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BT Toyota C15,VCE150,VCE125 Repair Manual – PDF DOWNLOAD
BT Toyota C15,VCE150,VCE125 Repair Manual – PDF DOWNLOAD
FILE DETAILS:
BT Toyota C15,VCE150,VCE125 Repair Manual – PDF DOWNLOAD
Language : English
Pages : 894
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
BT Toyota C15,VCE150,VCE125 Repair Manual – PDF DOWNLOAD
H Heading 1 - 1. Table of content.....................................................................................0 H Heading 1 - 2. General introduction.................................................................................0 H Heading 2 - 2.1 How to use this manual..........................................................................0 H Heading 2 - 2.2 Warning symbols.................................................................................0 H Heading 2 - 2.3 Pictograms......................................................................................0 H Heading 3 - 2.3.1 Screws/Nuts...............................................................................0 H Heading 4 - Identification of tools for screws and nuts.................................................0 H Heading 3 - 2.3.2 Repairable................................................................................0 H Heading 3 - 2.3.3 Other pictograms..........................................................................0 H Heading 1 - 3. General safety rules.................................................................................0 H Heading 2 - 3.1 Work safety.....................................................................................0 H Heading 2 - 3.2 Electrical systems..............................................................................0 H Heading 2 - 3.3 Safe lifting....................................................................................0 H Heading 2 - 3.4 Truck modifications.............................................................................0 H Heading 1 - 4. Chassis – 0000 Truck installation....................................................................0 H Heading 2 - 4.1 General.........................................................................................0 H Heading 2 - 4.2 Tool list.......................................................................................0 H Heading 2 - 4.3 Unloading the truck.............................................................................0 H Heading 3 - 4.3.1 Unloading a standing truck................................................................0 H Heading 4 - Drive the truck off the trailer.............................................................0 H Heading 4 - Towing the truck off the trailer............................................................0 H Heading 4 - Unloading with a counterweight truck........................................................0 H Heading 3 - 4.3.2 Unloading a truck lying down..............................................................0 H Heading 4 - Unloading the truck from a lorry using a counter balance truck..............................0 H Heading 3 - 4.3.3 Unloading the truck using cranes..........................................................0 H Heading 3 - 4.3.4 Erecting the truck........................................................................0 H Heading 3 - 4.3.5 Final assembly............................................................................0 H Heading 3 - 4.3.6 Assembly of the initial mast..............................................................0 H Heading 2 - 4.4 Preparations for commissioning..................................................................0 H Heading 2 - 4.5 Installation in narrow aisle....................................................................0 H Heading 3 - 4.5.1 General...................................................................................0 H Heading 3 - 4.5.2 Rail-guided truck.........................................................................0 H Heading 3 - 4.5.3 Wire-guided truck.........................................................................0 H Heading 3 - 4.5.4 Support arm collision guards..............................................................0 H Heading 4 - Assembling the guards during truck installation.............................................0 H Heading 1 - 5. Truck installation...................................................................................0 H Heading 2 - 5.1 General.........................................................................................0 H Heading 2 - 5.2 Tool list.......................................................................................0 H Heading 2 - 5.3 Unloading the truck.............................................................................0 H Heading 3 - 5.3.1 Unloading a standing truck................................................................0 H Heading 4 - Drive the truck off the trailer.............................................................0 H Heading 4 - Towing the truck off the trailer............................................................0 H Heading 4 - Unloading with a counterbalance truck.......................................................0 H Heading 3 - 5.3.2 Unloading a truck lying on its back.......................................................0 H Heading 4 - Unloading the truck from a lorry using a counter balance truck from the side................0 H Heading 4 - Unloading the truck from a lorry using a counter balance truck from the rear................0 H Heading 4 - Unloading the truck using cranes............................................................0 H Heading 3 - 5.3.3 Horizontal truck transport................................................................0 H Heading 4 - Transport with counterbalance truck.........................................................0 H Heading 4 - Transport with crane........................................................................0 H Heading 3 - 5.3.4 Raising the truck.........................................................................0 H Heading 3 - 5.3.5 Final