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SERVICE MANUAL
036-0410-07
C3E120
C4E120
C3E150
C4E150
C3E160
C4E160
C3E160L C4E160L
C3E180
C4E180
C3E180L C4E180L
C3E200
C4E200
04/2005

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Summarization of Contents

General Information
Technical Data
Detailed specifications and performance metrics for the truck model.
Capacity Diagrams
Visual representation of load capacity based on load center for different configurations.
Chassis Overview
Truck Layout and Operator Controls
Identification of main truck parts and operator interface elements like pedals and levers.
Dashboard Overview
Explanation of dashboard instruments, warning lights, and indicators for truck operation.
Lifting the Truck
Procedures and safety guidelines for lifting the forklift truck for maintenance or transport.
Motors and Engines
Electrical Motor Characteristics
Technical specifications for traction and lifting motors, including manufacturer and power ratings.
Electrical Motors Arrangement
Visual representation of the installed traction and lifting motors within the truck.
Transmission and Drive Gear
Reduction Gear View and Maintenance
Detailed diagram of the reduction gear and procedures for maintenance, including oil changes.
Brakes and Wheels System
Brake System Description
Explanation of the service brake system, including components and controls.
Standard Tyres and Tightening Torques
Information on tyre types, sizes, and required torque specifications for wheels and drive units.
Steering System
Steering Control and Hydraulics
Details on steering operation, hydraulic diagram, and pressure setting procedures.
Steering Axle Configurations
Specific checks and adjustments for 3-wheel and 4-wheel steering axle systems.
Electric and Electronic Systems
Battery and Charging Procedures
Guidelines for battery maintenance, charging warnings, and weight/capacity data.
Motor and Electronic Components
Characteristics of motors, encoders, and main electrical components like modules and fuses.
Control Consoles and Menus
Description of console functions, keyboard operations, and menu navigation for system setup.
Alarms and Troubleshooting
Comprehensive list of system alarms, error codes, and diagnostic procedures for fault finding.
Wiring Diagrams
Schematic diagrams illustrating the electrical connections and circuits of the truck system.
Hydraulic and Pneumatic Systems
Hydraulic Diagrams
Schematic diagrams of the hydraulic systems for control valve and joystick/fingertip versions.
Lifting and Tilting Performance
Tables detailing the performance specifications for lifting, tilting, and sideshift operations.
Oil and Filter Maintenance
Procedures for checking, changing hydraulic oil, and replacing the oil filter.
Mast Group Systems
Mast Groups and Sections Description
Description of mast profiles, cylinders, sideshift systems, and roller arrangements.
Lifting Cylinder Descriptions
Detailed diagrams and explanations of central, side, and telescopic lifting cylinders.
Fork Inspections and Adjustments
Procedures for checking mast chains, fork carriage positioning, and fork arm inspections.
Maintenance Tables
Oil and Grease Specifications
Table listing recommended oils and greases for various truck components and environments.
Maintenance Schedules
Tables outlining required maintenance tasks based on operating hours or time intervals.
Safety Information
Personal Protective Equipment and Workplace Safety
Guidelines on appropriate work attire and ensuring a safe working environment.
Vehicle Handling Safety
Precautions for lifting the truck and general safety during operations.
Electrical and Welding Safety
Safety measures for working with the electrical system, battery, and welding operations.

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