Toyota Forklift FBRE12 FBRE14 FBRE16 Repair Manual 7575392-040 – PDF DOWNLOAD
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Toyota Forklift FBRE12 FBRE14 FBRE16 Repair Manual 7575392-040 – PDF DOWNLOAD
Language : English
Pages : 538
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift FBRE12 FBRE14 FBRE16 Repair Manual 7575392-040 – PDF DOWNLOAD
General introduction:
2.1 How to use this manual:
The repair manual is divided into chapters containing the following information:
• General safety rules
• Operation and connection sequences – 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 – This chapter describes the action you should take when
the truck is completely or partially malfunctioning. 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 Cesab’s C code system.
• Instructions for disposal instructions – This chapter specifies the proper
sorting category for the materials used in the various truck components.
• Wiring diagram – This chapter provides information on electrical
components and wiring diagrams.
• Hydraulic diagram – This chapter provides information on electrical
components and hydraulic 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 an oil and grease
specification.
• Technical data
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Toyota Forklift FBRE12 FBRE14 FBRE16 Repair Manual 7575392-040 – PDF DOWNLOAD
1. Table of content...................................................................0 2. General introduction...............................................................0 2.1 How to use this manual........................................................0 2.2 Abbreviations.................................................................0 2.3 Warning symbols...............................................................0 2.4 Pictograms....................................................................0 2.4.1 Screws/Nuts.............................................................0 Identification of tools for screws and nuts...............................0 2.4.2 Repairable..............................................................0 2.4.3 Other pictograms........................................................0 3. General safety rules...............................................................0 3.1 Work safety...................................................................0 3.2 Electrical system.............................................................0 3.3 Safe lifting..................................................................0 3.4 Truck modifications...........................................................0 4. Operation and connection sequences.................................................0 4.1 Description...................................................................0 5. Parameters.........................................................................0 5.1 General.......................................................................0 5.2 Parameter settings............................................................0 Access........................................................................0 Parameter screens.............................................................0 5.3 Operator parameters...........................................................0 5.3.1 Overview................................................................0 Connection to logged-in operator..........................................0 5.3.2 Description.............................................................0 Parameter 2, 3 – Maximum travel speed.....................................0 Parameters 4 and 5 – Acceleration/Deceleration............................0 5.4 Service parameters............................................................0 5.4.1 Overview................................................................0 5.4.2 Description.............................................................0 Parameter 101/104 – Service/Log-out.......................................0 Parameter 107/108 – Battery...............................................0 Parameter 105/106/114/115/117 (Travel alarms 1 and 2).....................0 Parameters 109/110/111/112/117 – Collision sensor.........................0 Parameter 201 – Retardation when reversing................................0 Parameter 202/203/204 – Adjusting erroneous, maximum travel speeds........0 Parameter 208 - Creep speed in travel direction control...................0 Parameter 213 – Permanently reduced maximum travel speed..................0 Parameter 214 – Adjusting the maximum travel speed in main lift range.....0 Parameters 215/216........................................................0 5.4.3 Description.............................................................0 Parameters 301/302 – Extra valve function.................................0 Parameters 305/306 – Maximum oil pressure through valve Q18...............0 Parameters 309/310 – Maximum oil pressure through valve Q19...............0 Parameters 313/314 – Closing time.........................................0 Parameters 317/318 – Maximum oil flow through valve Q18...................0 Parameters 321/322 – Maximum oil flow through valve Q19...................0 Parameters 325/326 – Opening/closing time valve Q19.......................0 Parameters 329/330 – Opening/closing time valve Q19.......................0 Parameter 341/342 – Reducing the lifting/lowering speed...................0 Parameter 343 – Reduction of reach speed..................................0 Parameter 345- Lift/lower sensitivity.....................................0 Parameters 346/347 – Ramping speeds.......................................0 Parameters 371/373/375/378 – Height limitation............................0 Parameter 380 – Lift height limits........................................0 Parameter 387 – Configuring the lift height limitations...................0 Parameter 503 – Login method..............................................0 Parameter 508/509/512/513 – CID configuration.............................0 5.5 Factory parameters............................................................0 5.5.1 General factory parameters..............................................0 Overview..................................................................0 Description...............................................................0 Parameter 1001 - Truck type...............................................0 Parameter 1002 – Mast type................................................0 Parameter 1003 – Hydraulic pump...........................................0 Parameter 1007 – Activation of hydraulic levers...........................0 Parameter 1009 – Height indication........................................0 5.5.2 Factory parameters, activation of options...............................0 Overview..................................................................0 Description...............................................................0 5.5.3 Factory parameters, calibration.........................................0 Description...............................................................0 6. Installation.......................................................................0 6.1 Transporting the truck........................................................0 6.2 Transporting the mast.........................................................0 6.3 Transporting the truck........................................................0 Method 1......................................................................0 Method 2......................................................................0 6.4 Taking into operation.........................................................0 6.4.1 Battery.................................................................0 Placing the battery.......................................................0 6.5 Dismantling the