BT SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D Repair Manual 7590353 – PDF DOWNLOAD
DESCRIPTION:
BT SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D Repair Manual 7590353 – PDF DOWNLOAD
How to use this manual:
The repair manual is divided into chapters containing the following information:
• General safety rules.
• Operating principle
This chapter provides a basic description of the main functions of the truck and their interdependencies.
• Parameters
This chapter provides a basic description of the truck parameters.
• Installation
This chapter describes the preparatory work that is to be done before the truck is used for the first time
• Maintenance
This chapter provides an overview of periodic maintenance.
• Troubleshooting
The chapter describes the action you should take when the truck is completely or partially out of function. It also
describes the cause of the problem together with suggested remedies.
• C codes
This chapter describes the various truck systems, e.g. the hydraulic system and includes descriptions of system
parts and the necessary service procedures. These descriptions are divided according to the manufacturer’s C
code system.
• Instructions for disposal
This chapter specifies the proper sorting categories for the materials used in the various truck components.
• Wiring diagram
This chapter provides information on electrical components and wiring diagrams.
• Hydraulics schematics
This chapter provides information on hydraulic components and diagrams.
• Tools
This chapter provides a list of the special tools required.
• Service data and grease specifications
This chapter contains information on general tightening torques and specifications for lubricants.
• Technical data.
TABLE OF CONTENTS:
BT SPE120 SPE120L SPE140 SPE140L SPE140S SPE160 SPE160L SPE200 SPE200D Repair Manual 7590353 – PDF DOWNLOAD
1 General introduction 9
11 How to use this manual 9
12 Warning levels and symbols 9
13 Pictograms 10
2 General safety rules 13
21 Authorised personnel 13
22 Work safety 13
23 Electrical system 13
231 Electrostatic risks 14
232 Battery handling 14
24 Safe lifting 15
25 Truck modifications 15
26 Software 16
27 Hydraulic system 16
3 Operating principle 19
31 Description 19
311 Battery is connected 19
312 Login via keypad 19
313 Login via “ID key” option 19
314 Tiller arm lowered for driving 20
315 Driving in fork direction 20
316 Driving in the drive wheel direction 20
317 Braking in neutral 20
318 Reverse braking 21
319 Mechanical braking 21
3110 Emergency reversal 21
3111 Fork lowering 22
4 Parameters 25
41 Display/change parameters 25
42 Parameters in general 25
43 Parameter list 25
44 Parameter list 57
5 Installation 61
51 Transport 61
511 Transporting the truck 61
512 Transporting the mast 61
52 Lifting the truck 62
521 Lifting the truck 62
522 Lift using a jack 64
53 Commissioning 64
531 Parameters on commissioning 64
5311 Setting parameters 64
5312 Setting collision sensor parameters (option) 64
5313 Setting battery parameters 64
532 Battery 65
5321 Battery installation 65
6291 Placement of signs 69
6292 Placement of signs 71
6293 Placement of signs 73
6294 Placement of signs 75
7 Troubleshooting 81
71 Auxiliary functions 81
711 Towing a defective truck 81
7111 Towing and transporting a defective truck 81
712 Emergency driving mode 81
7121 Emergency driving mode 81
713 Error code history 82
7131 Error code history 82
714 Extended error log 82
7141 Extended error log 82
715 Built-in test function for the tiller arm 82
7151 General 82
7152 Display test 83
7153 Speed control 83
7154 Safety reversing 84
7155 Controls for lifting/lowering 84
7156 Sensilift 85
7157 Keypad 85
72 Initial troubleshooting 86
73 Concluding troubleshooting 86
74 Troubleshooting using error codes 86
741 List of error codes 86
8 Chassis C0000155
81 Overview155
82 Frame, chassis C0300156
821 Inspection covers C0340156
8211 Motor compartment covers156
82111 Overview156
82112 Replacing a service cover157
