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BT Forklift Toyota VRE125, VRE150, VRE125SF Repair Manual – PDF DOWNLOAD
BT Forklift Toyota VRE125, VRE150, VRE125SF Repair Manual – PDF DOWNLOAD
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BT Forklift Toyota VRE125, VRE150, VRE125SF Repair Manual – PDF DOWNLOAD
Language : English
Pages : 1354
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
BT Forklift Toyota VRE125, VRE150, VRE125SF Repair Manual – PDF DOWNLOAD
1. Contents........................................................................................................................................................................0 2. General introduction............................................................................................................................................................0 2.1 How to use this manual.....................................................................................................................................................0 2.2 Warning levels and symbols.................................................................................................................................................0 2.3 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. Chassis C0000...................................................................................................................................................................0 4.1 Inspection covers C0340....................................................................................................................................................0 4.1.1 Motor hood...........................................................................................................................................................0 4.1.2 Battery inspection cover.............................................................................................................................................0 4.2 Battery compartment parts C0390............................................................................................................................................0 4.2.1 Battery locking mechanism............................................................................................................................................0 Simple battery locking.................................................................................................................................................0 Battery locking at battery changing equipment..........................................................................................................................0 4.2.2 Battery side plate (option)..........................................................................................................................................0 4.3 Operator's cab C0500.......................................................................................................................................................0 4.3.1 Versions for cold-store cabs.........................................................................................................................................0 Properties.............................................................................................................................................................0 Emergency exit from the cab............................................................................................................................................0 4.4 Cab windows C0530..........................................................................................................................................................0 4.4.1 Electrically heated windows (Option).................................................................................................................................0 Activation.............................................................................................................................................................0 4.5 Cab door C0550.............................................................................................................................................................0 Door handle on cab.........................................................................................................................................................0 4.6 Operator's seat C0620......................................................................................................................................................0 4.6.1 Seat switch [B49]....................................................................................................................................................0 4.7 Cab heating/ventilation C0630..............................................................................................................................................0 4.8 Driver controls (mechanical) C0640.........................................................................................................................................0 4.8.1 Preconditions........................................................................................................................................................0 4.8.2 Brake pedal..........................................................................................................................................................0 Monitoring.............................................................................................................................................................0 Indications in CID.....................................................................................................................................................0 4.8.3 Accelerator..........................................................................................................................................................0 Monitoring.............................................................................................................................................................0 Indications in CID.....................................................................................................................................................0 4.9 Mirrors C0740..............................................................................................................................................................0 4.9.1 Mirror types.........................................................................................................................................................0 4.10 Overhead guard/roof C0810.................................................................................................................................................0 4.10.1 Protective overhead guard...........................................................................................................................................0 4.10.2 Vertical E-bar......................................................................................................................................................0 4.11 Finger/foot guards C0820..................................................................................................................................................0 4.12 Operator protection C0840.................................................................................................................................................0 4.12.1 Studs...............................................................................................................................................................0 4.12.2 Protective grating..................................................................................................................................................0 4.13 Signs, warnings, labels C0850.............................................................................................................................................0 5. Motors C1000....................................................................................................................................................................0 5.0.1 Electric pump motor C1710 Description....................................................................................................................................0 5.1............................................................................................................................................................................0 5.1.1 Description..........................................................................................................................................................0 5.1.2 Removing the pump motor..............................................................................................................................................0 5.1.3 Fitting the pump motor...............................................................................................................................................0 5.1.4 Replacing the temperature sensor.....................................................................................................................................0 5.1.5 Replacing the speed sensor...........................................................................................................................................0 5.1.6 Cleaning.............................................................................................................................................................0 5.1.7 Replacing the oil pump...............................................................................................................................................0 5.1.8 Replacing the bearing................................................................................................................................................0 5.1.9 Electric steering motor C1730 (steering servo assembly) Description..................................................................................................0 5.1.10 Description.........................................................................................................................................................0 5.1.11 Layout of the flange holes..........................................................................................................................................0 5.1.12 View from the underside of the steering motor: a: Attachment, b: Guide, c: Threaded hole for removing steering motor, M10×1,5.Replacing the steering servo motor....0 5.1.13 Electric fan motor/fan C1740 Description............................................................................................................................0 5.1.14 Description.........................................................................................................................................................0 5.1.15 Indications in CID..................................................................................................................................................0 5.1.16 Replacing the frequency converter fan...............................................................................................................................0 Method.................................................................................................................................................................0 5.1.17 Replacing the motor compartment fan.................................................................................................................................0 5.1.18 Electric drive motor C1760 Replacing the frequency converter fan....................................................................................................0 Method.................................................................................................................................................................0 5.1.19 Replacing the motor compartment fan.................................................................................................................................0 5.2............................................................................................................................................................................0 5.2.1 Description..........................................................................................................................................................0 5.2.2 Removing the drive motor.............................................................................................................................................0 5.2.3 Fitting the drive motor..............................................................................................................................................0 5.2.4 Replacing the temperature sensor.....................................................................................................................................0 5.2.5 Replacing the speed sensor...........................................................................................................................................0 5.2.6 Disassembly..........................................................................................................................................................0 5.2.7 Cleaning.............................................................................................................................................................0 5.2.8 Replacing the bearing................................................................................................................................................0 5.2.9 Assembly.............................................................................................................................................................0 6. Drive gear C2000................................................................................................................................................................0 6.1 Drive/Transmission Assembly................................................................................................................................................0 6.1.1 Overview.............................................................................................................................................................0 6.2 Description - Drive gear C2000.............................................................................................................................................0 6.2.1 Oil change...........................................................................................................................................................0 6.2.2 Leakage from the lower cover.........................................................................................................................................0 6.2.3 Checking the oil level...............................................................................................................................................0 6.2.4 Removing the drive gear..............................................................................................................................................0 6.2.5 Steering bearing.....................................................................................................................................................0 Replacing the steering bearing.........................................................................................................................................0 6.2.6 Mounting the drive gear..............................................................................................................................................0 7. Brake system/Wheels C3000.......................................................................................................................................................0 7.1 Brake system C3100.........................................................................................................................................................0 7.1.1 Description..........................................................................................................................................................0 Travel brake...........................................................................................................................................................0 Parking brake..........................................................................................................................................................0 Emergency brake........................................................................................................................................................0 7.1.2 Drive motor brake C3180..............................................................................................................................................0 Accelerator released...................................................................................................................................................0 Changing the direction of travel.......................................................................................................................................0 7.2 Support arm brake C3180....................................................................................................................................................0 7.2.1 Overview.............................................................................................................................................................0 7.2.2 Support arm brake (option) C3180.....................................................................................................................................0 7.2.3 Test of support arm brake function...................................................................................................................................0 Access.................................................................................................................................................................0 Table for reading the maximum braking distance.........................................................................................................................0 7.2.4 Support arm brake replacement........................................................................................................................................0 7.2.5 Checking the brake unit's air gap....................................................................................................................................0 7.2.6 Check of discs' thickness............................................................................................................................................0 7.2.7 Assembling the brake unit............................................................................................................................................0 7.2.8 Adjusting the air gap................................................................................................................................................0 7.3 Parking brake C3370........................................................................................................................................................0 7.3.1 Overview.............................................................................................................................................................0 7.3.2 Description - Parking brake C3370....................................................................................................................................0 7.3.3 Checking the parking brake's brake force.............................................................................................................................0 7.3.4 Checking the parking brake air gap...................................................................................................................................0 7.3.5 Replacing the brake unit.............................................................................................................................................0 7.3.6 