Toyota BT LPE200 LPE220 LPE250 LPE340BE Repair Manual 7572514 – PDF DOWNLOAD
DESCRIPTION:
Toyota BT LPE200 LPE220 LPE250 LPE340BE Repair Manual 7572514 – PDF DOWNLOAD
General safety rules
Authorised personnel
Authorised personnel
Only personnel trained in servicing and repair of this type of product are authorised to carry out service and repair activities.
2.2 Product modification
Product modification
2.2.1 Responsible
Responsible
The one designated by the sales company or the supplier as being the person responsible for the trucks.
2.2.2 What is it permitted to modify? 2.2.2
What is it permitted to modify?
Any modification of the product must be approved beforehand. No modification of product may be performed that may influence
the capacity, stability and safety of the product without prior written approval from the manufacturer, its representative
or successor.
See the table below, types A, B and C.
• All sales companies and suppliers may perform modifications type A.
• All modifications (changes) in addition to those stated as type A below, are to be ordered from the supplier according
to standard procedures for customer adaptations ( also applicable to software changes).
• Changes type B and C are only to be performed by the supplier.
Get in touch with our technical support for guidance and for any questions.
TABLE OF CONTENTS:
Toyota BT LPE200 LPE220 LPE250 LPE340BE Repair Manual 7572514 – PDF DOWNLOAD
1 General introduction 9
11 Images and other information 9
12 Warning levels and symbols 9
13 Pictograms 9
14 Abbreviations 10
2 General safety rules 15
21 Authorised personnel 15
22 Product modification 15
221 Responsible 15
222 What is it permitted to modify? 15
23 Work safety 16
24 Electrical system 17
241 Electrostatic risks 17
242 Battery handling 18
25 Safe lifting 18
26 Software 19
27 Hydraulic system 19
3 Operating principle 23
31 Description 23
311 Battery is connected 23
312 Login via keypad 23
313 Login via “ID key” option 23
314 Tiller arm lowered for driving 23
315 Driving in fork direction 24
316 Driving in the drive wheel direction 24
317 Braking in neutral 24
318 Reverse braking 25
319 Mechanical braking 25
3110 Emergency reversal 25
3111 Fork lifting 26
3112 Fork lowering 26
4 Parameters 29
41 Software 29
42 Display/change parameters 29
43 Parameters on commissioning 29
431 Setting parameters 29
432 Setting collision sensor parameters (option) 29
433 Setting battery parameters 30
44 Parameter list 30
5 Installation 79
51 Transport 79
511 Transporting the truck 79
512 Transporting the fork carriage 79
52 Lifting the truck 80
521 Lifting the truck 80
522 Lift using a jack 80
53 Commissioning 81
531 Battery 81
5311 Battery installation 81
6 Maintenance 85
61 Introduction 85
62 Maintenance instructions 85
621 Cleaning 85
622 High-pressure washers 85
623 Degreasing agents 86
624 Cleaning the exterior 86
625 Cleaning the chain 86
626 Cleaning the motor compartment 86
627 Electric components 86
628 Optical sensors and reflectors 86
629 Hydraulic system 87
6210 Signs, warnings and adhesive labels 87
62101 Placement of signs 87
63 Lubricants specification 88
64 Periodic maintenance 89
7 Troubleshooting105
71 Initial troubleshooting105
72 Concluding troubleshooting106
73 Auxiliary functions107
731 Towing a defective truck107
7311 Towing and transporting a defective truck107
732 Emergency driving mode107
7321 Emergency driving mode107
733 Error code history107
7331 Error code history107
734 Extended error log108
7341 Extended error log108
735 Built-in test function for the tiller arm108
7351 General108
7352 Display test109
7353 Speed control109
7354 Safety reversing109
7355 Controls for lifting/lowering110
7356 Sensilift110
7357 Keypad111
736 Digital input/output status111
7361 Test mode “9”111
7362 Test mode “12” SEU expansion unit (option)112
737 Service information113
7371 Service information113
738 Hydraulic pressure114
7381 Erroneous hydraulic system pressure114