assembly............................................................................0 H Heading 3 - 5.3.6 Installing the initial mast...............................................................0 H Heading 2 - 5.4 Preparations for commissioning..................................................................0 H Heading 2 - 5.5 Installation in narrow aisle....................................................................0 H Heading 3 - 5.5.1 General...................................................................................0 H Heading 3 - 5.5.2 Rail-guided truck.........................................................................0 H Heading 3 - 5.5.3 Wire-guided truck.........................................................................0 H Heading 3 - 5.5.4 Support arm collision guards..............................................................0 H Heading 4 - Assembling the guards during truck installation.............................................0 H Heading 1 - 6. Preparations for transport...........................................................................0 H Heading 2 - 6.1 General.........................................................................................0 H Heading 2 - 6.2 Tool list.......................................................................................0 H Heading 2 - 6.3 Dismantling the truck...........................................................................0 H Heading 2 - 6.4 Laying down the truck...........................................................................0 H Heading 2 - 6.5 Loading the truck...............................................................................0 H Heading 1 - 7. P2 (T code 712) - C15, VCE150........................................................................0 H Heading 2 - 7.1 Preventive maintenance – Maintenance schedule...................................................0 H Heading 2 - 7.2 Correct inspection procedure....................................................................0 H Heading 1 - 8. P2 (t-code 713) - VCE125.............................................................................0 H Heading 2 - 8.1 Preventive maintenance – Maintenance schedule...................................................0 H Heading 2 - 8.2 Correct inspection procedure....................................................................0 H Heading 1 - 9. P3 (T code 712) – C15, VCE150........................................................................0 H Heading 2 - 9.1 Oil and lubricant specifications................................................................0 H Heading 1 - 10. P3 (T code 713) – VCE125............................................................................0 H Heading 2 - 10.1 Oil and lubricant specification................................................................0 H Heading 1 - 11. Tools – P4..........................................................................................0 H Heading 2 - 11.1 Super Seal contact.............................................................................0 H Heading 3 - 11.1.1 AMP connectors...........................................................................0 H Heading 3 - 11.1.2 Other tools..............................................................................0 H Heading 1 - 12. Frame pivot – 0320..................................................................................0 H Heading 2 - 12.1 Removal/reassembly of rear chassis, including bearings.........................................0 H Heading 3 - 12.1.1 Special tools............................................................................0 H Heading 3 - 12.1.2 Standard hand tools......................................................................0 H Heading 3 - 12.1.3 Disassembly..............................................................................0 H Heading 4 - Jack up the truck to prepare for disassembly................................................0 H Heading 4 - Disassembly of components...................................................................0 H Heading 3 - 12.1.4 Dismantle the rear chassis...............................................................0 H Heading 2 - 12.2 Replacing the bearing frame links..............................................................0 H Heading 3 - 12.2.1 Remove the old bearings..................................................................0 H Heading 3 - 12.2.2 Install new bearings.....................................................................0 H Heading 3 - 12.2.3 Reinstall the rear chassis...............................................................0 H Heading 3 - 12.2.4 Reassemble the truck.....................................................................0 H Heading 3 - 12.2.5 Lower the truck to the ground............................................................0 H Heading 3 - 12.2.6 Final assembly...........................................................................0 H Heading 1 - 13. General tightening torque – 0400....................................................................0 H Heading 2 - 13.1 Galvanised, non-oiled bolts....................................................................0 H Heading 2 - 13.2 Untreated, lubricated bolts....................................................................0 H Heading 2 - 13.3 Tightening torques.............................................................................0 H Heading 1 - 14. Electric AC pump motor – 1710.1.....................................................................0 H Heading 2 - 14.1 General........................................................................................0 H Heading 2 - 14.2 Disassembled pump motor........................................................................0 H Heading 2 - 14.3 Disassembly and assembly of the pump motor.....................................................0 H Heading 3 - 14.3.1 Disassembly..............................................................................0 H Heading 3 - 14.3.2 Installation.............................................................................0 H Heading 2 - 14.4 Replacing the ball