Disassembly and inspection of wear...................................................................................................................................0 7.4 Emergency brake release....................................................................................................................................................0 7.4.1 Releasing the brake in case of a faulty parking brake unit...........................................................................................................0 7.4.2 Releasing the brake when the parking brake unit is intact............................................................................................................0 7.5 Wheels C3500...............................................................................................................................................................0 7.6 Drive wheel C3530..........................................................................................................................................................0 7.6.1 Overview.............................................................................................................................................................0 7.6.2 Replacing the drive wheel............................................................................................................................................0 7.6.3 Wheel stud replacement...............................................................................................................................................0 7.6.4 Support arm wheel C3550..............................................................................................................................................0 7.7 Support arm wheel C3550....................................................................................................................................................0 7.7.1 Overview.............................................................................................................................................................0 VRE TH, unbraked wheel.................................................................................................................................................0 VRE TH, braked wheel...................................................................................................................................................0 VRE SF, unbraked wheel.................................................................................................................................................0 7.7.2 Removing the support arm wheel, TH...................................................................................................................................0 7.7.3 Mounting the support arm wheel, TH...................................................................................................................................0 7.7.4 Removing the support arm wheel, TH...................................................................................................................................0 7.7.5 Mounting the support arm wheel, TH...................................................................................................................................0 7.7.6 Bearing replacement..................................................................................................................................................0 7.8 Side guide wheel C3580 (option)............................................................................................................................................0 7.8.1 Overview.............................................................................................................................................................0 7.8.2 Description..........................................................................................................................................................0 7.8.3 Replacing the side guide wheels (High profile).......................................................................................................................0 Dismantling............................................................................................................................................................0 Fitting................................................................................................................................................................0 7.8.4 Adjusting the side guide wheels (High profile).......................................................................................................................0 7.8.5 Replacing the side guide wheels (Low profile)........................................................................................................................0 Dismantling............................................................................................................................................................0 Assembly...............................................................................................................................................................0 7.8.6 Adjusting the side guide wheels (Low profile)........................................................................................................................0 8. Steering system C4000...........................................................................................................................................................0 8.1 Electric steering wheel C4310..............................................................................................................................................0 8.2 Steering unit C4330........................................................................................................................................................0 8.3 Steering angle reference sensor C4350......................................................................................................................................0 8.4 Steering bearing C4380.....................................................................................................................................................0 8.5 Wire guidance C4510........................................................................................................................................................0 8.5.1 Description..........................................................................................................................................................0 Wire signal/Antenna coils..............................................................................................................................................0 8.5.2 Operating modes......................................................................................................................................................0 8.6 Rail guidance C4510........................................................................................................................................................0 8.6.1 Description..........................................................................................................................................................0 8.6.2 Operating modes......................................................................................................................................................0 8.7 Wire guidance, antenna C4540...............................................................................................................................................0 9. Electrical system C5000.........................................................................................................................................................0 9.1 Battery C5110..............................................................................................................................................................0 9.1.1 Battery recommendations..............................................................................................................................................0 9.1.2 Measuring discharge current..........................................................................................................................................0 9.1.3 Measuring voltage....................................................................................................................................................0 9.1.4 Charging the battery.................................................................................................................................................0 9.1.5 BDI algorithm and parameter setting..................................................................................................................................0 9.1.6 Performance limitations due to battery status........................................................................................................................0 9.1.7 Performance limitations due to battery status and parameter setting..................................................................................................0 9.1.8 CID symbol...........................................................................................................................................................0 9.1.9 Resetting the battery indicator (BDI)................................................................................................................................0 9.1.10 Battery weight......................................................................................................................................................0 9.1.11 Parameter overview, battery.........................................................................................................................................0 9.2 General alarm signals (audible/visual) C5160...............................................................................................................................0 9.2.1 Horn [P4]............................................................................................................................................................0 9.3 Main contactor [Q10] C5190.................................................................................................................................................0 9.4 Instrument panel C5200.....................................................................................................................................................0 9.4.1 Operating controls...................................................................................................................................................0 Adjustment.............................................................................................................................................................0 Single-function control................................................................................................................................................0 Central Information Display (CID)......................................................................................................................................0 LED symbols............................................................................................................................................................0 Screen.................................................................................................................................................................0 Calibration functions..................................................................................................................................................0 9.4.2 Load Information Display – LID.......................................................................................................................................0 Technical data.........................................................................................................................................................0 Connections............................................................................................................................................................0 LED symbols............................................................................................................................................................0 When the truck travels in the emergency travel mode, all symbols blink at the same time................................................................................0 Symbols in the display part............................................................................................................................................0 9.5 Weighing system............................................................................................................................................................0 9.6 Overload limit.............................................................................................................................................................0 9.7 Height measurement system..................................................................................................................................................0 9.7.1 Monitoring...........................................................................................................................................................0 9.8 Height preselector (Option)................................................................................................................................................0 9.8.1 Symbols..............................................................................................................................................................0 9.8.2 Travel warning.......................................................................................................................................................0 9.8.3 Height preselector levels............................................................................................................................................0 9.8.4 Level selection......................................................................................................................................................0 9.8.5 Using the height preselector.........................................................................................................................................0 Aisle and level selection..............................................................................................................................................0 Presets................................................................................................................................................................0 9.8.6 Program the level....................................................................................................................................................0 9.8.7 Deleting a level.....................................................................................................................................................0 9.8.8 Height preselector and TruckCom......................................................................................................................................0 9.8.9 Lifting/lowering movement............................................................................................................................................0 Parameter settings, lift/lowering movement.............................................................................................................................0 9.8.10 Parameter overview, height preselector..............................................................................................................................0 9.9 Transistor panel C5460.....................................................................................................................................................0 9.10 Work function harnesses/fuse C5590........................................................................................................................................0 9.10.1 Fuse panel – FCM [A9]...............................................................................................................................................0 Fuse panel overview....................................................................................................................................................0 Fuses..................................................................................................................................................................0 [K20] Key relay........................................................................................................................................................0 [S133] Emergency brake release.........................................................................................................................................0 9.11 Main processor – MCU C5710................................................................................................................................................0 9.12 Fork control unit – FCU C5720.............................................................................................................................................0 9.12.1 Hydraulic functions.................................................................................................................................................0 Turret head fork unit..................................................................................................................................................0 Telescopic fork unit...................................................................................................................................................0 Common and other functions.............................................................................................................................................0 9.13 Expansion unit – GFU C5730................................................................................................................................................0 9.14 Sending units and sensors C5800...........................................................................................................................................0 9.14.1 Inductive sensors...................................................................................................................................................0 9.14.2 Position sensor.....................................................................................................................................................0 Steering reference sensor..............................................................................................................................................0 9.14.3 Pressure sensor.....................................................................................................................................................0 9.14.4 Pulse transducer....................................................................................................................................................0 Steering sensor........................................................................................................................................................0 Traversing sensor......................................................................................................................................................0 9.14.5 Angle sensor........................................................................................................................................................0 9.15 Safety probes/sensors C5830...............................................................................................................................................0 9.15.1 Safety pedal [B31]..................................................................................................................................................0 Indications in CID.....................................................................................................................................................0 