74 Troubleshooting using error codes114
741 First actions when an error code is displayed114
742 List of error codes115
8 Chassis C0000183
81 Overview183
82 Frame, chassis C0300183
821 Inspection of the rear chassis183
822 Inspection covers C0340184
8221 Motor compartment covers184
82211 Overview184
82212 Replacing a service cover185
822121 Removing a service cover185
822122 Installing a service cover185
82213 Replacing a side cover185
822131 Removing a side cover185
822132 Installing a side cover186
82214 Replacing an emblem cover186
822141 Removing an emblem cover186
822142 Installing an emblem cover187
82215 Replacing an upper cover187
822151 Removing an upper cover187
822152 Installing an upper cover188
82216 Replacing a cover188
822161 Removing a cover188
822162 Installing a cover189
823 Support arms, stabilizers C0350189
8231 Replacing the roller on the torsion tube189
82311 Removing the roller on the torsion tube189
82312 Fit the roller on the torsion tube190
8232 Replacing the wheel fork bushing191
82321 Removing the bushing191
82322 Installing the bushing192
824 Fork structure (low-lifter) C0380192
8241 Overview192
8242 Replacing the fork carriage193
82421 Removing the fork carriage193
82422 Installing the fork carriage196
8243 Checking the fork carriage199
8244 Replacing the torsion tube-linkage-wheel fork200
82441 Removing the torsion tube-linkage-wheel fork200
82442 Fitting the torsion tube-linkage-wheel fork202
8245 Checking the torsion tube-linkage-wheel fork204
8246 Push rod weld204
8247 Checking the wheel fork flexibility208
8248 Checking the linkage208
8249 Checking the fork carriage208
82410 Lubricating the beams209
82411 Checking the fork lift height limitation209
82412 Checking the fork carriage play209
825 Battery compartment parts C0390210
8251 Overview210
8252 Overview211
8253 Description211
82531 Battery lock, quick211
82532 Battery lock, fixed211
8254 Checking the battery lock212
8255 Checking the battery lock212
8256 Adjusting the battery lock212
83 Frame/chassis components C0400212
831 ESD protection (anti-static braid)212
8311 Replacing the ground strap212
83111 Removing the ground strap212
83112 Installing a ground strap213
832 Motor mount/brackets C0450214
8321 Checking the motor mounts214
8322 Drive unit mountings215
83221 Drive unit mountings 6/8 km/h215
832211 Overview 6/8 km/h215
832212 Description215
8322121 Technical data215
8322122 Technical data216
832213 Replacing the drive unit mountings 6/8 km/h216
8322131 Removing the drive unit mountings 6/8 km/h216
8322132 Installing the drive unit mountings 6/8 km/h219
83222 Drive unit mountings 10/125 km/h223
832221 Overview 10/125 km/h223
832222 Description224
8322221 Technical data224
8322222 Technical data224
8322223 Technical data224
8322224 Technical data225
8322225 Technical data225
8322226 Technical data225
8322227 Technical data226
832223 Replacing the drive unit mountings 10/125 km/h226
8322231 Removing the drive unit mountings 10/125 km/h226
8322232 Installing the drive unit mountings 10/125 km/h229
8323 PowerTrak234
83231 Description234
832311 Design234
83232 Increasing the spring tension235
83233 Increasing the spring tension237
83234 Releasing the spring tension240
83235 Releasing the spring tension241
83236 Adjusting tool V08-18302243
83237 Replacing the initial pressure spring244
832371 Removing the initial pressure spring244
832372 Fitting the initial pressure spring245
83238 Replacing the PowerTrak spring246
832381 Removing the PowerTrak spring246
832382 Installing the PowerTrak spring247
84 Operator compartment, cab C0500248
841 Platform including fixing points C0560248
8411 Overview248
8412 Overview249
8413 Overview250
8414 Checking the function of the platform switches251
8415 Adjusting the position sensor [B120]251
8416 Checking the platform252
8417 Gas strut252
84171 Checking the gas strut252
84172 Replacing a gas strut252
841721 Removing a gas strut252
841722 Installing a gas strut254