mast..........................................................0 6.5.1 Dismantling the working light...........................................0 6.6 Putting into operation........................................................0 6.6.1 Installing the mast in the truck........................................0 6.6.2 Fitting the working light...............................................0 7. Maintenance........................................................................0 7.1 Introduction..................................................................0 7.2 Safety precautions for maintenance work.......................................0 7.3 Maintenance instructions......................................................0 7.3.1 Cleaning and washing....................................................0 7.3.2 High-pressure washers...................................................0 7.3.3 Degreasing agents.......................................................0 7.3.4 Cleaning the exterior...................................................0 7.3.5 Cleaning the chain......................................................0 7.3.6 Cleaning the motor compartment..........................................0 7.3.7 Electric components.....................................................0 7.4 Symbols.......................................................................0 7.5 CCrack detection..............................................................0 7.5.1 Visual inspection.......................................................0 7.5.2 Crack detection.........................................................0 Crack detection with liquid penetrant.....................................0 Crack detection with magnetic yoke........................................0 7.6 Safety checks.................................................................0 7.7 Periodic maintenance..........................................................0 7.7.1 Every 500 operating hours/180 days......................................0 7.7.2 Every 1000 operating hours/360 days.....................................0 7.7.3 Every 2000 operating hours/720 days.....................................0 7.7.4 Every 3000 operating hours/1080 days....................................0 7.7.5 Every 4000 operating hours/1440 days....................................0 7.7.6.........................................................................0 7.7.7 Every 5000 operating hours/1800 days....................................0 7.7.8 Annual status inspection................................................0 8. Troubleshooting....................................................................0 8.1 Auxiliary functions...........................................................0 8.1.1 Error log menu..........................................................0 Description...............................................................0 Access....................................................................0 8.1.2 Error information menu..................................................0 Description...............................................................0 Access....................................................................0 8.1.3 Diagnostic screens......................................................0 Description...............................................................0 Access....................................................................0 Screen 1 – CID analogue inputs............................................0 Screen 2 – CID digital inputs.............................................0 Screen 3 – MCU analogue inputs............................................0 Screen 4 – MCU digital inputs.............................................0 Screen 5 – MCU digital outputs............................................0 Screen 6 – Pulse-width modulated outputs..................................0 Screen 11 – Temperatures..................................................0 Screen 12 – Voltages......................................................0 Screen 13 – travel function...............................................0 Screen 14 – Steering function.............................................0 Screen 15 – Displays information about lifting/lowering...................0 Screen 16 – Displays reach in and reach out information...................0 Screen 17 – Displays tilt and sideshift information.......................0 8.2 Initial troubleshooting.......................................................0 8.3 Troubleshooting using blocking symbol.........................................0 8.4 Troubleshooting using error codes.............................................0 8.4.2 MCU and other warnings and errors.......................................0 8.5 Troubleshooting without indications...........................................0 8.5.1 Mechanical brake (3000).................................................0 8.5.2 Steering (4000).........................................................0 9. Chassis C0000......................................................................0 9.1 Overview......................................................................0 9.2 Description...................................................................0 9.3 Floor C0330...................................................................0 9.3.1 Overview................................................................0 9.3.2 Description.............................................................0 9.3.3 Replacing the floor.....................................................0 Removing the floor........................................................0 Adjusting the floor.......................................................0 Fitting the floor.........................................................0 9.3.4 Protective covers.......................................................0 Overview..................................................................0 Description...............................................................0 Replacing the top cover...................................................0 Removing the top cover....................................................0 Fitting the top cover.....................................................0 Replacing the steering arm covers.........................................0 Removing the steering arm covers..........................................0 Fitting the steering arm covers...........................................0 Replacing the cover, wiring harness.......................................0 Removing the cover, wiring harness........................................0 Fitting the cover, wiring harness.........................................0 Replacing the elbow panel.................................................0 Removing the elbow panel..................................................0 Replacing the motor cover.................................................0 Removing the motor cover..................................................0 Fitting the motor cover...................................................0 Replacing the inner motor cover...........................................0 Removing the inner motor cover............................................0 Fitting the inner motor cover.............................................0 Replacing the front knee cover............................................0 Removing the front knee cover.............................................0 Fitting the front knee cover..............................................0 9.4 Support arm C0350.............................................................0 9.5 Battery compartment parts C0390...............................................0 9.5.1 Overview, battery support...............................................0 9.6 Operator's seat C0620.........................................................0 