9.15.2 Safety switch, door [B31]...........................................................................................................................................0 Location...............................................................................................................................................................0 Task and function......................................................................................................................................................0 Indications in CID.....................................................................................................................................................0 9.15.3 Emergency switch off [S21]..........................................................................................................................................0 9.16 Narrow aisle sensor C5840.................................................................................................................................................0 9.16.1 Magnet sensor.......................................................................................................................................................0 9.16.2 Photocell...........................................................................................................................................................0 9.16.3 Narrow aisle detection..............................................................................................................................................0 [B110] and [B111] – Magnet sensor......................................................................................................................................0 Power supply...........................................................................................................................................................0 Magnet detection.......................................................................................................................................................0 [B111] and [B115] – Photocells.........................................................................................................................................0 9.16.4 [B112]/[B113] End of aisle retardation..............................................................................................................................0 Power supply...........................................................................................................................................................0 Magnet detection.......................................................................................................................................................0 9.16.5 [B116] and [B117] End of aisle stop.................................................................................................................................0 Photocell..............................................................................................................................................................0 Power supply...........................................................................................................................................................0 Status – MCU inputs....................................................................................................................................................0 9.16.6 [B172] – [B174] Aisle ID............................................................................................................................................0 Photocell..............................................................................................................................................................0 Power supply...........................................................................................................................................................0 Status – GFU inputs....................................................................................................................................................0 10. Hydraulic system C6000.........................................................................................................................................................0 10.1 Hydraulic unit C6100......................................................................................................................................................0 10.1.1 Tank C6110..........................................................................................................................................................0 10.1.2 Filter C6130........................................................................................................................................................0 10.1.3 Hydraulic pump C6140................................................................................................................................................0 10.2 Main valve unit C6210.....................................................................................................................................................0 10.2.1 Definitions.........................................................................................................................................................0 10.2.2 Valve unit design, DX...............................................................................................................................................0 Inserts for quick change connector.....................................................................................................................................0 Lift function..........................................................................................................................................................0 Regenerative lowering function.........................................................................................................................................0 Pressure limitation....................................................................................................................................................0 Manual lowering function...............................................................................................................................................0 10.2.3 Valve unit design, TX...............................................................................................................................................0 Inserts for quick change connector.....................................................................................................................................0 Lift function..........................................................................................................................................................0 Regenerative lowering function (TX)....................................................................................................................................0 The pump rotates clockwise and the rpm determines the speed of the function............................................................................................0 Pressure limitation....................................................................................................................................................0 Manual lowering function...............................................................................................................................................0 10.2.4 Pressure sensor.....................................................................................................................................................0 10.3 Mast valve units C6310....................................................................................................................................................0 10.3.1 Valve unit design, SF...............................................................................................................................................0 Inserts for quick change connector.....................................................................................................................................0 Traversing.............................................................................................................................................................0 Pressure limitation....................................................................................................................................................0 10.3.2 Valve unit design, fork valve unit without extra functions..........................................................................................................0 Inserts for quick change connector.....................................................................................................................................0 Shunt function.........................................................................................................................................................0 10.3.3 Valve unit design, fork valve unit with extra functions with load holding...........................................................................................0 Inserts for quick change connector.....................................................................................................................................0 10.3.4 Valve unit design, fork valve unit with extra functions without load holding........................................................................................0 10.4 Calibration of proportional valves........................................................................................................................................0 10.5 Hydraulic cylinders C6600.................................................................................................................................................0 10.5.1 Main lift C6610.....................................................................................................................................................0 Bleeding the main lift cylinders.......................................................................................................................................0 10.5.2 Free lift C6620.....................................................................................................................................................0 10.5.3 Tilt (Option) C6660.................................................................................................................................................0 10.5.4 Other hydraulic cylinders C6670.....................................................................................................................................0 Rotation...............................................................................................................................................................0 Fork spread (Option)...................................................................................................................................................0 10.6 Filtering the hydraulic oil...............................................................................................................................................0 10.7 Pressure relief...........................................................................................................................................................0 11. Mast C7000.....................................................................................................................................................................0 11.1 Disassembling the mast....................................................................................................................................................0 11.2 Assembling the mast.......................................................................................................................................................0 12. Peripherals C8000..............................................................................................................................................................0 12.1 Magnet layout.............................................................................................................................................................0 12.1.1 Overview............................................................................................................................................................0 12.1.2 Function............................................................................................................................................................0 Rail guidance..........................................................................................................................................................0 Wire guidance..........................................................................................................................................................0 12.1.3 Alternative layout..................................................................................................................................................0 12.2 Photocell layout..........................................................................................................................................................0 12.2.1 “In narrow aisle”...................................................................................................................................................0 12.2.2 Aisle ID............................................................................................................................................................0 12.2.3 End of aisle stop...................................................................................................................................................0 13. Options/Extra equipment C9000..................................................................................................................................................0 13.1 Extra electrical equipment C9300..........................................................................................................................................0 13.1.1 Personal Protection System (PPS)....................................................................................................................................0 General................................................................................................................................................................0 Installation...........................................................................................................................................................0 Service and spare parts................................................................................................................................................0 Operator environment...................................................................................................................................................0 Connections............................................................................................................................................................0 13.2 Radio equipment C9330.....................................................................................................................................................0 13.3 Extra lighting C9360......................................................................................................................................................0 13.4 Extra warning lights/alarm C9370..........................................................................................................................................0 13.4.1 Travel alarm 1 – Buzzer.............................................................................................................................................0 13.4.2 Travel alarm 2 – Warning lamp.......................................................................................................................................0 13.4.3 Direction indicators................................................................................................................................................0 13.5 Positioning/TV equipment C9390............................................................................................................................................0 13.6 Extra electrical equipment C9400..........................................................................................................................................0 13.6.1 Extra power socket..................................................................................................................................................0 13.6.2 Longitudinal positioning lamp.......................................................................................................................................0 13.7 Truck log equipment, code lock C9420......................................................................................................................................0 13.7.1 Toyota Wireless Information System (T.W.I.S.).