8418 Platform suspension255
84181 Adjusting platform suspension255
84182 Adjusting the platform suspension [Fixed side guards]255
84183 Replacing the platform suspension256
841831 Removing the platform suspension256
841832 Fitting the platform suspension256
8419 Safety switch, platform [B119]257
84191 Adjusting the position sensor play [B119]257
84192 Checking the position sensor [B119]258
84110 Safety switch, platform [B119]/[B120]259
841101 Measuring the detection distance [B120]259
841102 Replacing sensor [B119]259
8411021 Removing the platform position sensor [B119]259
8411022 Fitting the platform position sensor [B119]259
841103 Replacing sensor [B120]260
8411031 Removing the platform position sensor [B120]260
8411032 Fitting the platform position sensor [B120]260
84111 Replacing the platform260
841111 Removing the platform260
841112 Removing the platform [Fixed side guards]263
841113 Installing the platform263
841114 Fitting the platform [Fixed side guards]265
85 Safety equipment C0800267
851 Operator protection C0840267
8511 Fixed side guard267
85111 Overview [Fixed side guards]267
85112 Replacing the fixed side guard268
851121 Removing the fixed side guard268
851122 Fitting fixed side guards269
85113 Checking the position sensor [B119] [Fixed side guards]271
8512 Gate272
85121 272
85122 Checking the gate bar273
85123 Checking the function of the gate switches273
85124 Replacing a gas strut273
851241 Removing the gate damper273
851242 Removing the gate damper274
851243 Fitting the gate damper274
851244 Fitting the gate damper275
85125 Replacing the pad275
851251 Removing the pad275
851252 276
851253 Fitting pads277
851254 278
85126 Replacing the gate278
851261 278
851262 279
85127 Replacing the gate bar281
851271 Removing the gate bar281
851272 281
851273 Installing the gate bar282
851274 282
8513 Back rest283
85131 Overview [Back protection]283
85132 Checking the position sensor [B119 back protection]283
85133 Replacing the back guard284
851331 Removing the back guard284
851332 Installing the back guard285
852 Signs, warnings, labels C0850285
8521 Checking signs and labels285
8522 Placement of signs285
9 Motors C1000289
91 Lubrication / cooling system C1300289
911 Mechanical cooling fan C1380289
9111 Checking the cooling system289
92 Electric motors C1700289
921 Electric pump motor C1710289
9211 Overview289
9212 Description290
92121 Construction290
9213 Replacing the carbon brushes290
92131 Removing the carbon brushes290
92132 Fitting carbon brushes291
9214 Replacing the pump motor292
92141 Removing the pump motor [M3]292
92142 Installing the pump motor [M3]293
922 Electric steering motor C1730295
9221 Overview295
9222 Description295
92221 Technical data295
9223 Cleaning the ring gear295
9224 Checking the electrical connections296
9225 Checking the steering motor gears296
9226 Checking the steering motor296
9227 Lubricating the ring gear296
9228 Check the drive gear’s attachment296
9229 Replacing the steering motor296
92291 Removing the steering motor [M6]296
92292 Installing the steering motor [M6]297
92210 Replacing the control unit298
922101 Removing the control unit298
922102 Installing the control unit299
923 Electric fan motor/fan C1740300
9231 Overview300
9232 Replacing the motor control fan300
92321 Removing a motor control fan300
92322 Installing a motor control fan302
924 Electric drive motor C1760303
9241 Overview 18, 25 kW303
9242 Overview304
9243 Checking the electrical connections305
9244 Checking the drive motor305
9245 Listen for any abnormal noise in the drive motor bearings305
9246 Check the drive motor fitting (18 and 25 kW)306
9247 Check the drive motor fitting (28 kW)306
9248 Checking the rotational speed sensor306
9249 Check the rotational speed sensor fitting307
92410 Replacing the drive motor307
924101 Removing the drive motor [M1]307
924102 Removing the drive motor [M1]309
924103 Removing the drive motor [M1]311
924104 Installing the drive motor [M1]313