9.6.1 Overview................................................................0 9.6.2 Description.............................................................0 9.6.3 Replacing the operator’s seat (Basic)...................................0 Removing the operator’s seat (Basic)......................................0 Fitting the operator’s seat (Basic).......................................0 Adjusting the operator’s seat (Basic).....................................0 Removing the operator’s seat (Comfort Low, Comfort High)..................0 Fitting the operator’s seat (Comfort Low, Comfort High)...................0 Adjusting the operator’s seat (Comfort Low, Comfort High).................0 9.6.4 Seat switch.............................................................0 Replacing the seat switch (Comfort).......................................0 Removing the seat switch (Comfort)........................................0 Removing the seat switch (Comfortt).......................................0 9.6.5 Replacing the backrest, chair seat......................................0 Removing the backrest (Comfort Low, Comfort High).........................0 Fitting the backrest (Comfort Low, Comfort High)..........................0 Removing the seat pad.....................................................0 Fitting the seat pad......................................................0 9.6.6 Replacing the seat plate................................................0 Removing the seat plate...................................................0 Fitting the seat plate....................................................0 9.7 Operator controls C0640.......................................................0 9.7.1 Overview................................................................0 9.7.2 Description.............................................................0 9.7.3 Preconditions...........................................................0 9.7.4 Accelerator/Brake pedal.................................................0 Replacing the accelerator/brake pedal.....................................0 Removing the accelerator/brake pedal......................................0 Fitting the accelerator/brake pedal.......................................0 9.7.5 Safety pedal............................................................0 Replacing the safety pedal................................................0 Removing the safety pedal.................................................0 Fitting the safety pedal..................................................0 9.8 Interior fittings C0680.......................................................0 9.9 Mirrors C0740.................................................................0 9.10 Overhead guard/Roof C0810....................................................0 9.10.1 Overview...............................................................0 9.10.2 Description............................................................0 9.10.3 Replacing the overhead guard roof......................................0 Removing the overhead guard roof..........................................0 Fitting the overhead guard roof...........................................0 9.10.4 Replacing the front roof support.......................................0 Remove the overhead guard roof............................................0 Removing the front roof support...........................................0 Fitting the front support.................................................0 9.10.5 Replacing the rear roof support........................................0 Removing the rear roof support............................................0 Fitting the rear support..................................................0 9.11 Finger-foot guard C0820......................................................0 Replacing a finger guard......................................................0 Removing the finger guard.....................................................0 Fitting the finger guard......................................................0 10. Motors C1000......................................................................0 10.1 Overview.....................................................................0 10.2 Description..................................................................0 10.3 Electric pump motor C1710....................................................0 10.3.1 Overview...............................................................0 10.3.2 Description............................................................0 10.3.3 Replacing the pump motor...............................................0 Removing the pump motor...................................................0 Method....................................................................0 Fitting the pump motor....................................................0 10.3.4 Replacing the temperature sensor.......................................0 Removing the temperature sensor...........................................0 Installing the external temperature sensor................................0 Method....................................................................0 10.4 Steering motor C1730.........................................................0 10.4.1 Overview...............................................................0 10.4.2 Description............................................................0 10.4.3 Layout of the flange holes.............................................0 10.4.4 Steering servo motor replacement.......................................0 Removing the steering servo motor.........................................0 Fitting the steering servo motor..........................................0 Lubrication of the steering servo motor ring gear.........................0 10.5 Electric fan motor / fan.....................................................0 10.5.1 Fan for frequency converter............................................0 Overview..................................................................0 Description...............................................................0 10.5.2 Replacing the frequency converter fan..................................0 Removing the frequency converter fan......................................0 Fitting the frequency converter fan.......................................0 10.5.3 Motor compartment fan..................................................0 Overview..................................................................0 Description...............................................................0 10.5.4 Replacing the motor compartment fan....................................0 Removing the motor compartment fan........................................0 Fitting the motor compartment fan.........................................0 10.6 Electric drive motor C1760...................................................0 10.6.1 Overview...............................................................0 10.6.2 Description............................................................0 10.6.3 Replacing the drive motor..............................................0 Removing the drive motor..................................................0 Fitting the drive motor...................................................0 Method....................................................................0 10.6.4 Replacing the temperature sensor.......................................0 Removing the temperature sensor...........................................0 Installing the external temperature sensor................................0 10.6.5 Replacing the RPM-sensor...............................................0 Removing the RPM-sensor...................................................0 Fitting the RPM-sensor....................................................0 11. Mechanical Drive Gear Unit