bearing.....................................................................0 H Heading 3 - 14.4.1 Disassembly..............................................................................0 H Heading 3 - 14.4.2 Installation.............................................................................0 H Heading 2 - 14.5 Assembly instruction for the external temperature sensor.......................................0 H Heading 1 - 15. Electric DC pump motor – 1710.2.....................................................................0 H Heading 2 - 15.1 General........................................................................................0 H Heading 2 - 15.2 Disassembled pump motor........................................................................0 H Heading 3 - 15.2.1 Connection...............................................................................0 H Heading 2 - 15.3 Disassembly and assembly of the pump motor.....................................................0 H Heading 3 - 15.3.1 Disassembly..............................................................................0 H Heading 3 - 15.3.2 Installation.............................................................................0 H Heading 2 - 15.4 Replacing the ball bearing.....................................................................0 H Heading 3 - 15.4.1 Disassembly (D side).....................................................................0 H Heading 3 - 15.4.2 Installation.............................................................................0 H Heading 3 - 15.4.3 Disassembly (N side).....................................................................0 H Heading 3 - 15.4.4 Assembly (N side)........................................................................0 H Heading 3 - 15.4.5 Carbon brushes and carbon brush-rocker...................................................0 H Heading 4 - New carbon brushes must always be smoothed beforehand.......................................0 H Heading 4 - Commutator..................................................................................0 H Heading 4 - Truing the commutator.......................................................................0 H Heading 1 - 16. Electric drive motor – 1760.........................................................................0 H Heading 2 - 16.1 General........................................................................................0 H Heading 2 - 16.2 Disassembled drive motor.......................................................................0 H Heading 2 - 16.3 Disassembly and assembly of the drive motor....................................................0 H Heading 3 - 16.3.1 Disassembly of the drive motor...........................................................0 H Heading 4 - Disassemble the gear wheel..................................................................0 H Heading 4 - Disassemble the brake.......................................................................0 H Heading 3 - 16.3.2 Assembly of the drive motor..............................................................0 H Heading 4 - Assemble the brake..........................................................................0 H Heading 4 - Assemble the gear wheel.....................................................................0 H Heading 2 - 16.4 Replacing the ball bearing.....................................................................0 H Heading 3 - 16.4.1 Disassembly..............................................................................0 H Heading 4 - N side......................................................................................0 H Heading 4 - D side......................................................................................0 H Heading 3 - 16.4.2 Installation.............................................................................0 H Heading 4 - N side......................................................................................0 H Heading 4 - D side......................................................................................0 H Heading 2 - 16.5 Assembly instruction for the external temperature sensor.......................................0 H Heading 1 - 17. Drive unit/gear – 2550..............................................................................0 H Heading 2 - 17.1 General........................................................................................0 H Heading 2 - 17.2 Components/data of the drive unit and gear.....................................................0 H Heading 3 - 17.2.1 Component identification.................................................................0 H Heading 3 - 17.2.2 Technical data...........................................................................0 H Heading 3 - 17.2.3 Dismantled gear..........................................................................0 H Heading 2 - 17.3 Replacing the drive motor/drive gear...........................................................0 H Heading 3 - 17.3.1 Dismantling of drive unit from truck.....................................................0 H Heading 3 - 17.3.2 Fitting the drive unit in truck..........................................................0 H Heading 3 - 17.3.3 Dismantling the drive motor and the gear.................................................0 H Heading 3 - 17.3.4 Fitting the drive motor and the gear.....................................................0 H Heading 2 - 17.4 Oil level check/replacement....................................................................0 H Heading 3 - 17.4.1 Checking/refilling the oil...............................................................0 H Heading 3 - 17.4.2 Oil change...............................................................................0 H Heading 2 - 17.5 Repairs........................................................................................0 H Heading 3 - 17.5.1 Replacing the drive axle jointing ring...................................................0 H Heading 3 - 17.5.2 Leakage from the top cover...............................................................0 H Heading 3 - 17.5.3 Leakage from