924105 Installing the drive motor [M1]315
924106 Installing the drive motor [M1]317
92411 Replacing the temperature sensor319
924111 Installing the temperature sensor319
92412 Replacing the rotational speed sensor320
924121 Removing a rotational speed sensor320
924122 Installing a rotational speed sensor322
92413 Replacing the toothed wheel323
924131 Removing a toothed wheel323
924132 Installing a toothed wheel324
10 Transmission/Drive gear C2000327
101 Drive unit, final gear C2500327
1011 Drive unit/gear C2550 327
10111 Overview327
10112 Overview328
10113 Description 328
101131 Design328
101132 Technical data328
101133 Technical data329
10114 Check the drive gear’s attachment 329
10115 Checking for leaks in the drive gear329
10116 Checking for noise in the drive gear330
10117 Replacing the drive gear 330
101171 Removing the drive gear330
101172 Installing the drive gear332
10118 Replacing the wheel hub seal 333
101181 Removing the wheel hub seal333
101182 Installing the wheel hub seal334
10119 Drive gear oil change335
101191 Empty the drive gear oil336
101192 Empty the drive gear oil337
101193 Filling oil in the drive gear338
101194 Filling oil in the drive gear339
101110 Replacing the drive gear steering bearing 339
1011101 Removing the drive gear steering bearing339
1011102 Removing the drive gear steering bearing340
1011103 Installing the drive gear steering bearing341
1011104 Installing the drive gear steering bearing342
101111 Stud replacement342
1011111 Removing a stud342
1011112 Installing a stud343
11 Brake/wheel/track system C3000347
111 Travel brake system C3100347
1111 Description347
11111 Brake types347
111111 Travel brake347
111112 Emergency brake347
111113 Parking brake347
112 Parking brake details C3300348
1121 Electrical parking brake, magnet brake C3370348
11211 Overview348
11212 Description349
112121 Technical data349
112122 Technical data349
11213 Cleaning the parking brake349
11214 Adjusting the parking brake gap350
11215 Adjusting the parking brake gap351
11216 Adjusting the parking brake gap351
11217 Tighten the parking brake mounting bolts352
11218 Emergency release of the parking brake352
11219 Checking the parking brake353
112110 Replacing the brake hub353
1121101 Disassembling the brake hub353
1121102 Installing a brake hub354
112111 Replacing the friction disc354
1121111 Removing the friction disc354
1121112 Fitting the friction disc355
1121113 Fitting the friction disc356
112112 Replacing the parking brake357
1121121 Removing the parking brake357
1121122 Fitting the parking brake359
113 Wheels C3500361
1131 Drive wheel C3530361
11311 Overview361
11312 Measuring the drive wheel tread361
11313 Measuring the drive wheel tread362
11314 Check the drive wheel mountings362
11315 Check the drive wheel mountings363
11316 Replacing the drive wheel363
113161 Disassembling the drive wheel363
113162 Installing a drive wheel364
1132 Support arm wheels/castor wheels C3540365
11321 Overview365
11322 Cleaning castor wheels366
11323 Measuring the castor wheel tread366
11324 Measuring the castor wheel tread366
11325 Measuring the castor wheel tread367
11326 Measuring the castor wheel tread367
11327 Checking the castor wheels367
11328 Replacing the castor wheel367
113281 Removing the castor367
113282 Removing the castor368
113283 Installing a castor wheel370
113284 Installing a castor wheel371
11329 Replacing the castor wheel assembly371
113291 Removing the castor wheel assembly371
113292 Installing the castor wheel assembly372
1133 Fork wheels/support arm wheels C3550373
11331 Overview373
11332 Description374
113321 Wheel wear374
11333 Cleaning the fork wheels374
11334 Measuring the fork wheel tread375
11335 Checking the fork wheel mounting375
11336 Checking the fork wheel bushings375
11337 Replacing a single wheel376
113371 Removing single wheels376
113372 Removing single wheels377
113373 Single wheel installation378
113374 Single wheel installation379
11338 Replacing bogie wheels380