C2000..................................................0 11.1 Overview.....................................................................0 11.2 Description..................................................................0 11.3 Checking the oil level.......................................................0 11.4 Oil change...................................................................0 11.5 Leakage from the lower cover.................................................0 11.6 Replacing the drive gear.....................................................0 11.6.1 Removing the drive gear................................................0 11.6.2 Fitting the drive gear.................................................0 11.7 Replacing the Steering bearings..............................................0 Removing the steering bearings................................................0 Fitting the steering bearing..................................................0 12. Brake system/Wheels C3000.........................................................0 12.1 Brake system C3100...........................................................0 12.1.1 Overview...............................................................0 12.1.2 Description............................................................0 Travel brake..............................................................0 Emergency brake...........................................................0 12.1.3 Drive motor brake (travel brake).......................................0 Accelerator released......................................................0 Changing the direction of travel..........................................0 12.2 Parking brake C3370..........................................................0 12.2.1 Overview...............................................................0 12.2.2 Description............................................................0 12.2.3 Replacing the parking brake............................................0 Removing the parking brake................................................0 Fitting the parking brake.................................................0 12.2.4 Replacing the dust plug................................................0 Removing the dust plug....................................................0 Fitting the dust plug.....................................................0 12.2.5 Replacing the hub......................................................0 Removing the hub..........................................................0 Fitting the hub...........................................................0 12.2.6 Replacing the rubber gaiter............................................0 Fitting the rubber gaiter.................................................0 12.2.7 Checking the parking brake's brake force...............................0 Checking the parking brake's brake force..................................0 12.2.8 Checking the parking brake air gap.....................................0 12.3 Wheels C3500.................................................................0 12.3.1 Description............................................................0 12.3.2 Wheel wear.............................................................0 12.4 Drive wheel C3530............................................................0 12.4.1 Overview...............................................................0 12.4.2 Replacing the drive wheel..............................................0 Removing the drive wheel..................................................0 Fitting the drive wheel...................................................0 12.5 Support arm wheel C3550......................................................0 12.5.1 Overview...............................................................0 12.5.2 Replacing an unbraked support arm wheel................................0 Removal of an unbraked support arm wheel..................................0 Method....................................................................0 Fitting of an unbraked support arm wheel..................................0 Method....................................................................0 12.5.3 Replacing bearings.....................................................0 Removing the bearings.....................................................0 Assembling bearings.......................................................0 12.5.4 Replacing the wheel bolt...............................................0 13. Steering system C4000.............................................................0 13.1 Description..................................................................0 13.2 Electric steering wheel C4310................................................0 13.2.1 Overview...............................................................0 13.2.2 Description............................................................0 13.2.3 Adjustment.............................................................0 13.2.4 Replacing pulse transducer [B13].......................................0 13.2.5 Replacing the steering console.........................................0 Removing the steering console.............................................0 Method....................................................................0 13.2.6 Replacing the wiring harness in the steering console...................0 13.2.7 Fit the steering console in the truck..................................0 13.2.8 Replacing the steering wheel...........................................0 13.3 Steering unit C4330..........................................................0 13.3.1 Description............................................................0 13.4 Steering reference sensor (4350).............................................0 13.4.1 Replacing the reference sensor [B17]...................................0 14. Electrical system C5000...........................................................0 14.1 Description..................................................................0 14.2 OTP..........................................................................0 Description...................................................................0 Travel speed reduction - steering angle.......................................0 14.3 Battery C5110................................................................0 14.3.1 Battery recommendations................................................0 14.3.2 Measuring discharge current............................................0 14.3.3 Measuring voltage......................................................0 14.3.4 Charging the battery...................................................0 14.3.5 BDI algorithm and parameter setting....................................0 14.3.6 Performance limitations due to battery status..........................0 14.3.7 Performance limitations due to battery status and parameter setting....0 14.3.8 CID symbol.............................................................0 14.3.9 Resetting the battery indicator (BDI)..................................0 14.3.10 Battery weight........................................................0 14.3.11 Parameter overview, battery...........................................0 14.3.12 Battery cable harness.................................................0 Overview..................................................................0 14.3.13 Battery cable replacement, machine part...............................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.3.14 Battery cable replacement, battery part...............................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.4 Signal / Alarm (Sound-light) C5160...........................................0 14.4.1 Horn...................................................................0 Overview..................................................................0 Description...............................................................0 14.4.2 Replacing the horn.....................................