821121 Removing a service cover157
821122 Installing a service cover157
82113 Replacing a side cover157
821131 Removing a side cover157
821132 Installing a side cover158
82114 Replacing an emblem cover158
821141 Removing an emblem cover158
821142 Installing an emblem cover159
82115 Replacing an upper cover159
821151 Removing an upper cover159
821152 Installing an upper cover160
82116 Replacing a cover161
821161 Removing a cover161
821162 Installing a cover161
822 Support arms, stabilizers C0350162
8221 Overview162
8222 Checking the linkage163
8223 Checking the wheel fork flexibility163
8224 Replacing the pressure rod163
82241 Removing a push rod163
82242 Installing a push rod166
8225 Replacing torsion tubes169
82251 Removing torsion tubes169
82252 Installing a torsion tube170
8226 Replacing the roller on the torsion tube171
82261 Removing the roller on the torsion tube171
82262 Fit the roller on the torsion tube172
8227 Replacing a wheel fork173
82271 Removing wheel fork173
82272 Installing a wheel fork175
8228 Replacing a bogie link, fork wheel177
82281 Removing a bogie link, fork wheel177
82282 Fitting a bogie link, fork wheel177
8229 Replacing a bogie link, support arm177
82291 Removing a bogie link, support arm177
82292 Installing a bogie link, support arm178
82210 Replacing the wheel fork bushing178
822101 Removing the wheel fork bushing178
822102 Fitting the wheel fork bushing179
82211 Replacing the support arm bushing179
822111 Removing the support arm bushing179
822112 Installing a support arm bushing180
823 Fork structure (low-lifter) C0380180
8231 Checking the fork lift height limitation180
824 Battery compartment parts C0390181
8241 Overview181
8242 Overview182
8243 Description182
82431 Design182
83 Frame/chassis components C0400182
831 Motor mount/brackets C0450182
8311 Checking the motor mounts182
8312 Drive unit mountings183
83121 Drive unit mountings 6/8 km/h183
831211 Overview 6/8 km/h183
831212 Description183
8312121 Technical data183
8312122 Technical data184
8312123 Technical data184
8312124 Technical data184
8312125 Technical data185
8312126 Technical data185
8312127 Technical data185
8312128 Technical data186
8312129 Technical data186
831213 Replacing the drive unit mountings 6/8 km/h186
8312131 Removing the drive unit mountings 6/8 km/h186
8312132 Installing the drive unit mountings 6/8 km/h189
83122 Drive unit mountings 10/125 km/h193
831221 Overview 10/125 km/h193
831222 Description193
8312221 Technical data193
8312222 Technical data194
8312223 Technical data194
8312224 Technical data194
8312225 Technical data195
831223 Replacing the drive unit mountings 10/125 km/h195
8312231 Removing the drive unit mountings 10/125 km/h195
8312232 Installing the drive unit mountings 10/125 km/h198
8313 PowerTrak201
83131 Description201
831311 Design201
83132 Increasing the spring tension202
83133 Releasing the spring tension204
83134 Adjusting tool V08-18302206
83135 Replacing the initial pressure spring207
831351 Removing the initial pressure spring207
831352 Fitting the initial pressure spring208
83136 Replacing the PowerTrak spring209
831361 Removing the PowerTrak spring209
831362 Installing the PowerTrak spring211
83137 Replacing a spacer213
831371 Removing a spacer213
831372 Installing a spacer214
8314 Decompression locking215
83141 Overview215
83142 Description215
831421 Design215
83143 Purging the decompression lock216
83144 Checking the decompression lock218
83145 Replacing the decompression lock218
831451 Removing the decompression lock218
831452 Fitting the decompression lock220
84 Operator compartment, cab C0500222
841 Platform including fixing points C0560222
8411 Overview222
8412 Overview223
8413 Overview224
8414 Checking the function of the platform switches224
8415 Adjusting the position sensor [B120]225
8416 Checking the platform225
8417 Inspection of the rear chassis225
8418 Gas strut225
84181 Checking the gas strut225
84182 Replacing a gas strut226
841821 Removing a gas strut226