the lower cover.............................................................0 H Heading 3 - 17.5.4 Replacing the wheel bolts................................................................0 H Heading 1 - 18. Brake system – 3100.................................................................................0 H Heading 2 - 18.1 General........................................................................................0 H Heading 2 - 18.2 Description of functions.......................................................................0 H Heading 3 - 18.2.1 Releasing the accelerator pedal..........................................................0 H Heading 3 - 18.2.2 Travel direction selector................................................................0 H Heading 3 - 18.2.3 Pressing the brake button................................................................0 H Heading 3 - 18.2.4 Parking brake............................................................................0 H Heading 3 - 18.2.5 Emergency braking........................................................................0 H Heading 2 - 18.3 Electro-mechanical disc brake, drive motor.....................................................0 H Heading 3 - 18.3.1 Maintenance schedule and maintenance work................................................0 H Heading 2 - 18.4 Replacing the brake unit and dismantling the brake unit to replace the friction disc...........0 H Heading 3 - 18.4.1 Replacing the brake unit.................................................................0 H Heading 3 - 18.4.2 Dismantling a brake unit/checking/replacing a brake disc.................................0 H Heading 3 - 18.4.3 Check and adjust the brake force.........................................................0 H Heading 3 - 18.4.4 Clean....................................................................................0 H Heading 3 - 18.4.5 Checking the air gap.....................................................................0 H Heading 3 - 18.4.6 Checking and adjusting the brake force...................................................0 H Heading 3 - 18.4.7 Troubleshooting..........................................................................0 H Heading 2 - 18.5 Disc brake with multiple discs, support arms...................................................0 H Heading 3 - 18.5.1 Checking the play/wear...................................................................0 H Heading 3 - 18.5.2 Dismantling..............................................................................0 H Heading 3 - 18.5.3 Inspection...............................................................................0 H Heading 3 - 18.5.4 Fitting..................................................................................0 H Heading 3 - 18.5.5 Maintenance..............................................................................0 H Heading 3 - 18.5.6 Adjusting the play.......................................................................0 H Heading 1 - 19. Wheels - 3500.......................................................................................0 H Heading 2 - 19.1 Drive wheels – 3530............................................................................0 H Heading 3 - 19.1.1 General..................................................................................0 H Heading 3 - 19.1.2 Disassemble the drive wheel..............................................................0 H Heading 3 - 19.1.3 Assembling the drive wheel...............................................................0 H Heading 3 - 19.1.4 Available wheel qualities................................................................0 H Heading 2 - 19.2 Support arm wheels – 3550......................................................................0 H Heading 3 - 19.2.1 Dismantling the wheel....................................................................0 H Heading 3 - 19.2.2 Assembling the wheel.....................................................................0 H Heading 3 - 19.2.3 Dismantling/assembling the wheel bearings................................................0 H Heading 3 - 19.2.4 Support arm wheels, shimming.............................................................0 H Heading 3 - 19.2.5 Available wheel qualities................................................................0 H Heading 1 - 20. Steering system – 4000..............................................................................0 H Heading 2 - 20.1 General........................................................................................0 H Heading 3 - 20.1.1 Steering components......................................................................0 H Heading 3 - 20.1.2 Hydraulic diagram, steering system.......................................................0 H Heading 2 - 20.2 Function description...........................................................................0 H Heading 3 - 20.2.1 Electrical System........................................................................0 H Heading 4 - Wire-guidance mode..........................................................................0 H Heading 3 - 20.2.2 Hydraulic system.........................................................................0 H Heading 3 - 20.2.3 Temperature and voltage compensation.....................................................0 H Heading 2 - 20.3 Troubleshooting................................................................................0 H Heading 3 - 20.3.1 Operations/repair, hydraulics............................................................0 H Heading 1 - 21. Steering cylinder - 4160............................................................................0 H Heading 2 - 21.1 Instructions for checking for internal leaks...................................................0 H Heading 3 - 21.1.1 Checks made together with 2000-hours service.............................................0 H Heading 3 - 21.1.2 When wear is suspected...................................................................0 H Heading 2 - 21.2 Recommended procedure..........................................................................0 