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Manual Coverage
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Systems Covered
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Description:
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Operators compartment and controls, Chassis, Drive and transmission, Electrical system, Steering, Mast, hydraulics and reach frame, Braking, Gas warning system.
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Electrical System Details:
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Detailed coverage of electrical system components, wiring diagrams, warning indicators, and motor controls.
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Hydraulic System Details:
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Comprehensive information on mast, reach frame hydraulics, troubleshooting guide for the hydraulic system, and hydraulic circuit diagrams.
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Braking System Details:
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Covers hydraulic footbrake, regenerative traction brake, and parking brake operation, maintenance, and adjustment.
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Procedures Included
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Operation:
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Mounting/dismounting, Driving (dual-pedal/single-pedal), Braking (regenerative, hydraulic, parking), Steering, Mast/reach frame control, Attachment operation (sideshift), Loading/unloading, Transporting, Hoisting, Side guidance, Height preselector system, Operator code entry, Truck Data Management.
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Maintenance:
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Daily checks, Safety inspections, Explosion protection checks, Fluid handling, Battery checks/charging/changing, Lubrication, Chain adjustment, Brake adjustment, Filter replacement, Sensor calibration, System checks (gas warning).
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Troubleshooting:
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Troubleshooting guide (hydraulic system), Electric circuit diagrams (standard and gas warning).
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Safety Procedures:
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Extensive safety rules, safety inspection protocols, explosion protection checks, and handling of fluids.
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Mechanical Repair:
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Includes procedures for wheel changes, mast removal, and securing components during maintenance.
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Transport And Storage:
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Instructions for slinging, towing, and transporting the truck on vehicles.
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Battery Management:
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Detailed instructions for checking charge, charging, and changing the battery, including different connection versions.
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Technical Depth
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Depth:
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Comprehensive, covering operation, basic maintenance, scheduled servicing, detailed inspection points, troubleshooting, and electrical schematics. Suitable for operators and maintenance personnel.
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Diagnostics Level:
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Includes basic troubleshooting through visual checks and indicator interpretation, supplemented by circuit diagrams for advanced diagnostics.
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Technology Features
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Infotainment
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Operator Display:
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Includes displays for hour meter, battery discharge, drive wheel position, motor brushes wear, overheating warnings, condition display, brake fluid level, service warning, parking brake warning, battery unlocked warning, slow speed indicator, gas warning system composite instrument.
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Driver Assistance
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Operator Interface:
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Multi-purpose display, operator code entry for logging on/off, supervisor menus, learner operation settings.
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Operator Feedback:
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Real-time indicators for system status, warnings, and operational parameters via the operator display.
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Connectivity
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Data Management:
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Truck Data Management (LFM) for data acquisition, condition codes, and special settings.
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Advanced Features
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Automation Aids:
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Height preselector system, side guidance for racking, 360° steering.
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Diagnostics
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Electrical Schematics:
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Includes Electric circuit diagrams for standard equipment and the Gas warning system.
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Maintenance
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Service Intervals
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Scheduled Inspections:
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After first 50 hours, 1000-hour, 2000-hour, 5000-hour, and 10000-hour or 5-year intervals.
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Fluid Specifications
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Lubricants And Fluids:
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Hydraulic oil, Multipurpose grease, Gear oil, General purpose oil, Chain Spray, Brake fluid. Specific grades typically detailed in 'Recommended Lubricants' section.
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Hydraulic Oil Type:
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Specific grade recommended in 'Recommended Lubricants' section (e.g., ISO VG 32 or similar).
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid typically specified.
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Gear Oil Type:
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Specific viscosity grade for steering drive gears.
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Known Issues
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Wear Components:
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Motor brushes, brake bands/shoes, hydraulic hoses, tyre condition, motor/battery connectors and cables.
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System Checks:
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Gas warning system sensors and calibration, leakage resistance of traction wheel, insulation.
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Component Replacement:
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Procedures for renewing/replacing hydraulic hoses, motor brushes, and filters are included.
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Tasks Included
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Daily:
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Checks for leakage, battery charge, general condition.
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Periodic:
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Lubrication of chains/mast/rollers, chain adjustment, motor brush replacement, hydraulic system checks/flushes, brake system checks/adjustments, sensor recalibration.
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Explosion Protection Maintenance:
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Specific checks and recalibrations for the gas warning system and sensors are detailed.
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