841822 Installing a gas strut228
8419 Platform suspension230
84191 Adjusting platform suspension230
84192 Adjusting the platform suspension [Fixed side guards]230
84193 Replacing the platform suspension231
841931 Removing the platform suspension231
841932 Fitting the platform suspension232
84110 Safety switch, platform [B119]233
841101 Adjusting the position sensor play [B119]233
841102 Checking the position sensor [B119]234
84111 Safety switch, platform [B119]/[B120]235
841111 Measuring the detection distance [B120]235
841112 Replacing sensor [B119]235
8411121 Removing the platform position sensor [B119]235
8411122 Fitting the platform position sensor [B119]236
841113 Replacing sensor [B120]236
8411131 Removing the platform position sensor [B120]236
8411132 Fitting the platform position sensor [B120]237
84112 Replacing the platform237
841121 Removing the platform237
841122 Removing the platform [Fixed side guards]241
841123 Installing the platform242
841124 Fitting the platform [Fixed side guards]244
85 Safety equipment C0800246
851 Operator protection C0840246
8511 Fixed side guard246
85111 Overview [Fixed side guards]246
85112 Replacing the fixed side guard247
851121 Removing the fixed side guard247
851122 Fitting fixed side guards248
85113 Checking the position sensor [B119] [Fixed side guards]250
8512 Gate251
85121 Overview [Gate]251
85122 Checking the gate bar251
85123 Replacing a gas strut252
851231 Removing the gate damper252
851232 Removing the gate damper252
851233 Fitting the gate damper253
851234 Fitting the gate damper254
85124 Replacing the pad254
851241 Removing the pad254
851242 Fitting pads255
85125 Replacing the gate256
851251 Removing the gate256
851252 Installing the gate258
85126 Replacing the gate bar259
851261 Removing the gate bar259
851262 Installing the gate bar260
8513 Back rest261
85131 Overview [Back protection]261
85132 Checking the position sensor [B119 back protection] 261
85133 Replacing the back guard262
851331 Removing the back guard262
851332 Installing the back guard263
852 Signs, warnings, labels C0850263
8521 Checking signs and labels263
8522 Placement of signs263
8523 Placement of signs265
8524 Placement of signs267
8525 Placement of signs269
9 Motors C1000275
91 Electric motors C1700275
911 Electric pump motor C1710275
9111 Overview275
9112 Replacing the pump motor275
91121 Removing a pump motor275
91122 Installing a pump motor276
912 Electric steering motor C1730277
9121 Overview277
9122 Description278
91221 Design278
9123 Cleaning the ring gear278
9124 Checking the electrical connections278
9125 Checking the steering motor gears278
9126 Checking the steering motor278
9127 Lubricating the ring gear278
9128 Check the drive gear’s attachment278
9129 Replacing the steering motor279
91291 Removing the steering motor [M6]279
91292 Installing the steering motor [M6]280
913 Electric fan motor/fan C1740281
9131 Overview281
9132 Description281
91321 Design281
9133 Replacing the motor control fan281
91331 Removing a motor control fan281
91332 Installing a motor control fan283
914 Electric drive motor C1760284
9141 Overview 18, 25 kW284
9142 Overview285
9143 Description285
91431 Design285
9144 Check the rotational speed sensor fitting286
9145 Checking the electrical connections286
9146 Checking the drive motor286
9147 Listen for any abnormal noise in the drive motor bearings286
9148 Check the drive motor fitting (18 and 25 kW)286
9149 Check the drive motor fitting (28 kW)286
91410 Checking the rotational speed sensor286
91411 Replacing the drive motor286
914111 Removing the drive motor [M1]286
914112 Removing the drive motor [M1]289
914113 Removing the drive motor [M1]291
914114 Installing the drive motor [M1]295
914115 Installing the drive motor [M1]299
914116 Installing the drive motor [M1]302
91412 Replacing the temperature sensor304
914121 Installing the temperature sensor304
91413 Replacing the rotational speed sensor305
914131 Removing a rotational speed sensor305