H Heading 2 - 21.3 Remedial actions...............................................................................0 H Heading 3 - 21.3.1 Measure..................................................................................0 H Heading 2 - 21.4 Removing a steering cylinder from the truck....................................................0 H Heading 2 - 21.5 Fitting a steering cylinder on the truck.......................................................0 H Heading 2 - 21.6 Repairs to the front steering cylinder mount...................................................0 H Heading 3 - 21.6.1 Background...............................................................................0 H Heading 3 - 21.6.2 Repair material..........................................................................0 H Heading 3 - 21.6.3 Measures.................................................................................0 H Heading 1 - 22. Wire guidance system – 4500.........................................................................0 H Heading 2 - 22.1 Wire guidance..................................................................................0 H Heading 3 - 22.1.1 General..................................................................................0 H Heading 4 - Abbreviations...............................................................................0 H Heading 4 - Definitions.................................................................................0 H Heading 2 - 22.2 Wire guidance components.......................................................................0 H Heading 3 - 22.2.1 Antennas, W1, W2.........................................................................0 H Heading 4 - Installing a new antenna....................................................................0 H Heading 4 - Adjusting the antennas......................................................................0 H Heading 4 - Steering angle sensor, R7...................................................................0 H Heading 4 - Activation switch...........................................................................0 H Heading 2 - 22.3 General description of the function............................................................0 H Heading 4 - Narrow aisle type...............................................................................0 H Heading 3 - 22.3.1 Travel speeds............................................................................0 H Heading 3 - 22.3.2 Description of the function..............................................................0 H Heading 4 - Run mode....................................................................................0 H Heading 4 - Wire guidance, mode in Run mode.............................................................0 H Heading 4 - Automatic steering control..................................................................0 H Heading 2 - 22.4 “Best practice” for adjusting the wire guidance................................................0 H Heading 3 - 22.4.1 Set-up procedure.........................................................................0 H Heading 4 - Battery check...............................................................................0 H Heading 4 - Check antenna heights.......................................................................0 H Heading 4 - Learn steering valves.......................................................................0 H Heading 4 - Set the chassis straight and learn the pivot angle..........................................0 H Heading 4 - Check the waist pot voltage with TruckCom...................................................0 H Heading 4 - Learn wire guidance frequency...............................................................0 H Heading 4 - Learn the wire..............................................................................0 H Heading 4 - Fine-tuning the pivot point adjustment......................................................0 H Heading 4 - Battery setting.............................................................................0 H Heading 2 - 22.5 Parameters.....................................................................................0 H Heading 3 - 22.5.1 General wire guidance parameters.........................................................0 H Heading 3 - 22.5.2 Learned calibration values, steering.....................................................0 H Heading 3 - 22.5.3 Learned calibration data, wire guidance..................................................0 H Heading 2 - 22.6 Warning and error codes........................................................................0 H Heading 1 - 23. Electrical system – 5000............................................................................0 H Heading 2 - 23.1 General........................................................................................0 H Heading 3 - 23.1.1 Terminologi..............................................................................0 H Heading 3 - 23.1.2 Truck firmware applications..............................................................0 H Heading 3 - 23.1.3 Communication............................................................................0 H Heading 2 - 23.2 Main Computer Unit, MCU (A5)...................................................................0 H Heading 3 - 23.2.1 General..................................................................................0 H Heading 3 - 23.2.2 Power supply.............................................................................0 H Heading 3 - 23.2.3 Battery negative.........................................................................0 H Heading 3 - 23.2.4 Electric connectors......................................................................0 H Heading 3 - 23.2.5 Internal status monitoring...............................................................0 H Heading 3 - 23.2.6 Resetting the battery indicator..........................................................0 H Heading 3 - 23.2.7 External inputs and outputs..............................................................0 H Heading 4 - X130 