113381 Removing bogie wheels380
113382 Fitting the bogie wheel381
11339 Replacing a bogie link382
113391 Removing a bogie link382
113392 Installing a bogie link383
12 Steering system C4000387
121 Description387
1211 Power steering387
122 Mechanical steering system C4100387
1221 Steering arm/wheel/lever C4110387
12211 Overview tiller arm387
12212 Operating panel389
122121 Overview operating panel389
122122 Controls390
1221221 Checking the hydraulic functions390
1221222 Checking the stomach button390
1221223 Replacing the signal button/switch390
12212231 Removing the signal button/switch390
12212232 Fitting the signal button/switch391
1221224 Replacing the lift/lower button391
12212241 Removing the lift/lower button391
12212242 Fitting the lift/lower button392
1221225 Replacing a switch button394
12212251 Removing a switch button394
12212252 Fitting a switch button394
1221226 Changing the position of the controls – support arm lift/fork lift395
1221227 Replacing the safety reversing switch395
12212271 Removing the safety reversing switch395
12212272 Fitting the safety reversing switch396
1221228 Replacing the keypad397
12212281 Removing the keypad397
12212282 Installing a keypad397
122123 Replacing the operating panel398
1221231 Removing the operating panel398
1221232 Installing an operating panel398
1221233 Checking the speed control399
122124 Replacing the operating panel “Built-in”400
1221241 Removing the operating panel “Built-in”400
1221242 Installing the operating panel “Built-in”401
122125 Replacing the logic card402
1221251 Removing the logic card402
1221252 Installing a logic card403
1221253 Logic card [A5]404
12213 Tiller arm handle405
122131 Replacing the handle to the tiller arm405
1221311 Removing the tiller arm handle405
1221312 Fitting the handle to the tiller arm405
122132 Replacing the tiller arm handle “Built-in”406
1221321 Removing the tiller arm handle “Built-in”406
1221322 Installing the tiller arm handle “Built-in”407
12214 Tiller arm407
122141 Replacing the tiller arm407
1221411 Removing the tiller arm407
1221412 Fitting tiller arm409
122142 Replacing the tiller arm “Built-in”411
1221421 Removing the tiller arm “Built-in”411
1221422 Installing the tiller arm “Built-in”413
122143 Checking the brake microswitches414
122144 Checking the play and the return travel415
122145 Replacing the tiller arm cover415
1221451 Removing the tiller arm cover415
1221452 Installing the tiller arm cover416
122146 Replacing the tiller arm cover “Built-in”416
1221461 Removing the tiller arm cover “Built-in”416
1221462 Installing the tiller arm cover “Built-in”417
12215 Steering yoke418
122151 Overview418
122152 Overview steering servo419
122153 Overview Ergo420
122154 Replacing the steering yoke421
1221541 Removing the steering yoke421
1221542 Installing a steering yoke422
122155 Changing the tiller arm spring422
1221551 Removing the tiller arm spring422
1221552 Installing the tiller arm spring423
122156 Replacing the safety switch423
1221561 Removing the safety switch [B60]423
1221562 Installing the safety switch [B60]425
122157 Replacing the safety switch “Built-in”425
1221571 Removing the safety switch “Built-in”425
1221572 Installing the safety switch “Built-in”426
12216 Steering adapter428
122161 Overview steering servo428
122162 Overview Mechanical steering429
122163 Overview steering servo431
122164 Overview Mechanical steering432
122165 Replacing the steering adapter433
1221651 Removing the steering adapter433
1221652 Removing the steering adapter434
1221653 Removing the steering adapter435
1221654 Removing the steering adapter436
1221655 Installing a steering adapter437
1221656 Installing a steering adapter439
1221657 Installing a steering adapter440
1221658 Installing a steering adapter442
122166 Replacing the steering adapter cover443
1221661 Removing the steering adapter cover443
1221662 Installing the steering adapter cover444
122167 Replacing a gas strut – height adjuster444
1221671 Removing a gas strut – height adjuster444
1221672 Installing a gas strut – height adjuster444
1221673 Checking the height adjuster445
122168 Replacing the height adjustment lock445
1221681 Removing the height adjustment lock445
1221682 Removing the height adjustment lock445
1221683 Installing the height adjustment lock447
1221684 Installing the height adjustment lock447
1221685 Checking the height adjustment lock448
122169 Replacing the mechanical stop of the steering shaft448
1221691 Removing the mechanical stop of the steering shaft (power steering)448
1221692 Fitting the mechanical stop of the steering shaft (power steering)450
12217 Tiller arm wiring harness452
122171 Replacing the tiller arm wiring harness452
1221711 Removing the tiller arm wiring harness452
1221712 Fitting the tiller arm wiring harness455
12218 Replacing the steering bearing461
122181 Removing the steering bearing461
122182 Removing the steering bearing462
122183 Fitting the steering bearing464
122184 Fitting the steering bearing465
12219 Replacing the rubber seals467
122191 Removing rubber seals467
122192 Installing rubber seals467
123 Electric steering system C4300469
1231 Overview469
1232 Overview470
1233 Steering angle sensor C4350470
12331 Description470
123311 Design470
12332 Replacing the steering angle sensor servo unit471
123321 Removing the steering angle sensor471
123322 Installing steering angle sensor472
12333 Checking the reference sensor473
12334 Replacing the steering angle sensor mech 474
123341 Removing the steering angle sensor mech474
123342 Installing the steering angle sensor mech475
12335 Replacing the steering damper476
123351 Removing the steering damper [A83]476
123352 Removing the steering damper [A83]477
123353 Installing the steering damper [A83]477
123354 Installing the steering damper [A83]479
13 Electrical system C5000485
131 Description485
1311 General485
132 Using the anti-static carpet485
133 Programming tools485
1331 TruckCom485
13311 Connect the CAN interface to the truck485
1332 Software486
13321 Software update486
134 General electric equipment C5100486
1341 Battery C5110486
13411 Cleaning the battery486
13412 Checking the connections487
13413 Checking the battery cables487
13414 Checking the battery487
13415 Checking cell and terminal protectors488
13416 Checking the level of the electrolyte488
13417 Checking the electrolyte density488
13418 Battery replacement488
134181 Replacing a battery using a lifting device488
1341811 Removing a battery using a lifting device488
1341812 Installing a battery using a lifting device489
134182 Replacing a battery using a battery changing table491
1341821 Removing a battery using a battery changing table491
1341822 Installing a battery using a battery changing table491
1342 Battery Li-ion C5110493
13421 Battery module493
134211 Disconnection/connection493
1342111 Resetting/restarting the battery493
1343 General alarm signals (audible/visual) C5160494
13431 Horn494
134311 Overview494
134312 Checking the horn function495
1344 Battery charger (built-in) C5170495
13441 Checking the battery charger cables495
13442 Checking the battery charger parameters495
1345 Battery cut out switch, main contactor C5190495
13451 Main contactor495
134511 Replacing the main contactor495
1345111 Removing the main contactor495
1345112 Removing the main contactor498
1345113 Fitting the main contactor499
1345114 Fitting the main contactor502
135 Instrument panel, display C5200502
1351 Menu502
13511 Menus502
13512 Menu navigation503
13513 Menu overview504
13514 Menu list504
13515 Menu information505
13516 Show hour meter values505
13517 Show error codes506
13518 Show part numbers for software/hardware506
13519 Built-in test ICH506
135110 Show collisions506
135111 Show/change parameters507
135112 Emergency driving mode507
135113 Calibration507
135114 Show/change PIN code507
135115 PIN codes507
1351151 General507
1351152 PIN code for resetting the truck508