......................................................................................................................0 13.8 Other extra equipment C9500...............................................................................................................................................0 13.8.1 Horizontal E-bar....................................................................................................................................................0 13.8.2 Fire extinguisher...................................................................................................................................................0 14. Operation and connection sequences.............................................................................................................................................0 14.1 Battery is connected......................................................................................................................................................0 1. Battery is connected....................................................................................................................................................0 2a. Login via unit connected to the MCU....................................................................................................................................0 2b. Login via keypad.......................................................................................................................................................0 2c. Login via “ID key” option..............................................................................................................................................0 2d. Login to emergency driving mode........................................................................................................................................0 3. Basic conditions........................................................................................................................................................0 4. Driving in fork direction...............................................................................................................................................0 5. Driving in the drive wheel direction....................................................................................................................................0 6. Braking in neutral......................................................................................................................................................0 7. Reverse braking.........................................................................................................................................................0 8. Automatic braking.......................................................................................................................................................0 9. Depressing the brake pedal..............................................................................................................................................0 10. Manual control.........................................................................................................................................................0 11. Wire search............................................................................................................................................................0 13. In rail-guided narrow aisle............................................................................................................................................0 14. Fork lifting...........................................................................................................................................................0 15. Fork lowering..........................................................................................................................................................0 16. Traversing to the right................................................................................................................................................0 17.Traversing, left........................................................................................................................................................0 18. Clockwise rotation.....................................................................................................................................................0 19. Anticlockwise rotation.................................................................................................................................................0 20. Auto-rotation, traversing to the left/clockwise rotation...............................................................................................................0 21. Auto-rotation, traversing right/anticlockwise rotation.................................................................................................................0 22. Traversing right (SF)..................................................................................................................................................0 23. Traversing left (SF)...................................................................................................................................................0 24. Extra hydraulic function <TBD>.........................................................................................................................................0 25. Logout.................................................................................................................................................................0 26. Emergency lowering.....................................................................................................................................................0 15. Parameters.....................................................................................................................................................................0 15.1 General...................................................................................................................................................................0 15.2 Parameter settings........................................................................................................................................................0 15.2.1 Operator parameters.................................................................................................................................................0 Access.................................................................................................................................................................0 Parameter screens......................................................................................................................................................0 15.2.2 Parameter menu (PAR)................................................................................................................................................0 Access.................................................................................................................................................................0 Parameter screens......................................................................................................................................................0 15.3 Operator parameters.......................................................................................................................................................0 15.3.1 Overview............................................................................................................................................................0 15.3.2 Connection to logged-in operator....................................................................................................................................0 15.3.3 Description.........................................................................................................................................................0 Parameter 1 – Steering.................................................................................................................................................0 Parameter 2, 3 6 and 7 – Maximum travel speed..........................................................................................................................0 Parameters 4 and 5 – Acceleration/Deceleration.........................................................................................................................0 15.4 General service parameters................................................................................................................................................0 15.4.1 Overview............................................................................................................................................................0 15.4.2 Description.........................................................................................................................................................0 Parameter 101/104 – Service/Log-out....................................................................................................................................0 Parameter 105/106/114/115/117/118/119 (Travel alarms 1 and 2)..........................................................................................................0 Parameter 107/108/113 – Battery........................................................................................................................................0 Parameter 109/110/111/112 – Collision sensor...........................................................................................................................0 Parameter 116 (Door on cold store cabs)................................................................................................................................0 15.5 Service parameters, travel functions......................................................................................................................................0 15.5.1 Overview............................................................................................................................................................0 15.5.2 Description.........................................................................................................................................................0 Parameter 201 – Retardation when reversing.............................................................................................................................0 Parameter 202/203/204 – Adjusting condition-related maximum travel speeds..............................................................................................0 Parameters 205/206/207 – Adjusting function-related, maximum travel speeds.............................................................................................0 Parameter 208 - Creep speed in travel direction control................................................................................................................0 Parameter 209/210 – Adjustment of maximum travel speed above a certain lift height.....................................................................................0 Parameters 211/212/213/214/215/216 – Adjusting application-related, maximum travel speeds..............................................................................0 15.6 Service parameters, hydraulics............................................................................................................................................0 15.6.1 Overview............................................................................................................................................................0 15.6.2 Description.........................................................................................................................................................0 Parameter 341/342 – Adjustment of application related, maximum lift/ lowering speeds...................................................................................0 Parameter 343 – Oil filtration.........................................................................................................................................0 Parameter 344 - Reduction of fork lowering speed before floor level....................................................................................................0 Parameter 347/348 – Prevent the lifting/lowering of forks..............................................................................................................0 Parameter 350 – Hydraulic function priority............................................................................................................................0 Parameter 356 – Limitation of maximum travel speed under certain lift height with load on forks........................................................................0 Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds................................................................................0 Parameter 367/368 – Lowering height limitation.........................................................................................................................0 Parameter 369 – Fork height for limitation of lifting speed, forks not in home position................................................................................0 Parameter 371 through 379 – Height preselector.........................................................................................................................0 Parameter 380 through 386 – Lift height limitations in aisle...........................................................................................................0 Parameters 387 through 394 – Configuration of lift height limitations..................................................................................................0 Parameter 354/355 – Configuration of lift height limitations outside of aisle..........................................................................................0 Parameters 395/396/397 – Function-related, maximum lift heights........................................................................................................0 Parameters 398/399 – Operator profile dependent, maximum lift heights..................................................................................................0 15.7 Service parameters, CID...................................................................................................................................................0 15.7.1 Overview............................................................................................................................................................0 15.7.2 Description.........................................................................................................................................................0 Parameter 503 – Login method...........................................................................................................................................0 Parameters 504/505/506/507 – Smart Access..............................................................................................................................0 Parameter 508/509/512/513 – CID configuration..........................................................................................................................0 Parameters 510/511 – Height pre-selection..............................................................................................................................0 15.8 Service parameters, VNA...................................................................................................................................................0 15.8.1 Overview............................................................................................................................................................0 15.8.2 Description.........................................................................................................................................................0 Parameters 601/602/603/604/605 – Truck over wire.......................................................................................................................0 Parameter 606 – Wire guidance frequency................................................................................................................................0 Parameters 607/608/609/610 – Speed reduction and stop at aisle ends....................................................................................................0 15.9 Service parameters, FCU...................................................................................................................................................0 15.9.1 Overview............................................................................................................................................................0 15.9.2 Description.........................................................................................................................................................0 Parameter 751 – Stroke length for half pallets.........................................................................................................................0 Parameters 752/755/758 – Adjusting application dependent, maximum fork unit speeds.....................................................................................0 Parameters 753/754/756/757 Acceleration/deceleration distance, fork unit functions.....................................................................................0 Parameters 760/761/762/763 – Extra hydraulic functions.................................................................................................................0 Parameter 764/765/766 – Reversed direction, fork unit functions........................................................................................................0 15.10 General factory parameters...............................................................................................................................................0 15.10.1 Overview...........................................................................................................................................................0 15.10.2 Description........................................................................................................................................................0 Parameters 1001/1003/1007/1008/1011/1070/1071/1072/1078/1080/1081/ 1082/1083 – General factory parameters with several choices.........................................0 Parameter 1011 – Rated weight..........................................................................................................................................0 Parameter 1072 – Boom length...........................................................................................................................................0 Parameter 1078 – Camera switch.........................................................................................................................................0 Parameter 1080 – Operating controls....................................................................................................................................0 Parameter 1081 – Fork unit weight......................................................................................................................................0 Parameter 1083 – Fork valve unit type..................................................................................................................................0 15.11 Factory parameters, narrow aisle.........................................................................................................................................0 15.11.1 Overview...........................................................................................................................................................0 15.11.2 Description........................................................................................................................................................0 Parameter 1020 – Distance between wire guidance antennas...............................................................................................................0 Parameter 1021 – Aisle indication, wire guidance.......................................................................................................................0 Parameter 1022 – Aisle indication, rail guidance.......................................................................................................................0 Parameter 1023 – support for RFID (TNS)................................................................................................................................0 Parameter 1024 – Aisle layout..........................................................................................................................................0 Parameter 1025 – Sensor direction......................................................................................................................................0 15.12 Factory parameters, activation of options................................................................................................................................0 15.12.1 Overview...........................................................................................................................................................0 15.12.2 Description........................................................................................................................................................0 15.13 Factory parameters, calibration..........................................................................................................................................0 Hydraulic system...........................................................................................................................................................0 16. Installation...................................................................................................................................................................0 16.1 Transporting the truck....................................................................................................................................................0 16.2 Transporting the mast.....................................................................................................................................................0 16.3 Safe lifting..............................................................................................................................................................0 16.4 Commissioning.............................................................................................................................................................0 16.4.1 Common steps for both rail and wire guidance........................................................................................................................0 