connector..............................................................................0 H Heading 4 - I = Input, O = Output.......................................................................0 H Heading 4 - X131 connector..............................................................................0 H Heading 4 - X132 connector..............................................................................0 H Heading 3 - 23.2.8 Installing a new card in the truck.......................................................0 H Heading 3 - 23.2.9 Programming the MCU......................................................................0 H Heading 2 - 23.3 Fork computer unit, FCU (A4)...................................................................0 H Heading 3 - 23.3.1 General..................................................................................0 H Heading 3 - 23.3.2 Power supply.............................................................................0 H Heading 3 - 23.3.3 Battery negative.........................................................................0 H Heading 3 - 23.3.4 Electric connectors......................................................................0 H Heading 3 - 23.3.5 Safety measure...........................................................................0 H Heading 3 - 23.3.6 External inputs and outputs..............................................................0 H Heading 4 - Connector plug..............................................................................0 H Heading 3 - 23.3.7 Installing a new card in the truck.......................................................0 H Heading 3 - 23.3.8 Programming..............................................................................0 H Heading 2 - 23.4 Integrated Control Panel, ICP (A16)............................................................0 H Heading 3 - 23.4.1 General..................................................................................0 H Heading 3 - 23.4.2 ICP modules..............................................................................0 H Heading 3 - 23.4.3 Power supply.............................................................................0 H Heading 3 - 23.4.4 Battery negative.........................................................................0 H Heading 3 - 23.4.5 External inputs and outputs..............................................................0 H Heading 4 - X100 connector..............................................................................0 H Heading 4 - X101 connector..............................................................................0 H Heading 4 - X102 connector..............................................................................0 H Heading 4 - X103 connector..............................................................................0 H Heading 4 - X104 connector..............................................................................0 H Heading 4 - X106 connector..............................................................................0 H Heading 4 - X107 connector..............................................................................0 H Heading 3 - 23.4.6 Installing a new ICP in the truck........................................................0 H Heading 3 - 23.4.7 Programming..............................................................................0 H Heading 3 - 23.4.8 Replacing the ICP and shock absorbers....................................................0 H Heading 4 - Fitting the ICP.............................................................................0 H Heading 4 - Remove the upper shock absorber.............................................................0 H Heading 4 - Fit the upper shock absorber................................................................0 H Heading 4 - Remove the lower shock absorber.............................................................0 H Heading 4 - ............................................................................................0 H Heading 4 - Fit the lower shock absorber................................................................0 H Heading 4 - ............................................................................................0 H Heading 4 - Remove the inner shock absorber.............................................................0 H Heading 4 - Fit the inner shock absorber................................................................0 H Heading 4 - Separate the telescopic arm.................................................................0 H Heading 2 - 23.5 AC regulators, ACTL (A1), ACTR (A31) and ACH (A2)..............................................0 H Heading 3 - 23.5.1 General..................................................................................0 H Heading 3 - 23.5.2 Connection terminal and terminal pillars.................................................0 H Heading 3 - 23.5.3 Technical data...........................................................................0 H Heading 3 - 23.5.4 Installing a new frequency converter in the truck........................................0 H Heading 3 - 23.5.5 Programming..............................................................................0 H Heading 3 - 23.5.6 Maintenance..............................................................................0 H Heading 3 - 23.5.7 Safety...................................................................................0 H Heading 3 - 23.5.8 Cleaning.................................................................................0 H Heading 2 - 23.6 DC regulator, DCHI (A32).......................................................................0 H Heading 3 - 23.6.1 General description......................................................................0 H Heading 3 - 23.6.2 Connection terminal and terminal pillars.................................................0 H Heading 3 - 23.6.3 Technical data...........................................................................0 H Heading 3 - 23.6.4 Installing a new transistor panel........................................................0 H Heading 2 - 