1351153 Programming PIN codes508
1351154 PIN code at delivery509
1351155 PIN code defaults510
1352 Hour counter, tachograph C5290511
13521 Checking error log and operating hours511
136 Control system travel function C5300511
1361 Direction selector/speed regulator511
1362 Safety reversing511
1363 Battery indicator511
1364 Hour meter511
1365 Lifting and lowering control511
1366 Signal buttons511
1367 Option buttons512
1368 Display512
1369 Symbols on keypad and display512
13610 Weighing system512
13611 Pressure equalization512
137 Power system travel function C5400513
1371 Transistor panel C5460513
13711 Overview ACT513
13712 Overview ACC514
13713 Description514
137131 General514
13714 Checking the contactors515
13715 Checking the cable connections515
13716 Checking the electric panel mounting515
13717 Cleaning the electric panel heatsink516
13718 Replacing the motor control panel516
137181 Removing the motor control panel516
137182 Installing the motor control panel517
137183 Installing the motor control panel518
138 Control system, working function C5500519
1381 Work function harnesses/fuse C5590519
13811 Checking the wiring harnesses519
139 Power system working function C5600519
1391 Pump contactor C5610519
13911 Replacing the pump contactor519
139111 Removing the pump contactor519
139112 Fitting the pump contactor521
1310 Control/protection electronics C5700523
13101 Protective electronics wiring harness and fuse C5790523
131011 Check the CAN bus523
131012 Check the CAN node523
1311 Protective sensors, position sensors C5800523
13111 Description523
131111 Pressure sensor523
13112 Safety probes/sensors C5830524
131121 Emergency switch off524
1311211 Description524
13112111 Task and function524
1311212 Checking the emergency switch function524
131122 Gate switches [B121]/[B122]524
1311221 Replacing the gate switch [B120]524
13112211 Removing the position sensor [B121]524
13112212 525
13112213 Installing the position sensor [B121]526
13112214 527
1311222 Replacing the gate switch [B122]527
13112221 Removing the position sensor [B122]527
13112222 528
13112223 Installing the position sensor [B122]529
13112224 529
131123 Photocell530
1311231 Overview [Photocells for fixed side guards]530
1311232 Description530
13112321 Function530
1311233 Checking the photocell531
1312 Calibrations531
13121 Steering angle calibration531
13122 Weight measuring calibration532
13123 Weight measuring calibration532
13124 Steering angle manual steering533
13125 Weight measuring calibration533
14 Hydraulics/Pneumatics C6000537
141 Overview537
142 Description537
1421 Hydraulic hygiene537
14211 Definitions – hydraulic parts537
14212 Inside cleaning538
14213 Packaging538
14214 Handling538
14215 Storage538
14216 Work procedures538
1422 Construction539
143 Quick change connectors539
1431 Overview quick change connectors539
1432 Removing female quick change connectors539
1433 Installing female quick change connectors540
1434 Removing a quick change connector (male)541
1435 Installing a quick change connector (male)542
144 Hydraulic unit C6100543
1441 Overview543
1442 Hydraulic oil tank C6110544
14421 Overview544
14422 Cleaning the tank544
14423 Checking the tank544
14424 Oil change545
144241 Draining oil545
144242 Topping up with oil545
14425 Replacing the tank546
144251 Removing the tank546
144252 Fitting the tank547
1443 Filter, filter housing C6130547
14431 Air filter547
144311 Cleaning the air filter547
14432 548
144321 Replacing the suction filter548
1443211 Removing suction filter548
1443212 Installing the suction filter548
14433 Oil filter replacement548
144331 Oil filter replacement548
14434 Replacing the return filter549
144341 Removing the return filter549
144342 Fitting the return filter550
1444 Hydraulic pump C6140551
14441 Overview551
14442 Description551
144421 Construction551
14443 Replacing the hydraulic pump551
144431 Removing the hydraulic pump551
144432 Removing the hydraulic pump552
144433 Installing the hydraulic pump553