914132 Installing a rotational speed sensor307
91414 Replacing the toothed wheel309
914141 Removing a toothed wheel309
914142 Installing a toothed wheel309
10 Transmission/Drive gear C2000313
101 Drive unit, final gear C2500313
1011 Drive unit/gear C2550 313
10111 Overview313
10112 Overview314
10113 Description 314
101131 Design314
101132 Technical data314
101133 Technical data315
10114 Check the drive gear’s attachment 315
10115 Checking for leaks in the drive gear315
10116 Checking for noise in the drive gear315
10117 Replacing the drive gear 315
101171 Removing the drive gear315
101172 Installing the drive gear318
10118 Replacing the wheel hub seal 320
101181 Removing the wheel hub seal320
101182 Installing the wheel hub seal321
10119 Drive gear oil change322
101191 Empty the drive gear oil322
101192 Empty the drive gear oil323
101193 Filling oil in the drive gear324
101194 Filling oil in the drive gear325
101110 Replacing the drive gear steering bearing 326
1011101 Removing the drive gear steering bearing326
1011102 Removing the drive gear steering bearing327
1011103 Installing the drive gear steering bearing327
1011104 Installing the drive gear steering bearing328
101111 Stud replacement 329
1011111 Removing a stud329
1011112 Installing a stud329
11 Brake/wheel/track system C3000333
111 Travel brake system C3100333
1111 Description333
11111 Brake types333
111111 Travel brake333
111112 Emergency brake333
111113 Parking brake333
112 Parking brake details C3300334
1121 Electrical parking brake, magnet brake C3370334
11211 Overview334
11212 Description335
112121 Technical data335
112122 Technical data335
112123 Technical data335
11213 Cleaning the parking brake336
11214 Adjusting the parking brake gap336
11215 Adjusting the parking brake gap337
11216 Adjusting the parking brake gap337
11217 Adjusting the parking brake gap338
11218 Tighten the parking brake mounting bolts339
11219 Emergency release of the parking brake339
112110 Checking the parking brake339
112111 Replacing the brake hub340
1121111 Disassembling the brake hub340
1121112 Installing a brake hub340
112112 Replacing the friction disc341
1121121 Removing the friction disc341
1121122 Fitting the friction disc342
112113 Replacing the parking brake343
1121131 Removing the parking brake343
1121132 Fitting the parking brake344
113 Wheels C3500345
1131 Drive wheel C3530345
11311 Overview345
11312 Description346
113121 Wheel wear346
11313 Measuring the drive wheel tread346
11314 Measuring the drive wheel tread346
11315 Replacing the drive wheel346
113151 Disassembling the drive wheel346
113152 Installing a drive wheel348
1132 Support arm wheels/castor wheels C3540350
11321 Overview350
11322 Description350
113221 Wheel wear350
11323 Cleaning castor wheels351
11324 Measuring the castor wheel tread351
11325 Measuring the castor wheel tread351
11326 Measuring the castor wheel tread351
11327 Measuring the castor wheel tread352
11328 Checking the castor wheels352
11329 Replacing the castor wheel352
113291 Removing the castor352
113292 Removing the castor353
113293 Installing a castor wheel354
113294 Installing a castor wheel355
113210 Replacing the castor wheel assembly356
1132101 Removing the castor wheel assembly356
1132102 Installing the castor wheel assembly357
1133 Fork wheels/support arm wheels C3550358
11331 Overview358
11332 Description358
113321 Wheel wear358
11333 Cleaning the fork wheels359
11334 Measuring the fork wheel tread359
11335 Checking the fork wheel mounting359
11336 Checking the fork wheel bushings359
11337 Replacing a single wheel359
113371 Removing single wheels359
113372 Single wheel installation360
11338 Replacing bogie wheels361
113381 Removing bogie wheels361
113382 Removing bogie wheels363
113383 Fitting the bogie wheel365
113384 Fitting the bogie wheel366
11339 Replacing a bogie link368
113391 Removing a bogie link368
113392 Removing a bogie link368
113393 Installing a bogie link369
113394 Installing a bogie link369