23.7 Parameters.....................................................................................0 H Heading 2 - 23.8 Diagnostics and troubleshooting................................................................0 H Heading 3 - 23.8.1 Maintenance..............................................................................0 H Heading 3 - 23.8.2 Safety...................................................................................0 H Heading 3 - 23.8.3 Cleaning.................................................................................0 H Heading 3 - 23.8.4 Using the hand-held terminal.............................................................0 H Heading 3 - 23.8.5 Viewing and adjusting parameters.........................................................0 H Heading 3 - 23.8.6 SPECIAL PROGRAM MODE.....................................................................0 H Heading 3 - 23.8.7 Using the TEST mode......................................................................0 H Heading 3 - 23.8.8 Using the DIAGNOSTICS MODE...............................................................0 H Heading 3 - 23.8.9 SPECIAL DIAGNOSTICS MODE.................................................................0 H Heading 2 - 23.9 Electric system, overview......................................................................0 H Heading 2 - 23.10 Symbol list and electric wiring diagram.......................................................0 H Heading 3 - 23.10.1 List of symbols.........................................................................0 H Heading 3 - 23.10.2 Electrical wiring diagram VCE150A (T code 712)..........................................0 H Heading 3 - 23.10.3 Electrical wiring diagram VCE125ASF (T code 713)........................................0 H Heading 2 - 23.11 Component List................................................................................0 H Heading 2 - 23.12 Component location............................................................................0 H Heading 3 - 23.12.1 Cabling contacts........................................................................0 H Heading 2 - 23.13 General description of the function...........................................................0 H Heading 2 - 23.14 Functional description, starting, driving, steering and braking...............................0 H Heading 3 - 23.14.1 Battery connected, truck switched off...................................................0 H Heading 3 - 23.14.2 Log-in / Start-up.......................................................................0 H Heading 3 - 23.14.3 Log-out / Switch-off....................................................................0 H Heading 3 - 23.14.4 Presence check..........................................................................0 H Heading 3 - 23.14.5 Selecting the drive direction / Driving.................................................0 H Heading 3 - 23.14.6 Emergency driving mode..................................................................0 H Heading 3 - 23.14.7 Travel speeds...........................................................................0 H Heading 3 - 23.14.8 Control units...........................................................................0 H Heading 3 - 23.14.9 Braking.................................................................................0 H Heading 2 - 23.15 Electrical description of the hydraulic functions.............................................0 H Heading 3 - 23.15.1 Permitted combined functions............................................................0 H Heading 3 - 23.15.2 Monitoring and functional limitations...................................................0 H Heading 3 - 23.15.3 Slack chain guard.......................................................................0 H Heading 3 - 23.15.4 Height measurement......................................................................0 H Heading 3 - 23.15.5 Cabin lifting...........................................................................0 H Heading 3 - 23.15.6 Special height (lifting height limitation)..............................................0 H Heading 3 - 23.15.7 Cab lowering............................................................................0 H Heading 3 - 23.15.8 Special function with cab lifting/lowering and forks set straight ahead.................0 H Heading 2 - 23.16 Turret head fork unit (T code 712)............................................................0 H Heading 3 - 23.16.1 Auto rotation...........................................................................0 H Heading 3 - 23.16.2 Miscellaneous electrical functions......................................................0 H Heading 4 - Warning lamp................................................................................0 H Heading 4 - Personal protection system (PPS)............................................................0 H Heading 3 - 23.16.3 Narrow aisle ID system..................................................................0 H Heading 3 - 23.16.4 Alternative “narrow aisle system”.......................................................0 H Heading 2 - 23.17 Shuttle fork unit (T code 713)................................................................0 H Heading 3 - 23.17.1 Extending the forks.....................................................................0 H Heading 4 - Description of the function.................................................................0 H Heading 3 - 23.17.2 Fork lifting/lowering...................................................................0 H Heading 2 - 23.18 Display.......................................................................................0 H Heading 3 - 23.18.1 Normal mode.............................................................................0 H Heading 3 - 23.18.2 Information mode........................................................................0 H Heading 1 - 24. Parameters – 5700...................................................................................0 H Heading 2 - 24.1 General........................................................................................0 