................469 15.8.1.5.2 Installing a fork carriage..................................................470 16 Auxiliary equipment, installation equipment C8000...................................................475 17 Optional equipment/Extra equipment C9000............................................................479 17.1 Overview......................................................................................479 17.2 Extra electrical equipment C9400..............................................................480 17.2.1 Extra power socket......................................................................480 17.2.1.1 Overview..........................................................................480 17.2.1.2 Description.......................................................................480 17.2.1.2.1 DC/DC converter.............................................................480 17.2.2 Truck log equipment, code lock C9420....................................................481 17.2.2.1 Overview..........................................................................481 17.2.2.2 I_Site............................................................................481 17.2.2.2.1 Description.................................................................481 17.2.2.2.1.1 I_Site................................................................481 17.2.2.3 Impact Manager....................................................................482 17.2.2.3.1 Description.................................................................482 17.2.2.3.1.1 Collision sensor......................................................482 17.2.2.3.2 Checking the reference sensor parameters....................................482 17.2.2.3.3 Checking DHU/TWIS [K110]....................................................482 17.3 Other extra equipment C9500...................................................................482 17.3.1 Fire extinguisher.......................................................................482 17.3.1.1 Description.......................................................................482 17.3.1.1.1 Fire extinguisher...........................................................482 17.3.2 Horizontal E-bar........................................................................483 17.3.2.1 Description.......................................................................483 17.3.2.1.1 E-bar.......................................................................483 17.3.2.2 Checking the E-bar lock...........................................................484 17.3.3 Spider expansion unit...................................................................484 17.3.3.1 Description.......................................................................484 17.3.3.1.1 Spider expansion unit.......................................................484 18 Instructions for disposal...........................................................................489 18.1 General.......................................................................................489 18.2 Marking of plastics...........................................................................489 18.2.1 General marking of products and packaging...............................................489 18.2.2 Marking according to the manufacturer’s standards.......................................489 18.2.2.1 Abbreviations.....................................................................489 18.2.2.2 Marking examples..................................................................490 18.3 Pressure vessels..............................................................................490 18.3.1 Gas struts..............................................................................490 18.4 Sorting categories............................................................................491 19 Wiring diagram......................................................................................495 19.1 Colour code table.............................................................................495 19.2 Diagram.......................................................................................495 19.2.1 Component list..........................................................................495 19.2.2 Component placement.....................................................................499 19.2.3 Detailed diagrams.......................................................................517 20 Hydraulics schematics...............................................................................545 20.1 Component list................................................................................545 20.2 Component location............................................................................546 20.2.1 Picture 1...............................................................................546 20.2.2 Picture 2...............................................................................547 20.2.3 Picture 3...............................................................................548 20.2.4 Picture 4...............................................................................549 20.3 Valve unit....................................................................................550 20.3.1 Valve unit 1-function...................................................................550 20.3.2 Valve unit 2-functions..................................................................551 20.4 Diagram.......................................................................................552 20.5 Diagram.......................................................................................552 20.6 Diagram.......................................................................................554 20.7 Diagram.......................................................................................555 21 Tools...............................................................................................559 21.1 Tools for electric connectors.................................................................559 21.1.1 AMP connectors..........................................................................559 21.1.2 MQS connectors..........................................................................559 21.1.3 CPC connectors..........................................................................560 21.1.4 AMP Seal connectors.....................................................................561 21.2 Special tools.................................................................................561 22 Service data and grease specifications..............................................................571 22.1 General tightening torques....................................................................571 22.1.1 Galvanised, non-oiled screws............................................................571 22.1.2 Untreated, oiled screws.................................................................571 22.2 Lubricants specification......................................................................572 23 Technical data......................................................................................573 24 Index...............................................................................................575
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