12 Steering system C4000373
121 Description373
1211 Power steering373
122 Mechanical steering system C4100373
1221 Steering arm/wheel/lever C4110373
12211 Overview tiller arm373
12212 Operating panel375
122121 Overview operating panel375
122122 Controls376
1221221 Replacing the signal button/switch376
12212211 Removing the signal button/switch376
12212212 Fitting the signal button/switch377
1221222 Replacing the lift/lower button379
12212221 Removing the lift/lower button379
12212222 Fitting the lift/lower button380
12212223 Checking the hydraulic functions381
1221223 Replacing the stomach button381
12212231 Removing the stomach button381
12212232 Installing a stomach button382
12212233 Checking the stomach button383
1221224 Replacing the sensilift383
12212241 Removing the sensilift383
12212242 Installing sensilift384
1221225 Changing the position of the controls – support arm lift/fork lift384
1221226 Replacing the keypad385
12212261 Removing the keypad385
12212262 Installing a keypad385
122123 Replacing the operating panel385
1221231 Removing the operating panel385
1221232 Installing an operating panel386
1221233 Checking the speed control388
122124 Replacing the operating panel “Built-in”388
1221241 Removing the operating panel “Built-in”388
1221242 Installing the operating panel “Built-in”389
1221243 Checking the speed control390
122125 Replacing the logic card391
1221251 Removing the logic card391
1221252 Installing a logic card392
1221253 Logic card [A5]393
12213 Tiller arm handle394
122131 Replacing the handle to the tiller arm394
1221311 Removing the tiller arm handle394
1221312 Fitting the handle to the tiller arm395
122132 Replacing the tiller arm handle “Built-in”395
1221321 Removing the tiller arm handle “Built-in”395
1221322 Installing the tiller arm handle “Built-in”396
12214 Tiller arm396
122141 Replacing the tiller arm396
1221411 Removing the tiller arm396
1221412 Fitting tiller arm398
122142 Replacing the tiller arm “Built-in”400
1221421 Removing the tiller arm “Built-in”400
1221422 Installing the tiller arm “Built-in”401
122143 Checking the brake microswitches403
122144 Checking the play and the return travel403
122145 Replacing the tiller arm cover404
1221451 Removing the tiller arm cover404
1221452 Installing the tiller arm cover404
122146 Replacing the tiller arm cover “Built-in”405
1221461 Removing the tiller arm cover “Built-in”405
1221462 Installing the tiller arm cover “Built-in”405
12215 Steering yoke407
122151 Overview steering servo407
122152 Overview Ergo408
122153 Replacing the steering yoke409
1221531 Removing the steering yoke409
1221532 Installing a steering yoke410
122154 Changing the tiller arm spring410
1221541 Removing the tiller arm spring410
1221542 Installing the tiller arm spring411
122155 Replacing the safety switch411
1221551 Removing the safety switch [B60]411
1221552 Installing the safety switch [B60]413
122156 Replacing the safety switch “Built-in”413
1221561 Removing the safety switch “Built-in”413
1221562 Installing the safety switch “Built-in”414
12216 Steering adapter416
122161 Overview steering servo416
122162 Replacing the steering adapter417
1221621 Removing the steering adapter417
1221622 Installing a steering adapter418
122163 Replacing the steering adapter cover420
1221631 Removing the steering adapter cover420
1221632 Installing the steering adapter cover421
122164 Replacing a gas strut – height adjuster421
1221641 Removing a gas strut – height adjuster421
1221642 Installing a gas strut – height adjuster422
1221643 Checking the height adjuster422
122165 Replacing the height adjustment lock422
1221651 Removing the height adjustment lock422
1221652 Installing the height adjustment lock423
1221653 Checking the height adjustment lock423
122166 Replacing the mechanical stop of the steering shaft424
1221661 Removing the mechanical stop of the steering shaft (power steering)424
1221662 Fitting the mechanical stop of the steering shaft (power steering)425
12217 Tiller arm wiring harness427
122171 Replacing the tiller arm wiring harness427
1221711 Removing the tiller arm wiring harness427
12218 Replacing the steering bearing430
122181 Removing the steering bearing430
122182 Fitting the steering bearing432
12219 Replacing the rubber seals433
122191 Removing rubber seals433
122192 Installing rubber seals434
123 Electric steering system C4300436
1231 Overview436
1232 Steering angle sensor C4350437
12321 Description437
123211 Design437
12322 Replacing the steering angle sensor servo unit437
123221 Removing the steering angle sensor437
123222 Installing steering angle sensor438
12323 Checking the reference sensor439
12324 Replacing the steering damper440
123241 Removing the steering damper [A83]440
123242 Installing the steering damper [A83]440
13 Electrical system C5000447
131 Description447
1311 General447
1312 Truck firmware applications447
132 Software update447
133 Programming tools447
1331 TruckCom447
13311 Connect the CAN interface to the truck447
1332 Software448
13321 Software update448
134 General electric equipment C5100448
1341 Battery C5110448
13411 Cleaning the battery448
13412 Checking the connections448
13413 Checking the battery cables449
13414 Checking the battery449
13415 Checking cell and terminal protectors449
13416 Checking the level of the electrolyte449
13417 Checking the electrolyte density450
13418 Checking the battery parameters450
13419 Checking the battery voltage450
134110 Resetting/restarting the battery450
134111 Charging the battery451
134112 Replacing a battery using a lifting device452
1341121 Removing a battery using a lifting device452
1341122 Installing a battery using a lifting device452
134113 Replacing a battery using a battery changing table455
1341131 Removing a battery using a battery changing table455
1341132 Installing a battery using a battery changing table455
1342 General alarm signals (audible/visual) C5160458
13421 Horn458
134211 Overview458
134212 Checking the horn function458
1343 Battery charger (built-in) C5170458
13431 Checking the battery charger cables458
13432 Checking the battery charger parameters458
1344 Battery cut out switch, main contactor C5190459
13441 Main contactor459
134411 Replacing the main contactor459
1344111 Removing the main contactor459
1344112 Fitting the main contactor462
135 Instrument panel, display C5200464
1351 Menu464
13511 Menus464
13512 Menu navigation464
13513 Menu list465
13514 Menu information465
13515 Show hour meter values465
13516 Show error codes466
13517 Show part numbers for software/hardware466
13518 Built-in test ICH466
13519 Show collisions467
135110 Show/change parameters467
135111 Emergency driving mode467
135112 Calibration467
135113 Show/change PIN code467
135114 PIN codes468
1351141 General468
1351142 PIN code for resetting the truck468
1351143 Programming PIN codes468
1351144 PIN code defaults470
1352 Hour counter, tachograph C5290470
13521 Checking error log and operating hours470
136 Control system travel function C5300470
1361 Direction selector/speed regulator470
1362 Pressure equalization471
1363 Weighing system471
1364 Display471
1365 Symbols on keypad and display471
1366 Option buttons471
1367 Signal buttons471
1368 Lifting and lowering control471
1369 Hour meter472
13610 Battery indicator472
13611 Safety reversing472
13612 Travel function wiring/fuse C5390472
136121 Description472
1361211 Fuses472
137 Power system travel function C5400473
1371 Overview473
1372 Transistor panel C5460473
13721 Description473
137211 General473
13722 Checking the contactors474
13723 Checking the cable connections474
13724 Checking the electric panel mounting474
13725 Cleaning the electric panel heatsink474
13726 Replacing the motor control panel474
137261 Removing the motor control panel474
137262 Installing the motor control panel475
138 Control system, working function C5500476
1381 Work function harnesses/fuse C5590476
13811 Checking the wiring harnesses476
139 Protective sensors, position sensors C5800476