H Heading 2 - 24.2 Accessing parameters...........................................................................0 H Heading 3 - 24.2.1 Operator parameters (service key not connected)..........................................0 H Heading 4 - Operator parameters (operators 1-10)........................................................0 H Heading 2 - 24.3 Truck parameters...............................................................................0 H Heading 3 - 24.3.1 MCU parameters...........................................................................0 H Heading 4 - Basic parameters............................................................................0 H Heading 4 - Wire guidance parameters and other new parameters...........................................0 H Heading 4 - Learned calibration values, steering........................................................0 H Heading 4 - Learned calibration data, wire guidance.....................................................0 H Heading 4 - Parameters Odometer function................................................................0 H Heading 4 - Parameter Navigation Solutions..............................................................0 H Heading 4 - Parameters, Brand...........................................................................0 H Heading 3 - 24.3.2 FCU parameters, turret head fork unit (T code 712).......................................0 H Heading 4 - Basic parameters, turret head fork unit.....................................................0 H Heading 4 - Learned calibration data, turret head fork unit.............................................0 H Heading 3 - 24.3.3 FCU parameters, shuttle fork unit (T code 713)...........................................0 H Heading 3 - 24.3.4 ICP parameters...........................................................................0 H Heading 1 - 25. Calibration – 5700..................................................................................0 H Heading 2 - 25.1 General........................................................................................0 H Heading 3 - 25.1.1 Open the calibration mode................................................................0 H Heading 3 - 25.1.2 Using the menu...........................................................................0 H Heading 2 - 25.2 Calibration of the ICP controls, “CONTROLS”....................................................0 H Heading 2 - 25.3 Calibration of steering - “STEERING”...........................................................0 H Heading 3 - 25.3.1 Calibration of the articulated centre potentiometer......................................0 H Heading 3 - 25.3.2 Calibration of the steering valves.......................................................0 H Heading 2 - 25.4 Calibration of wire guidance - “WIRE”..........................................................0 H Heading 3 - 25.4.1 “Learn Offset”...........................................................................0 H Heading 3 - 25.4.2 Learn frequency..........................................................................0 H Heading 2 - 25.5 Calibration of turret head functions, "FORKS" (T code 712).....................................0 H Heading 3 - 25.5.1 Counter-clockwise rotation...............................................................0 H Heading 3 - 25.5.2 Clockwise rotation.......................................................................0 H Heading 3 - 25.5.3 Calibration of traversing/lifting, “TRAV/LIFT”...........................................0 H Heading 3 - 25.5.4 Fork lowering “LOWER”....................................................................0 H Heading 2 - 25.6 Calibration for height measurement.............................................................0 H Heading 2 - 25.7 Calibration of the shuttle fork unit (T code 713)..............................................0 H Heading 3 - 25.7.1 Calibration of traversing/lifting, “TRAV/LIFT”...........................................0 H Heading 3 - 25.7.2 Fork lowering “LOWER”....................................................................0 H Heading 2 - 25.8 Calibration of weight indication, “WEIGHT”.....................................................0 H Heading 2 - 25.9 Calibration of the B cylinder pressure, “PRESSURE”.............................................0 H Heading 2 - 25.10 Learning status codes – FCU...................................................................0 H Heading 1 - 26. Error codes - 5700..................................................................................0 H Heading 2 - 26.1 General........................................................................................0 H Heading 2 - 26.2 Warning and error codes........................................................................0 H Heading 3 - 26.2.1 Safety logic.............................................................................0 H Heading 2 - 26.3 Description of warning and error codes.........................................................0 H Heading 3 - 26.3.1 ICP, code group 1........................................................................0 H Heading 4 - ICP warning codes...........................................................................0 H Heading 4 - ICP error codes.............................................................................0 H Heading 3 - 26.3.2 MCU, code group 2........................................................................0 H Heading 4 - MCU warning codes...........................................................................0 H Heading 4 - MCU error codes.............................................................................0 H Heading 3 - 26.3.3 Drive system, code group 3...............................................................0 H Heading 4 - Travel system-error codes...................................................................0 H Heading 3 - 26.3.4 Cab lift system, code group 4............................................................0 H Heading 4 - Cab lift system-warning codes...............................................................0 H Heading 4 - