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Explains how the repair manual is divided into chapters and the information each chapter contains.
Details the warning levels (DANGER, WARNING, NOTE) and associated symbols used in the manual.
Illustrates various symbols used in the manual and their meanings, relating to inspection, cleaning, measurement, etc.
Provides guidelines for safer work practices and accident prevention, including site cleanliness and posture.
Outlines safety precautions when working on the truck's electrical system, emphasizing battery disconnection and insulated tools.
Details safe lifting procedures, emphasizing level surfaces, proper lifting points, and securing the truck.
States that truck modifications require prior manufacturer approval and outlines the conditions for user-arranged modifications.
Explains the meaning of various symbols found on the keypad and display of the truck.
Describes the event of the battery being connected, including preceding events, actions, influencing elements, and resulting conditions.
Details the process of logging into the truck using a PIN code via the keypad.
Explains the conditions and actions required for the tiller arm to be lowered for driving.
Describes how to drive the truck in the fork direction, including speed control and resulting conditions.
Explains how to drive the truck in the drive wheel direction.
Details the neutral position braking mechanism, where the drive motor acts as a generator.
Explains the reverse braking process, where the drive motor acts as a generator.
Describes how the mechanical brake is applied when the tiller arm is raised or lowered.
Explains how the emergency reversal button functions to run the drive motor at reduced speed.
Details the process of lifting the forks for the S210 model, involving pressing the fork lift button.
Outlines the procedure for lifting the support arm on specific models, involving pressing a button.
Explains the steps for lowering the forks, involving pressing the fork lowering button.
Details how to lower the support arm on specific models, involving pressing the support arm lowering button.
Describes the Click-2-Creep function, activated by double-actuating the speed control.
Explains how to activate the Turtle function and its effect on maximum travel speed.
Introduces parameters used to configure the truck for specific tasks and mentions their division into groups.
Provides a step-by-step guide on how to show and change truck parameters using the CAN key or PIN code.
Explains operator parameters (1-100) used to adapt truck characteristics and mentions the possibility of storing profiles.
Details how operator parameters are adjusted based on login profiles and parameter numbers.
Explains how parameters 3 (Acceleration) and 4 (Deceleration) can be used to smooth acceleration/deceleration.
Explains parameters 6 and 7, which limit the maximum travel speed for the logged-in operator profile.
States that a CAN service key must be connected to change service parameters.
Lists general service parameters (101-112) that can be used to adapt truck performance.
Provides detailed descriptions for specific service parameters like Service intervals, Operator access, Start-up, and Collision sensor.
Explains that factory parameters are preset and can only be changed using TruckCom software.
Lists factory parameters (1001-1118) related to truck type, options, speed, battery, and hardware version.
Provides detailed descriptions for factory parameters like Truck type and Non-configurable options.
Details how the truck should be properly anchored with stropping for safe transport on a lorry.
Provides safety instructions for lifting the truck, emphasizing level surfaces, proper lifting points, and securing the truck.
Guides on installing the correct size battery, checking electrolyte level, and connecting cables safely.
Explains the use of PIN codes for linking operator experience levels to truck characteristics (operator profiles).
Covers parameters that need setting during commissioning, referring to the Parameters chapter for details.
Provides a checklist of items to inspect before putting the truck into use, covering various truck areas.
Emphasizes carrying out specified service program points to maintain safety and minimize downtime.
Provides general maintenance instructions, including cleaning, washing, and using approved spare parts.
Highlights the importance of cleaning and washing for truck reliability and outlines weekly procedures.
Details the correct usage of high-pressure washers, specifying metal surfaces only and avoiding certain components.
Specifies service intervals of 750 operating hours or 12 months, whichever comes first.
Explains that this section covers error codes, causes, and corrective remedies for truck malfunctions.
Provides instructions for towing a defective truck, emphasizing the need for an operator and load removal.
Describes how to activate the emergency travel mode to move the truck at low speed when immobile.
Explains how to display and interpret the error code log, which stores up to 50 recent error events.
Explains the structure of error codes (X.YZZ) and the meaning of the 'X' group indicator for truck systems.
Lists specific error codes (e.g., 2:002, 2:004, 2:005) with their descriptions, truck behavior, causes, and procedures.
Divides troubleshooting into categories based on truck symptoms like 'cannot be driven' or 'behaves abnormally'.
Lists symptoms, influencing elements, and possible causes for the truck being unable to drive.
Identifies symptoms, influencing elements, and causes for the truck only traveling at reduced speed.
Explains how to activate and use the built-in service information mode for troubleshooting.
Details the procedure for lateral adjustment of the support arm lift, including loosening nuts and adjusting screws.
Provides instructions for replacing springs in the motor mounts, excluding the S212S model.
Outlines the steps for removing the platform, including loosening bolts and handling tensioned springs.
Provides an overview of the electric drive motor, identifying key components like the speed sensor and temperature sensor.
Guides on removing the motor, including cover removal, cable disconnection, and unscrewing retaining screws.
Details the process of removing the toothed wheel from the drive motor, involving circlip and brake hub removal.
Depicts the drive motor mounting screws and specifies tightening torques.
Describes the drive gear as a two-stage angle gear integrated with the motor and brake assembly.
Shows an overview of the drive gear, detailing components like the transmission housing and bearings.
Provides step-by-step instructions for removing the gear from the truck, excluding the S212S model.
Covers checking and changing the oil, including draining old oil and refilling.
Describes the three types of brakes: travel, parking, and emergency brakes, and how the parking brake functions.
States that the parking brake requires no maintenance in normal environments and outlines safety precautions.