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.5 Main contactor C5190.........................................................0 Overview......................................................................0 Description...................................................................0 14.5.1 Replacing the contactor................................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.6 Instrument panel C5200.......................................................0 Description...................................................................0 14.6.1 Operating controls.....................................................0 14.6.2 Replacing the operating controls.......................................0 Dismantling...............................................................0 Assembly..................................................................0 14.6.3 Replacing the switch for travel direction selection / horn.............0 14.6.4 Replacing the controls on the operating panel..........................0 14.6.5 Central Information Display (CID)......................................0 Menu navigation...........................................................0 LED symbols...............................................................0 14.6.6 Replacing the CID......................................................0 Overview..................................................................0 Method....................................................................0 Dismantling...............................................................0 14.7 Height indication............................................................0 Overview......................................................................0 Description...................................................................0 14.7.1 Replacing the sensor bearing...........................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.7.2 Replacing the height reference sensor..................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.7.3 Hight indication wire..................................................0 14.7.4 Check and adjust the wire..............................................0 14.7.5 Replacing the height indication wiring.................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.8 Travel function wiring/ fuse C5390...........................................0 14.8.1 Chassis wiring.........................................................0 Removing the chassis wiring...............................................0 14.8.2 Operator control wiring................................................0 Method....................................................................0 Dismantling...............................................................0 14.9 Drive motor cables/resistor/fuse C5430.......................................0 14.9.1 Replacing motor cables.................................................0 14.10 Transistor panel C5460......................................................0 Overview......................................................................0 Description...................................................................0 14.10.1 Replacing the ACT.....................................................0 Removing the covers.......................................................0 Method....................................................................0 Fitting the ACT...........................................................0 Method....................................................................0 Software update...........................................................0 Checking the ACT..........................................................0 Fitting the floor.........................................................0 Fit the covers............................................................0 14.10.2 Replacing ACH.........................................................0 Removing the floor........................................................0 Removing the covers.......................................................0 Method....................................................................0 Fitting the ACH...........................................................0 Method....................................................................0 Software update...........................................................0 Checking the ACH..........................................................0 Fitting the floor.........................................................0 Fit the covers............................................................0 14.11 Work function harnesses / fuse C5590........................................0 14.11.1 Fuse panel............................................................0 Overview..................................................................0 Description...............................................................0 14.11.2 Checking fuses........................................................0 Method....................................................................0 14.11.3 Roof wiring...........................................................0 Description...............................................................0 Overview..................................................................0 14.11.4 Replacing the roof wiring.............................................0 14.11.5 Mast wiring...........................................................0 Description...............................................................0 Overview..................................................................0 14.11.6 Replacing the mast harness............................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.11.7 Check and adjust the mast wiring......................................0 Description...............................................................0 Overview..................................................................0 14.11.8 Reach carriage wiring.................................................0 Description...............................................................0 Overview..................................................................0 Replacing the reach carriage wiring harness...............................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.12 Main processor – MCU C5710..................................................0 14.12.1 Replacing the MCU.....................................................0 Replacing the MCU.........................................................0 Removing the floor........................................................0 Removing the MCU..........................................................0 Method....................................................................0 Fitting the MCU...........................................................0 Method....................................................................0 Fitting the floor.........................................................0 14.13 Sending units and sensors C5800.............................................0 14.13.1 Inductive sensors.....................................................0 14.13.2 Position sensor.......................................................0 Steering reference sensor.................................................0 14.13.3 Pressure sensor.......................................................0 14.13.4 Pulse transducer......................................................0 Steering sensor...........................................................0 14.14 Safety sensor / - sensors C5830.............................................0 14.14.1 Emergency switch off..................................................0 