Method.................................................................................................................................................................0 16.4.2 Rail guidance.......................................................................................................................................................0 16.4.3 Wire guidance.......................................................................................................................................................0 16.4.4 Parameter setting...................................................................................................................................................0 Setting battery parameters.............................................................................................................................................0 Setting maximum travel speed...........................................................................................................................................0 General................................................................................................................................................................0 16.4.5 Configuration.......................................................................................................................................................0 Calendar...............................................................................................................................................................0 PIN-code handling......................................................................................................................................................0 16.4.6 Test driving and checks.............................................................................................................................................0 Functions..............................................................................................................................................................0 In narrow aisle........................................................................................................................................................0 18. Maintenance....................................................................................................................................................................0 18.1 Introduction..............................................................................................................................................................0 18.2 Safety precautions for maintenance work...................................................................................................................................0 18.3 Maintenance instructions..................................................................................................................................................0 18.3.1 Cleaning and washing................................................................................................................................................0 18.3.2 High-pressure washers...............................................................................................................................................0 18.3.3 Degreasing agents...................................................................................................................................................0 18.3.4 Cleaning the exterior...............................................................................................................................................0 18.3.5 Cleaning the chain..................................................................................................................................................0 18.3.6 Cleaning the motor compartment......................................................................................................................................0 18.3.7 Electric components.................................................................................................................................................0 18.4 Lubricants specification..................................................................................................................................................0 18.5 Symbols...................................................................................................................................................................0 18.6 Safety checks.............................................................................................................................................................0 18.7 Periodic maintenance......................................................................................................................................................0 18.7.1 Every 500 operating hours/180 days..................................................................................................................................0 18.7.2 Every 1000 operating hours/360 days.................................................................................................................................0 18.7.3 Every 2000 operating hours/720 days.................................................................................................................................0 18.7.4 Every 3000 operating hours/1080 days................................................................................................................................0 18. Troubleshooting................................................................................................................................................................0 18.1 Auxiliary functions.......................................................................................................................................................0 18.1.1 Error log menu......................................................................................................................................................0 Description............................................................................................................................................................0 Access.................................................................................................................................................................0 18.1.2 Error information menu..............................................................................................................................................0 Description............................................................................................................................................................0 Access.................................................................................................................................................................0 18.1.3 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 7 – FCU.........................................................................................................................................................0 Screen 8 – FCU.........................................................................................................................................................0 Screen 9 – GFU digital inputs/outputs..................................................................................................................................0 Screen 11 – Temperatures...............................................................................................................................................0 Screen 12 – Voltages...................................................................................................................................................0 Screen 13 – travel function............................................................................................................................................0 Screen 14 – Steering function..........................................................................................................................................0 Screen 15 – Hydraulic functions 1......................................................................................................................................0 Screen 17 – Hydraulic information......................................................................................................................................0 Screen 18 – VNA functions..............................................................................................................................................0 Screen 19 – Pressure sensor............................................................................................................................................0 18.2 Initial troubleshooting...................................................................................................................................................0 18.3 Troubleshooting using a blocking symbol...................................................................................................................................0 18.4 Troubleshooting using error codes.........................................................................................................................................0 18.4.1 CID – Group 1.......................................................................................................................................................0 18.4.2 MCU – Group 2.......................................................................................................................................................0 18.4.3 Drive system – Group 3..............................................................................................................................................0 18.4.4 Hydraulic system – Group 4..........................................................................................................................................0 18.4.5 Steering system – Group 5...........................................................................................................................................0 18.4.6 Narrow aisle equipment – Group 6....................................................................................................................................0 18.4.7 FCU – Group 7.......................................................................................................................................................0 18.4.8 GFU – Group 8.......................................................................................................................................................0 18.5 Troubleshooting without an error code.....................................................................................................................................0 19. Chassis C0000..................................................................................................................................................................0 19.1 Hatches, covers C0340.....................................................................................................................................................0 19.1.1 Open/close motor cover..............................................................................................................................................0 19.1.2 Replacing the motor cover...........................................................................................................................................0 19.1.3 Adjusting the motor cover...........................................................................................................................................0 19.1.4 Remove/fit the floor................................................................................................................................................0 19.2 Installing counterbalance C0370...........................................................................................................................................0 Method.....................................................................................................................................................................0 19.3 Cab windows C0530.........................................................................................................................................................0 19.3.1 Fitting a window....................................................................................................................................................0 19.3.2 Electrically heated windows (Option)................................................................................................................................0 Activation of the function.............................................................................................................................................0 19.4 Cab door C0550............................................................................................................................................................0 19.4.1 Disassembly of the door lock........................................................................................................................................0 19.4.2 Disassembly of the lock device......................................................................................................................................0 19.5 Operator's seat C0620.....................................................................................................................................................0 19.5.1 Adjustment:.........................................................................................................................................................0 Seat heater button (Option)............................................................................................................................................0 19.5.2 Replacing the seat assembly.........................................................................................................................................0 19.5.3 Replacing the seat switch...........................................................................................................................................0 19.5.4 Replacing the back rest.............................................................................................................................................0 19.5.5 Replacing the chair seat............................................................................................................................................0 19.5.6 Replacing the seat heater switch....................................................................................................................................0 19.5.7 Installing the safety belt/armrest (Option).........................................................................................................................0 19.6 Cab heating/ventilation C0630.............................................................................................................................................0 19.6.1 Replacing the air filter on the cold store cab......................................................................................................................0 19.6.2 Replacement of wiring harness with potentiometer....................................................................................................................0 19.6.3 Replacing the air outlet............................................................................................................................................0 19.6.4 Climate control knobs...............................................................................................................................................0 19.7 Operator controls (mechanical) C0640......................................................................................................................................0 19.7.1 Replacing pedals....................................................................................................................................................0 19.8 Overhead guard/roof C0810.................................................................................................................................................0 19.8.1 Overview............................................................................................................................................................0 19.8.2 Removing the overhead guard.........................................................................................................................................0 19.8.3 Fastening the overhead guard........................................................................................................................................0 19.8.4 Removing the roof cassette..........................................................................................................................................0 19.8.5 Fastening the roof cassette.........................................................................................................................................0 19.9 Finger/foot guards C0820..................................................................................................................................................0 19.9.1 Replacing a figure guard............................................................................................................................................0 19.10 Operator protection C0840................................................................................................................................................0 19.10.1 Replacing the fender...............................................................................................................................................0 19.10.2 Adjusting tilt stops...............................................................................................................................................0 20. Motors C1000...................................................................................................................................................................0 20.1 Electric pump motor C1710.................................................................................................................................................0 20.1.1 Overview............................................................................................................................................................0 20.1.2 Removing the pump motor.............................................................................................................................................0 20.1.3 Fitting the pump motor..............................................................................................................................................0 20.1.4 Replacing the temperature sensor....................................................................................................................................0 20.1.5 Replacing the speed sensor..........................................................................................................................................0 20.1.6 Cleaning............................................................................................................................................................0 20.1.7 Replacing the RPM-sensor............................................................................................................................................0 20.1.8 Replacing the bearing...............................................................................................................................................0 20.2 Electric steering motor C1730.............................................................................................................................................0 20.2.1 Overview............................................................................................................................................................0 20.2.2 Replacing