1391 Description476
13911 Inductive sensors476
139111 Position sensors476
139112 Steering reference sensor477
13912 Pressure sensor478
13913 Pulse transducer478
1392 Safety probes/sensors C5830479
13921 Emergency switch off479
139211 Description479
1392111 Task and function479
139212 Checking the emergency switch function479
13922 Gate switches [B121]/[B122]479
139221 Replacing the gate switch [B120]479
1392211 Removing the position sensor [B121]479
1392212 Installing the position sensor [B121]480
139222 Replacing the gate switch [B122]481
1392221 Removing the position sensor [B122]481
1392222 Installing the position sensor [B122]481
13923 Photocell482
139231 Overview [Photocells for fixed side guards]482
139232 Description482
1392321 Function482
139233 Checking the photocell482
1310 Calibrations483
13101 Steering angle calibration483
13102 Hydraulic valve calibration483
131021 Proportional valve calibration483
131022 Tilt angle calibration484
13103 Pressure sensor calibration484
131031 Weight measuring calibration484
131032 Overload calibration485
14 Hydraulics/Pneumatics C6000489
141 Overview489
142 Description489
1421 Hydraulic hygiene489
14211 Washing489
14212 Packaging490
14213 Handling490
14214 Storage490
14215 Work procedures490
14216 General rules490
14217 Measures491
1422 Design492
143 Quick change connectors492
1431 Overview quick change connectors492
1432 Removing quick change connectors (female)492
1433 Installing quick change connector (female)493
1434 Removing a quick change connector (male)494
1435 Installing a quick change connector (male)495
144 Hydraulic unit C6100496
1441 Hydraulic unit496
1442 Description496
14421 Pressure limiting valve496
1443 Hydraulic oil tank C6110497
14431 Tank497
14432 Description497
144321 Design497
14433 Cleaning the tank497
14434 Checking the tank497
14435 Oil change498
144351 Draining oil498
144352 Topping up with oil498
14436 Replacing the tank499
144361 Removing the tank499
144362 Fitting the tank500
1444 Filter, filter housing C6130500
14441 Cleaning the suction filter500
14442 Oil filter replacement500
144421 Removing oil filter500
144422 Installing the oil filter501
14443 Replacing the suction filter502
144431 Removing suction filter502
144432 Installing the suction filter502
1445 Hydraulic pump C6140503
14451 Hydraulic pump503
14452 Description503
144521 Design503
1446 Pressure/flow control valve C6170503
14461 Description503
144611 Checking the pressure limiting valve503
14462 Replacing the flow control valve504
144621 Removing the flow control valve504
144622 Fitting the flow control valve505
14463 Replacing the pressure limiting valve505
144631 Removing the pressure limiting valve505
144632 Fitting the pressure limiting valve506
1447 Replacing the hydraulic unit506
14471 Removing the hydraulic unit506
14472 Installing the hydraulic unit507
1448 Replacing the valve coil508
14481 Removing the valve coil508
14482 Fitting the valve coil509
1449 Replacing the pressure sensor510
14491 Removing the pressure sensor510
14492 Fitting the pressure sensor510
145 Hydraulic system, fitted on the mast C6300510
1451 Mast hydraulic conduits C6320510
14511 Checks for leaks from hydraulic conduits and connections, hydraulic unit510
14512 Checks for leaks from hydraulic conduits and connections, mast511
146 Hydraulic cylinder C6600511
1461 Main lift cylinders C6610511
14611 Checking for leaks in the lift cylinder511
14612 Replacing the main lift cylinders511
146121 Removing the lift cylinder511
146122 Fitting the lift cylinder513
1462 Support arm/initial lift cylinder C6630515
14621 Replacing the main initial lift cylinder515
146211 Removing the initial lift cylinder515
146212 Installing the initial lift cylinder516
1463 PowerTrak cylinder C6680517
14631 Replacing the PowerTrak cylinder517
146311 Removing the PowerTrak cylinder517
146312 Installing the PowerTrak cylinder519
15 Work function – lifting masts C7000523
151 Description523