14.14.2 Emergency switch off [S21]............................................0 Description...............................................................0 Overview..................................................................0 Indications in CID........................................................0 Replacing the emergency switch off........................................0 Method....................................................................0 Dismantling...............................................................0 Assembly..................................................................0 14.14.3 Safety pedal [B31]....................................................0 Description...............................................................0 Location..................................................................0 Indication in CID.........................................................0 Replacing the safety pedal................................................0 14.15 Height measurement system...................................................0 Description...................................................................0 Monitoring....................................................................0 14.16 Calibration.................................................................0 14.16.1 Calibration of the joystick...........................................0 14.16.2 Height measurement/reach movement length calibration..................0 14.16.3 Reference sensor, main lift. (Screen 1)...............................0 14.16.4 Pulse length for main lift sensor bearing (Screen 2)..................0 14.16.5 Max. lift height. (Screen 3)..........................................0 14.16.6 Calibration of the reach carriage extension...........................0 14.16.7 Valve calibration.....................................................0 14.16.8 Lowering valve, starting value. (Screen 1-S)..........................0 14.16.9 Lowering valve, final value. (Screen 1-E).............................0 14.16.10 Lifting height limiting..............................................0 15. Hydraulic system C6000............................................................0 15.1 General......................................................................0 15.2 Hydraulic hygiene............................................................0 15.2.1 Washing................................................................0 15.2.2 Packaging..............................................................0 15.2.3 Handling...............................................................0 15.2.4 Storage................................................................0 15.2.5 Work procedures........................................................0 15.3 Bleeding the air from the hydraulic system...................................0 15.4 Hose inspection..............................................................0 15.5 Hydraulic couplings C6230....................................................0 Overview......................................................................0 15.5.1 Quick change connectors................................................0 Assembling the quick change connector.....................................0 Disassembly of the quick change connector.................................0 15.5.2 Tightening torques for hydraulic connections...........................0 Tapered coupling with O-ring..............................................0 Tredo seal................................................................0 Pipe coupling.............................................................0 15.6 Hydraulic unit C6100.........................................................0 15.6.1 Hydraulic oil tank C6110...............................................0 Description...............................................................0 Checking the oil level....................................................0 Filling the tank..........................................................0 Replacing the tank........................................................0 Removing the tank.........................................................0 Fitting the tank..........................................................0 15.6.2 Hydraulic hoses C6120..................................................0 Replacing the suction hose................................................0 Method....................................................................0 15.6.3 Filter C6130...........................................................0 Overview..................................................................0 Description...............................................................0 Filter replacement (for air and oil)......................................0 Method....................................................................0 15.7 Hydraulic pump C6140.........................................................0 Description...................................................................0 15.7.1 Replacing the hydraulic pump...........................................0 15.7.2 Replacing the driver...................................................0 Disassembly...............................................................0 Assembly..................................................................0 Replacing O-rings.........................................................0 Disassembly...............................................................0 Assembly..................................................................0 15.8 Main valve unit C6210........................................................0 Description...................................................................0 Overview......................................................................0 15.8.1 Definitions............................................................0 Inserts for quick change connectors.......................................0 Tightening torques for valve components...................................0 Lift function.............................................................0 Overview..................................................................0 Description...............................................................0 Lowering function.........................................................0 Overview..................................................................0 Description...............................................................0 Reach function............................................................0 Pressure limitation.......................................................0 15.8.2 Replacing a complete valve unit........................................0 Disassembly...............................................................0 Assembly..................................................................0 15.8.3 Replacing a valve......................................................0 Disassembly...............................................................0 Assembly..................................................................0 Lowering valve............................................................0 Description...............................................................0 Replacing the lowering valve..............................................0 Adjusting the lowering valve..............................................0 Calibrating the lowering valve............................................0 Replacing the pressure limiting valve.....................................0 Overview..................................................................0 Disassembly:..............................................................0 Assembly..................................................................0 Adjustment................................................................0 