the steering servo motor..................................................................................................................................0 20.3 Electric fan motor/fan C1740..............................................................................................................................................0 20.3.1 Overview............................................................................................................................................................0 20.3.2 Replacing the frequency converter fan...............................................................................................................................0 Method.................................................................................................................................................................0 20.3.3 Replacing the motor compartment fan.................................................................................................................................0 20.4 Electric drive motor C1760................................................................................................................................................0 20.4.1 Overview............................................................................................................................................................0 20.4.2 Removing the drive motor............................................................................................................................................0 20.4.3 Fitting the drive motor.............................................................................................................................................0 20.4.4 Replacing the temperature sensor....................................................................................................................................0 20.4.5 Replacing the speed sensor..........................................................................................................................................0 20.4.6 Disassembly.........................................................................................................................................................0 20.4.7 Cleaning............................................................................................................................................................0 20.4.8 Replacing the bearing...............................................................................................................................................0 20.4.9 Assembly............................................................................................................................................................0 21. Drive gear C2000...............................................................................................................................................................0 21.1 Drive/Transmission Assembly...............................................................................................................................................0 21.1.1 Overview............................................................................................................................................................0 21.1.2 Oil change..........................................................................................................................................................0 21.1.3 Leakage from the lower cover........................................................................................................................................0 21.1.4 Checking the oil level..............................................................................................................................................0 21.1.5 Removing the drive gear.............................................................................................................................................0 21.1.6 Steering bearing....................................................................................................................................................0 Replacing the steering bearing.........................................................................................................................................0 21.1.7 Mounting the drive gear.............................................................................................................................................0 22. Brake system/Wheels C3000......................................................................................................................................................0 22.1 Support arm brake C3180...................................................................................................................................................0 22.1.1 Overview............................................................................................................................................................0 22.1.2 Test of support arm brake function..................................................................................................................................0 Access.................................................................................................................................................................0 Table for reading the maximum braking distance.........................................................................................................................0 22.1.3 Support arm brake replacement.......................................................................................................................................0 22.1.4 Checking the brake unit's air gap...................................................................................................................................0 22.1.5 Check of discs' thickness...........................................................................................................................................0 22.1.6 Assembling the brake unit...........................................................................................................................................0 22.1.7 Adjusting the air gap...............................................................................................................................................0 22.2 Parking brake C3370.......................................................................................................................................................0 22.2.1 Overview............................................................................................................................................................0 22.2.2 Checking the parking brake's brake force............................................................................................................................0 22.2.3 Checking the parking brake air gap..................................................................................................................................0 22.2.4 Replacing the brake unit............................................................................................................................................0 22.2.5 Disassembly and inspection of wear..................................................................................................................................0 22.3 Emergency brake release...................................................................................................................................................0 22.3.1 Releasing the brake in case of a faulty parking brake unit..........................................................................................................0 22.3.2 Releasing the brake when the parking brake unit is intact...........................................................................................................0 22.4 Wheels C3500..............................................................................................................................................................0 22.5 Drive wheel C3530.........................................................................................................................................................0 22.5.1 Overview............................................................................................................................................................0 22.5.2 Replacing the drive wheel...........................................................................................................................................0 22.5.3 Wheel stud replacement..............................................................................................................................................0 22.6 Support arm wheel C3550...................................................................................................................................................0 22.6.1 Overview............................................................................................................................................................0 VRE TH, unbraked wheel.................................................................................................................................................0 VRE TH, braked wheel...................................................................................................................................................0 VRE SF, unbraked wheel.................................................................................................................................................0 22.6.2 Removing the support arm wheel, TH..................................................................................................................................0 22.6.3 Mounting the support arm wheel, TH..................................................................................................................................0 22.6.4 Removing the support arm wheel, TH..................................................................................................................................0 22.6.5 Mounting the support arm wheel, TH..................................................................................................................................0 22.6.6 Bearing replacement.................................................................................................................................................0 22.7 Side guide wheel C3580 (option)...........................................................................................................................................0 22.7.1 Overview............................................................................................................................................................0 22.7.2 Removing the side guide wheels......................................................................................................................................0 22.7.3 Mounting the side guide wheels......................................................................................................................................0 22.7.4 Replacing the bracket...............................................................................................................................................0 22.7.5 Adjusting the side guide wheels.....................................................................................................................................0 23. Steering system C4000..........................................................................................................................................................0 23.1 Electric steering wheel C4310.............................................................................................................................................0 23.1.1 Replacing the steering wheel........................................................................................................................................0 23.1.2 Replacing the steering knob.........................................................................................................................................0 23.1.3 Adjustment..........................................................................................................................................................0 23.1.4 Replacing pulse transducer [B13]....................................................................................................................................0 23.1.5 Removing the steering console from the truck........................................................................................................................0 23.1.6 Replacing the wiring harness in the steering console................................................................................................................0 23.1.7 Fit the steering console in the truck...............................................................................................................................0 23.2 Steering angle reference sensor C4350.....................................................................................................................................0 23.2.1 Overview............................................................................................................................................................0 23.2.2 Replacing the steering angle reference sensor [B59].................................................................................................................0 23.3 Steering bearing C4380....................................................................................................................................................0 24. Electrical system C5000........................................................................................................................................................0 24.1 Battery C5110.............................................................................................................................................................0 24.1.1 Charging the battery................................................................................................................................................0 24.1.2 Battery installation................................................................................................................................................0 24.2 Main contactor C5190......................................................................................................................................................0 24.2.1 Replacing the main contactor........................................................................................................................................0 24.2.2 Overview............................................................................................................................................................0 24.2.3 Replacing the main contactor........................................................................................................................................0 24.3 Instrument panel C5200....................................................................................................................................................0 24.3.1 Overview............................................................................................................................................................0 24.3.2 Lever replacement/installation......................................................................................................................................0 Required tools.........................................................................................................................................................0 Method.................................................................................................................................................................0 24.3.3 Replacing the multi-function control................................................................................................................................0 Method.................................................................................................................................................................0 Replacing the multi-function control's buttons.........................................................................................................................0 24.3.4 Removing the control console from the truck.........................................................................................................................0 Required tools.........................................................................................................................................................0 Method.................................................................................................................................................................0 24.3.5 Replacing the access card's circuit board...........................................................................................................................0 24.3.6 Dismantling the control console.....................................................................................................................................0 Required tools.........................................................................................................................................................0 Method.................................................................................................................................................................0 24.3.7 Installing an extra option button...................................................................................................................................0 24.3.8 Replacing the travel direction selector with signal button..........................................................................................................0 24.3.9 Replacing the display...............................................................................................................................................0 24.3.10 Assembling the control console.....................................................................................................................................0 24.3.11 Placing the control console in the truck...........................................................................................................................0 Required tools.........................................................................................................................................................0 Method.................................................................................................................................................................0 24.4 Drive motor cables/resistors/fuses C5430..................................................................................................................................0 24.4.1 Overview............................................................................................................................................................0 24.4.2 Replacing copper braid, VRE125SF and VRE150.........................................................................................................................0 Method.................................................................................................................................................................0 24.4.3 Replacing copper braid, VRE125......................................................................................................................................0 Method.................................................................................................................................................................0 24.4.4 Replacing the fuse [F3], VRE125SF and VRE150........................................................................................................................0 24.4.5 Replacing fuse [F3], VRE125.........................................................................................................................................0 24.4.6 Replacing the fuse [F1], VRE125SF and VRE150........................................................................................................................0 24.4.7 Replacing fuse [F1], VRE125.........................................................................................................................................0 24.4.8 Replacing the terminal block B+, VRE125SF and VRE150................................................................................................................0 24.4.9 Replacing terminal block B+, VRE125.................................................................................................................................0 24.4.10 Replacing the terminal block B-, VRE125SF and VRE150...............................................................................................................0 24.4.11 Replacing terminal block B-, VRE125................................................................................................................................0 24.4.12 Replacing the motor cables.........................................................................................................................................0 24.5 Transistor panel C5460....................................................................................................................................................0 24.5.1 Overview............................................................................................................................................................0 24.5.2 Removing ACT/ACH - VRE150 and VRE125SF..............................................................................................................................0 24.5.3 Replacing ACT - VRE150 and VRE125SF.................................................................................................................................0 24.5.4 Replacing ACH - VRE150 and VRE125SF.................................................................................................................................0 24.5.5 Attaching ACT/ACH - VRE150 and VRE125SF.............................................................................................................................0 24.5.6 Removing ACT/ACH - VRE125...........................................................................................................................................0 24.5.7 Replacing ACT - VRE125..............................................................................................................................................0 24.5.8 Replacing ACH - VRE125..............................................................................................................................................0 24.5.9 Attaching ACT/ACH - VRE125..........................................................................................................................................0 24.6 Work function harnesses/fuse C5590........................................................................................................................................0 24.6.1 Fuse panel [A9].....................................................................................................................................................0 Fuse panel overview....................................................................................................................................................0 Replacing fuse.........................................................................................................................................................0 Checking fuses.........................................................................................................................................................0 Replacing the fuse panel...............................................................................................................................................0 24.7 Main processor – MCU C5710................................................................................................................................................0 24.7.1 Replacing the MCU...................................................................................................................................................0 24.8 Fork control unit – FCU C5720.............................................................................................................................................0 24.8.1 Replacing FCU [A7]..................................................................................................................................................0 24.8.2 Replacing FCU [A7] SF...............................................................................................................................................0 24.9 Safety probes/sensors C5830...............................................................................................................................................0 24.9.1 Safety pedal........................................................................................................................................................0 Replacing the safety pedal.............................................................................................................................................0 24.9.2 Safety switch, door.................................................................................................................................................0 Replacing the safety switch............................................................................................................................................0 24.9.3 Emergency switch off................................................................................................................................................0 Overview...............................................................................................................................................................0 Removing the emergency switch off......................................................................................................................................0 24.10 Calibrations.............................................................................................................................................................0 24.10.1 Hydraulic levers...................................................................................................................................................0 24.10.2 Reference sensor – height measurement/rotation angle...............................................................................................................0 Calibrating height measurement.........................................................................................................................................0 Calibrating rotational angle...........................................................................................................................................0 24.10.3 Hydraulic valves...................................................................................................................................................0 Free lift valve........................................................................................................................................................0 Free lowering valve....................................................................................................................................................0 Main lift valve........................................................................................................................................................0 Main lowering valve....................................................................................................................................................0 Valve for traversing right.............................................................................................................................................0 Valve for traversing left..............................................................................................................................................0 Valve for anticlockwise rotation.......................................................................................................................................0 24.10.4 Mast transition between free lift and main lift....................................................................................................................0 24.10.5 Pressure sensor....................................................................................................................................................0 Zero point, free lift..................................................................................................................................................0 Weight measurement, free lift..........................................................................................................................................0 Zero point, main lift..................................................................................................................................................0 Weight measurement, main lift..........................................................................................................................................0 24.10.6 Wire guidance......................................................................................................................................................0 Steering angle.........................................................................................................................................................0 Frequency..............................................................................................................................................................0 Offset.................................................................................................................................................................0 24.10.7 Semi-automatic calibration of traversing...........................................................................................................................0 24.10.8 Semi-automatic calibration of rotation.............................................................................................................................0 25. Hydraulic system C6000.........................................................................................................................................................0 25.1 Hydraulic hygiene.........................................................................................................................................................0 25.1.1 Washing.............................................................................................................................................................0 25.1.2 Packaging...........................................................................................................................................................0 25.1.3 Handling............................................................................................................................................................0 25.1.4 Storage.............................................................................................................................................................0 25.1.5 Work procedures.....................................................................................................................................................0 25.2 Hydraulic system, bleeding................................................................................................................................................0 25.3 Hose inspection...........................................................................................................................................................0 25.4 Quick change connector....................................................................................................................................................0 Overview...................................................................................................................................................................0 Assembling the quick change connector......................................................................................................................................0 Dismantling the quick change connector.....................................................................................................................................0 25.5 Tank C6110................................................................................................................................................................0 25.5.1 Emptying the tank...................................................................................................................................................0 25.5.2 Filling the tank....................................................................................................................................................0 25.5.3 Replacing the tank..................................................................................................................................................0 25.6 Filter C6130..............................................................................................................................................................0 25.6.1 Overview............................................................................................................................................................0 25.6.2 Filter replacement (for air and oil)................................................................................................................................0 Method.................................................................................................................................................................0 25.7 Oil pump C6140............................................................................................................................................................0 25.8 Mast valve units C6310....................................................................................................................................................0 25.8.1 Replacing the control valve assembly [Q28]/[Q29]....................................................................................................................0 25.9 Hydraulic cylinders C6600.................................................................................................................................................0 25.9.1 Other hydraulic cylinders C6670.....................................................................................................................................0 Rotation cylinder......................................................................................................................................................0 26. Mast C7000.....................................................................................................................................................................0 26.1 Ordering a replacement mast...............................................................................................................................................0 26.2 Disassembling the mast....................................................................................................................................................0 26.3 Assembling the mast.......................................................................................................................................................0 26.4 Adjusting/setting mast inclination on the truck...........................................................................................................................0 Method.....................................................................................................................................................................0 26.5 Main lifting chain system C7120...........................................................................................................................................0 26.5.1 Check...............................................................................................................................................................0 26.5.2 Lubrication.........................................................................................................................................................0 26.5.3 Checking/adjusting lifting chains and guide flatness................................................................................................................0 26.5.4 Checking/adjusting fork height – VRE150.............................................................................................................................0 26.6 Forks C7410...............................................................................................................................................................0 26.6.1 Overview............................................................................................................................................................0 26.6.2 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 26.6.3 Repairs and testing.................................................................................................................................................0 Repairs................................................................................................................................................................0 Testing the yield point................................................................................................................................................0 Replacing forks........................................................................................................................................................0 26.7 Turret head fork unit C7700...............................................................................................................................................0 26.7.1 Setting backlash....................................................................................................................................................0 Tools..................................................................................................................................................................0 26.8 Traversing function, fork unit C7710......................................................................................................................................0 26.8.1 Overview............................................................................................................................................................0 26.8.2 Replacing sensor bearings [B9]......................................................................................................................................0 26.8.3 Removing the hydraulic motor........................................................................................................................................0 Method.................................................................................................................................................................0 26.8.4 Mounting the hydraulic motor........................................................................................................................................0 Method.................................................................................................................................................................0 26.8.5 Replacing the drive unit shaft......................................................................................................................................0 Method.................................................................................................................................................................0 