Provides an overview of the parking brake components, listing parts like dust seals, O-rings, and the hub.
Explains how to manually release the parking brake using screws for service or repair.
Guides on removing the parking brake, including disconnecting steering yoke, tiller arm, and cable connections.
Details the steps for fitting the parking brake, including torque tightening screws and connecting the tiller arm.
Explains how to check the air gap in the parking brake, including cleaning and measurement procedures.
Guides on replacing the castor wheel, emphasizing safety and proper reassembly.
Provides an overview of the tiller arm components, identifying various parts like buffers, bolts, and sensors.
Guides on removing the tiller arm, including cover removal, cable detachment, and unscrewing yoke retaining screws.
Outlines the steps for removing and installing the safety sensor, including shaft adjustment and cable connections.
Introduces the electric steering system and its components like the tiller arm handle and keypad.
Guides on removing and installing the keypad, including disconnecting it from the logic card.
Details the process of removing and installing the upper cover, including keypad removal and CAN connection.
Explains how to remove and install the logic card, emphasizing static electricity precautions.
Covers resetting/restarting the battery and inspecting its condition, including checking the green lamp and connections.
Provides instructions for replacing the wiring harness, including disconnecting connectors and removing the bracket.
Details the process of replacing the transistor regulator, including removing inspection covers and disconnecting cables.
Emphasizes safety precautions for hydraulic systems, including depressurizing, checking for leaks, and handling hot oil.
Stresses the importance of hydraulic hygiene to prevent malfunctions and damage, detailing washing, packaging, and handling procedures.
Provides an overview of the hydraulic unit, identifying components like the pump motor, solenoid valves, and tank.
Guides on emptying the hydraulic tank by loosening screws and disconnecting cables.
Details procedures for bleeding the hydraulic system, with separate instructions for cylinders with and without bleeding valves.
Guides on replacing the hose rupture valve, noting its location and the importance of preventing dirt entry.
Describes the calibration function for proportional valves, including service mode settings and affected parameters.
Provides instructions for adjusting the pressure limiting valve to ensure the truck can handle rated loads.
Outlines the steps for disassembling the hydraulic unit, including disconnecting hoses, cables, and lifting the unit.
Covers components of the main mast and their tightening torques.
Lists components of the main mast, including upper and lower mast fixing points with specified torques.
Details maintenance for the fixing points, recommending visual inspection and replacement of bolts if loose.
Explains the lubrication procedure for the beam flanges, recommending specific lubricants.
Covers maintenance of the fork carriage, including checking play and adjusting shims.
Covers general procedures for replacing the chain bolt and associated nuts and cotter pins.
Details common types of chain wear like outline wear, stretching, damaged bolts, and stiff links, recommending replacement.
Details how chain stretch is measured and the permitted amount of stretch, along with nominal and maximum chain lengths.
States that the chain should be replaced if it is damaged in any way.
Guides on replacing the fork carriage, including lifting the carriage, removing the chain bolt, and lowering it.
Outlines the procedure for replacing the mast, involving disconnecting fork carriage, lift height switches, and hydraulic hoses.
Details replacing the idler roller, including using a puller and fitting shims.
Explains how to check and adjust the mast angle after replacement, ensuring the truck is on a level surface.
Introduces the Spider expansion unit (SEU) for handling more inputs/outputs via CAN bus and its connection.
Explains the function of the Spider expansion unit (SEU) for increased inputs/outputs via CAN bus.
Refers to a separate manual for information on the Truck log system.
Refers to a separate manual for information on the ID unit software.
Describes the DC/DC converter for supplying power to equipment, noting its protection features.
Explains that the collision sensor registers impacts and counts them as collisions if they exceed specified levels.
Provides notes on retrofitting or replacing the built-in battery charger and torque tightening nuts.
Details the battery charging process, including display indications for main charging, equalizing, and completion.
States that disposal instructions support environmental protection through recycling and reducing emissions.
Explains plastic markings consist of arrows, numbers, and material designations, providing examples like polypropylene.
States that pressure vessels for recycling must be depressurized and opened, giving examples like gas struts.
Warns about the high internal pressure of gas struts and provides instructions for safely disassembling them.
Lists various sorting categories for truck components, including plastic, iron/steel, oils, and electronic parts.
Presents a table summarizing major electric components, their symbols, descriptions, functions, and remarks.
Introduces wiring diagrams and lists symbols used.
Provides a table of symbols used in wiring diagrams, defining components like batteries, fuses, motors, and switches.
Displays a general wiring diagram showing connections between various electrical components.
Shows a chart illustrating the hydraulic system for different mast types (Simplex, Duplex, Triplex).
Lists components of the hydraulic system with their corresponding positions and descriptions.
Describes the MQS Basic toolbox and its contents, including pliers and splice sleeves for connector repair.
Lists AMP connector types (PT, JPT, MPT) and the corresponding tools for pin/sleeve removal and crimping.
Lists various grease guns and their specifications, including nozzle types and hose lengths.
Mentions other necessary tools like the CAN service key and service instruments for programming.
Provides general tightening torques for millimetre threads (M3 to M24) based on strength class and lubrication.
Lists recommended lubricants based on ambient temperature and viscosity class, including usage for hydraulic systems and bearings.
Presents technical data for drive motors, brakes, transmission, and fuses for S210, S212, and S214 models.
Lists technical data for drive motors, brakes, transmission, and fuses for S212L, S214L, and S220D models.
Provides technical data for the S212S model, including drive motor, brake, and transmission specifications.
Details overflow pressure for masts based on type and rated load, including pump flow and recommended overflow pressure.
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