1511 Ordering a replacement mast523
152 Chain system, general523
1521 General523
1522 Adjusting the chain523
1523 Lubrication523
1524 Checking the chains524
15241 Noise524
15242 Surface rust524
15243 Rusty links524
15244 Stiff links524
15245 Bolt rotation524
15246 Loose bolts525
15247 Outline wear525
15248 Chain gauge526
15249 Stretching526
152410 Damaged plates527
152411 Damaged bolts527
152412 Other damage527
152413 Dirty chain527
153 Checking the chains528
154 Lubricating the chains528
155 Checking the split pins529
156 Check-tighten the locking nuts529
157 Main mast C7100529
1571 Check the position of the mast guide529
1572 Check for cracks/damages to the mast530
1573 Lubrication of the mast roller guides 530
1574 Measuring the mast inclination530
1575 Adjusting the mast inclination531
1576 Replacing the roller532
15761 Installing a roller532
1577 Replacement of the mast532
15771 Disassembling the mast532
15772 Removing a roller534
15773 Assembling the mast535
15774 Installing a roller537
1578 Main mast fork carriage C7130537
15781 Replacing the idler roller537
157811 Removing a roller537
1579 Initial lift of frame/mast C7160538
15791 Replacing the main initial lift cylinder538
157911 Disassembling the fork carriage538
157912 Installing a fork carriage539
15710 Main mast suspension C7190540
157101 Mast mount540
1571011 Tightening the upper mast fixing points540
1571012 Check-tighten the locking nuts541
1571013 Tightening the lower mast fixing points541
158 Lifting/carrying/clamping devices C7400541
1581 Fork carriage unit/with integrated sideshift/fork spread C7420541
15811 Checking the fork carriage541
15812 Check the play of the fork carriage541
15813 Lubricating the beams542
15814 Measuring the fork-to-floor distance542
15815 Replacing the fork carriage542
158151 Disassembling the fork carriage542
158152 Installing a fork carriage544
16 Auxiliary equipment, installation equipment C8000549
17 Optional equipment/Extra equipment C9000553
171 Overview553
172 Extra electrical equipment C9400554
1721 Extra power socket554
17211 Overview554
17212 Description554
172121 DC/DC converter554
1722 Truck log equipment, code lock C9420555
17221 Overview555
17222 I_Site555
172221 Description555
1722211 I_Site555
17223 Impact Manager556
172231 Description556
1722311 Collision sensor556
172232 Checking the reference sensor parameters556
172233 Checking DHU/TWIS [K110]556
173 Other extra equipment C9500556
1731 Ground strap556
17311 Replacing the ground strap556
173111 Removing the ground strap556
173112 Installing a ground strap557
1732 Fire extinguisher558
17321 Description558
173211 Fire extinguisher558
1733 Horizontal E-bar559
17331 Description559
173311 E-bar559
17332 Checking the E-bar lock559
1734 Spider expansion unit560
17341 Description560
173411 Spider expansion unit560
18 Instructions for disposal563
181 General563
182 Marking of plastics563
1821 General marking of products and packaging563
1822 Marking according to the manufacturer’s standards563
18221 Abbreviations563
18222 Marking examples564
183 Pressure vessels564
1831 Gas struts564
184 Sorting categories565
19 Wiring diagram569
191 Colour code table569
192 Diagram569
1921 Component list569
1922 Component placement573
1923 Detailed diagrams587
20 Hydraulics schematics615
201 Component list615
202 Component location616
2021 Picture 1616
2022 Picture 2617
2023 Picture 3618
2024 Picture 4618
203 Valve unit620
2031 Valve unit 1-function620
2032 Valve unit 2-functions621
2033 Valve unit 1-function + AUX622
204 Diagram623
205 Diagram623
206 Diagram625
21 Tools629
211 Tools for electric connectors629
2111 AMP connectors629
2112 MQS connectors629
2113 CPC connectors630
2114 AMP Seal connectors631
212 Special tools631
22 Service data and grease specifications635
221 General tightening torques635
2211 Galvanised, non-oiled screws635
2212 Untreated, oiled screws635
222 Lubricants specification636
23 Technical data639
24 641
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