26.8.6 Replacing rollers on the unit arm...................................................................................................................................0 Method.................................................................................................................................................................0 26.8.7 Replacing the reference sensor [B7].................................................................................................................................0 26.9 Swivel/rotation function, fork unit C7720.................................................................................................................................0 26.9.1 Replacing rotation angle sensor [B8]................................................................................................................................0 26.10 Shuttle fork unit C7800..................................................................................................................................................0 26.10.1 Adjusting chains...................................................................................................................................................0 Checking drive chain tension...........................................................................................................................................0 Adjusting the drive chain..............................................................................................................................................0 26.10.2 Replacing the idler roller.........................................................................................................................................0 26.10.3 Replacing guide....................................................................................................................................................0 26.11 Shuttle fork power unit C7820............................................................................................................................................0 26.11.1 Replacing the reference sensor [B7] SF.............................................................................................................................0 26.11.2 Replacing sensor bearings [B9] SF..................................................................................................................................0 27. Peripherals C8000..............................................................................................................................................................0 28. Options/Extra equipment C9000..................................................................................................................................................0 28.1 E-bar C9500...............................................................................................................................................................0 28.1.1 Overview............................................................................................................................................................0 28.1.2 Fitting the E-bar...................................................................................................................................................0 28.1.3 Installing accessories..............................................................................................................................................0 Method.................................................................................................................................................................0 29. Instructions for disposal......................................................................................................................................................0 29.1 General...................................................................................................................................................................0 29.2 Marking of plastics.......................................................................................................................................................0 29.2.1 General marking of products and packaging...........................................................................................................................0 29.2.2 Marking according to the manufacturer’s standards...................................................................................................................0 Abbreviations..........................................................................................................................................................0 Marking examples.......................................................................................................................................................0 29.3 Pressure vessels..........................................................................................................................................................0 29.3.1 Gas struts..........................................................................................................................................................0 29.4 Sorting categories........................................................................................................................................................0 30. Wiring diagram.................................................................................................................................................................0 30.1 Components................................................................................................................................................................0 30.2 Component location........................................................................................................................................................0 Picture 1..................................................................................................................................................................0 Picture 2..................................................................................................................................................................0 Picture 3..................................................................................................................................................................0 Picture 4..................................................................................................................................................................0 Picture 5..................................................................................................................................................................0 Picture 6..................................................................................................................................................................0 Picture 7..................................................................................................................................................................0 Picture 8..................................................................................................................................................................0 Picture 9..................................................................................................................................................................0 Picture 10.................................................................................................................................................................0 Picture 11.................................................................................................................................................................0 Picture 12.................................................................................................................................................................0 Picture 13.................................................................................................................................................................0 Picture 14.................................................................................................................................................................0 Picture 15.................................................................................................................................................................0 Picture 16.................................................................................................................................................................0 Picture 17.................................................................................................................................................................0 Picture 18.................................................................................................................................................................0 Picture 19.................................................................................................................................................................0 Picture 20.................................................................................................................................................................0 Picture 21.................................................................................................................................................................0 Picture 22.................................................................................................................................................................0 Picture 23.................................................................................................................................................................0 Picture 24.................................................................................................................................................................0 Picture 25.................................................................................................................................................................0 Picture 26.................................................................................................................................................................0 Picture 27.................................................................................................................................................................0 Picture 28.................................................................................................................................................................0 Picture 29.................................................................................................................................................................0 Picture 30.................................................................................................................................................................0 Picture 31.................................................................................................................................................................0 Picture 32.................................................................................................................................................................0 Picture 33.................................................................................................................................................................0 Picture 34.................................................................................................................................................................0 Picture 35.................................................................................................................................................................0 Picture 36.................................................................................................................................................................0 Picture 37.................................................................................................................................................................0 Picture 38.................................................................................................................................................................0 Picture 40.................................................................................................................................................................0 Picture 41.................................................................................................................................................................0 30.3 Cable connections and terminal posts......................................................................................................................................0 30.3.1 ACT [T1]............................................................................................................................................................0 30.3.2 ACH [T2]............................................................................................................................................................0 30.3.3 CID [A1]............................................................................................................................................................0 30.3.4 MCU [A5]............................................................................................................................................................0 30.3.5 FCU [A7]............................................................................................................................................................0 30.3.6 GFU [A8]............................................................................................................................................................0 30.4 Fuse panel [A9]...........................................................................................................................................................0 30.5 Overview..................................................................................................................................................................0 30.6 Detailed diagram From 6191182 - 6257600...................................................................................................................................0 30.7 Detailed diagram From 6257601.............................................................................................................................................0 30.8 CC Detailed diagram From 6191182 - 6257600................................................................................................................................0 30.9 Detailed diagram From 6257601.............................................................................................................................................0 31. Hydraulics schematics..........................................................................................................................................................0 31.1 Main valve unit, VRE duplex...............................................................................................................................................0 31.2 Main valve unit, VRE triplex..............................................................................................................................................0 31.3 Fork valve unit, turret head fork unit 2 functions........................................................................................................................0 31.4 Fork valve unit, turret head fork unit 3 functions........................................................................................................................0 31.5 Fork valve unit, SF.......................................................................................................................................................0 31.6 Valve unit for tilt (Option)..............................................................................................................................................0 31.7 List of symbols...........................................................................................................................................................0 31.8 Detailed diagrams.........................................................................................................................................................0 TH.........................................................................................................................................................................0 SF.........................................................................................................................................................................0 32. Tools..........................................................................................................................................................................0 32.1 AMP contacts..............................................................................................................................................................0 32.2 MQS contacts..............................................................................................................................................................0 32.3 CPC contacts..............................................................................................................................................................0 32.4 Other tools...............................................................................................................................................................0 33. Service data and grease specifications.........................................................................................................................................0 33.1 General tightening torques................................................................................................................................................0 33.1.1 Galvanised, non-oiled screws........................................................................................................................................0 33.1.2 Untreated, oiled screws.............................................................................................................................................0 33.2 Oil and grease specification..............................................................................................................................................0 34. Technical data.................................................................................................................................................................0 34.1 Basic data................................................................................................................................................................0 34.2 Mast type and weight (kg).................................................................................................................................................0 34.3 IP classes on components and units........................................................................................................................................0 34.4 Battery sizes.............................................................................................................................................................0 34.5 Truck dimensions..........................................................................................................................................................0 34.5.1 VRE125, VRE150......................................................................................................................................................0 34.5.2 VRE125SF............................................................................................................................................................0
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