Adjustment table..........................................................0 15.9 Control valve C6220..........................................................0 Description...................................................................0 Overview......................................................................0 Tilt function.................................................................0 Overview......................................................................0 Sideshift function............................................................0 15.10 Chassis-mounted hydraulic hoses C6230.......................................0 15.10.1 Replacing the supply hose.............................................0 Overview..................................................................0 Disassembly...............................................................0 Assembly..................................................................0 15.10.2 Replacing the return hose.............................................0 Overview..................................................................0 Disassembly...............................................................0 Assembly..................................................................0 15.11 Mast hydraulic conduits C6320...............................................0 Replacing the supply hose to the free lift cylinder...........................0 Overview......................................................................0 Disassembly...................................................................0 Assembly......................................................................0 15.11.1 Fork carriage.........................................................0 Overview..................................................................0 Replacing the hose to the sideshift.......................................0 Disassembly...............................................................0 Assembly..................................................................0 Replacing the pipe in the fork carriage...................................0 Disassembly...............................................................0 Assembly..................................................................0 15.12 Main lift cylinder C6610....................................................0 Overview......................................................................0 Cylinder nomenclature.........................................................0 Nomenclature for cylinder head................................................0 Nomenclature for piston.......................................................0 15.12.1 Removing the air cylinder from the mast...............................0 15.12.2 Replacing the hose rupture valve......................................0 15.12.3 Dismantling the cylinder..............................................0 Method....................................................................0 15.12.4 Dismantling the piston................................................0 Method....................................................................0 15.12.5 Dismantling the cylinder head.........................................0 15.12.6 Fitting the cylinder head seals.......................................0 Method....................................................................0 15.12.7 Fitting the piston guide belt.........................................0 Method....................................................................0 15.12.8 Assembling the cylinder...............................................0 Method....................................................................0 15.12.9 Assembling a mast cylinder............................................0 15.13 Free lift cylinder C6620....................................................0 Cylinder nomenclature.........................................................0 Nomenclature for cylinder head................................................0 Nomenclature for piston.......................................................0 15.13.1 Removing the free lift cylinder from the truck........................0 15.13.2 Replacing the hose rupture valve, free lift cylinder..................0 15.13.3 Dismantling the cylinder..............................................0 Method....................................................................0 15.13.4 Dismantling the piston................................................0 Method....................................................................0 15.13.5 Dismantling the cylinder head.........................................0 Method....................................................................0 15.13.6 Fitting the cylinder head seals.......................................0 Method....................................................................0 15.13.7 Fitting the piston seals..............................................0 Method....................................................................0 15.13.8 Assembling the cylinder...............................................0 Method....................................................................0 15.13.9 Assembling the free lift cylinder in the mast.........................0 15.14 Reach/telescopic cylinder C6650.............................................0 Overview......................................................................0 Cylinder nomenclature.........................................................0 Nomenclature for cylinder head................................................0 Nomenclature for piston.......................................................0 15.14.1 Removing the reach cylinder from the truck............................0 15.15 Dismantling the cylinder....................................................0 Method........................................................................0 Carefully pull out the cylinder head, piston rod and piston...................0 15.15.1 Fitting the reach cylinder in the truck...............................0 15.16 Tilting cylinder C6660......................................................0 Overview......................................................................0 15.16.1 Remove the tilt cylinder from the truck...............................0 Mast with valve on the fork carriage......................................0 Method....................................................................0 15.16.2 Fit the tilt cylinder in the truck....................................0 Mast with valve on the fork carriage......................................0 Method....................................................................0 15.17 Sideshift cylinder C6670....................................................0 Overview......................................................................0 15.17.1 Overview..............................................................0 Cylinder nomenclature.....................................................0 Nomenclature for cylinder head............................................0 Nomenclature for piston...................................................0 15.17.2 Dismantling the cylinder from the truck...............................0 Method....................................................................0 15.18 Dismantling the cylinder....................................................0 Method........................................................................0 15.18.1 Removing the piston rod...............................................0 Method....................................................................0 Dismantling the cylinder head.............................................0 Method....................................................................0 15.18.2 Fitting the cylinder head seals.......................................0 