144434 Installing the hydraulic pump554
1445 555
14451 Checking the pressure limiting valve555
14452 Replacing the flow control valve556
144521 Removing the flow control valve556
144522 Fitting the flow control valve557
14453 Replacing the pressure limiting valve557
144531 Removing the pressure limiting valve557
144532 Fitting the pressure limiting valve558
14454 Adjusting the lifting capacity558
144541 Adjusting the lifting capacity, reducing558
144542 Adjusting the lifting capacity, increasing559
1446 Replacing the hydraulic unit559
14461 Removing the hydraulic unit559
14462 Installing the hydraulic unit560
1447 Replacing the valve coil561
14471 Removing the valve coil561
14472 Removing the valve coil562
14473 Fitting a solenoid valve563
14474 Fitting a solenoid valve564
1448 Replacing the pressure sensor564
14481 Removing the pressure sensor [B4]564
14482 Fitting the pressure sensor [B4]565
145 Hydraulic system, fitted to chassis C6200566
1451 Main valve lift/reach/tilt C6210566
14511 Overview566
146 Hydraulic system, fitted on the mast C6300566
1461 Mast hydraulic conduits C6320566
14611 Checks for leaks from hydraulic conduits and connections, hydraulic unit566
147 Hydraulic cylinder C6600567
1471 Main lift cylinders C6610567
14711 Description567
147111 Construction567
14712 Checking the attachment of the lift cylinders567
14713 Checking for leaks in the lift cylinder567
14714 Replacing the main lift cylinders567
147141 Removing the lift cylinder, right side567
147142 Removing the lift cylinder, left side568
147143 Fitting the lift cylinder, right side570
147144 Fitting the lift cylinder, left side571
1472 PowerTrak cylinder C6680572
14721 Replacing the PowerTrak cylinder572
147211 Removing the PowerTrak cylinder572
147212 Installing the PowerTrak cylinder573
15 Work function – lifting masts C7000577
16 Auxiliary equipment, installation equipment C8000581
17 Optional equipment/Extra equipment C9000585
171 Overview585
172 Extra electrical equipment C9400586
1721 Extra power socket586
17211 Overview586
17212 Description586
172121 DC/DC converter586
1722 Truck log equipment, code lock C9420587
17221 Overview587
17222 I_Site587
172221 Description587
1722211 I_Site587
17223 Impact Manager588
172231 Impact sensor588
172232 Description588
1722321 Impact sensor588
172233 Checking the impact sensor parameters588
172234 Checking DHU/I-site [K110]588
17224 PreOpCheck588
173 Other extra equipment C9500590
1731 Fire extinguisher590
17311 Description590
173111 Fire extinguisher590
17312 Inspection of fire extinguisher591
1732 Horizontal E-bar592
17321 Overview592
17322 E-bar592
17323 Description593
173231 E-bar593
17324 Checking the E-bar lock594
1733 Spider expansion unit594
17331 Description594
173311 Spider expansion unit594
18 Instructions for disposal597
181 General597
182 Marking of plastics597
1821 General marking of products and packaging597
1822 Marking according to the manufacturer’s standards597
18221 Abbreviations597
18222 Marking examples598
183 Pressure vessels598
1831 Gas struts598
184 Sorting categories599
19 Wiring diagram603
191 Colour code table603
192 List of fuses603
193 Diagram604
1931 Component list604
1932 Component placement607
1933 Detailed diagrams621
20 Hydraulics schematics639
201 List of symbols639
202 Component list641
203 Component location642
2031 Picture 1642
2032 Picture 2643
2033 Picture 3644
204 Diagram645
21 Tools649
211 Tools for electric connectors649
2111 AMP connectors649
2112 MQS connectors649
2113 CPC connectors650
2114 AMP Seal connectors651
2115 Super Seal connectors651
2116 Molex connectors652
212 Lubricating tool653
213 Special tools654
22 Service data and grease specifications661
221 General tightening torques661
2211 Galvanised, non-oiled screws661
2212 Untreated, oiled screws661
222 Lubricants specification662
23 Technical data665
231 Truck Dimensions665
232 Truck data665
24 Index667
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