Method....................................................................0 15.18.3 Mounting the piston rod...............................................0 15.18.4 Assembling the cylinder...............................................0 Method....................................................................0 15.18.5 Refitting the cylinder in the truck...................................0 16. Mast C7000........................................................................0 16.1 Description..................................................................0 16.1.1 The available combinations of truck and mast...........................0 16.1.2 Ordering replacement masts.............................................0 16.1.3 Mast type and weight...................................................0 16.2 Installing a mast in a newly delivered truck.................................0 16.2.1 Adjusting/setting mast inclination.....................................0 16.3 Main mast C7100..............................................................0 16.4 Main lifting chain system C7120..............................................0 16.4.1 Check..................................................................0 16.4.2 Lubrication............................................................0 16.4.3 Replacing the free lift chain..........................................0 Removing the free lift chain..............................................0 Fitting the free lift chain...............................................0 16.4.4 Replacing the mast chain...............................................0 Removing the mast chain...................................................0 Fitting the mast chain....................................................0 Adjusting the mast chain..................................................0 16.4.5 Replacing the mast harness.............................................0 Removing the mast cables..................................................0 Fitting the mast wiring harness...........................................0 16.5 Fork carriage C7130..........................................................0 16.5.1 Checking the fork carriage’s wear strip................................0 16.5.2 Lubricating the fork carriage..........................................0 16.5.3 Replacing the fork yoke................................................0 16.6 Main mast suspension C7190...................................................0 16.7 Forks C7410..................................................................0 16.7.1 Overview...............................................................0 16.7.2 Inspection procedures..................................................0 Inspection................................................................0 Inspection intervals......................................................0 Surface cracks............................................................0 Difference in height between the fork tips................................0 Position lock.............................................................0 Marking legibility........................................................0 Wear – fork blade and fork face...........................................0 Wear – fork mounting fixtures.............................................0 16.7.3 Repairs and testing....................................................0 Repairs...................................................................0 Testing the yield point...................................................0 17. Wiring diagram....................................................................0 17.1 Component list...............................................................0 17.2 Component location...........................................................0 Figure 1......................................................................0 Figure 2......................................................................0 Figure 4......................................................................0 Figure 5......................................................................0 Figure 6......................................................................0 Figure 7......................................................................0 Figure 8......................................................................0 Figure 9......................................................................0 Figure 10.....................................................................0 Figure 11.....................................................................0 Figure 12.....................................................................0 Figure 13.....................................................................0 Figure 14.....................................................................0 Figure 15.....................................................................0 Duplex mast...................................................................0 Figure 16.....................................................................0 17.3 Connections..................................................................0 17.3.1 ACT [T1]...............................................................0 17.3.2 ACH [T2]...............................................................0 17.3.3 CID [A1]...............................................................0 17.3.4 MCU [A5]...............................................................0 17.3.5 Fuse panel [A9]........................................................0 17.3.6 Steering motor [ [A2]..................................................0 17.4 General wiring diagram.......................................................0 17.5 Detailed diagrams............................................................0 18. Hydraulics schematics.............................................................0 18.1 Component list...............................................................0 18.2 Component location...........................................................0 18.3 Valve unit...................................................................0 18.3.1 Main valve unit........................................................0 18.3.2 Fork carriage valve....................................................0 18.4 Hydraulics schematics........................................................0 18.4.1........................................................................0 19. Tools.............................................................................0 19.1 AMP connectors...............................................................0 19.2 MQS contacts.................................................................0 19.3 CPC contacts.................................................................0 19.4 Other tools..................................................................0 20. Service data and grease specifications............................................0 20.1 General tightening torques...................................................0 20.1.1 Galvanised, non-oiled screws...........................................0 20.1.2 Untreated, oiled screws................................................0 20.2 Oil and grease specification.................................................0 21. Technical data....................................................................0 21.1 Mast type and weight (kg)....................................................0 21.2 IP classes on components and units...........................................0 21.3 Battery sizes................................................................0 21.4 Truck dimensions.............................................................0 21.4.1........................................................................0
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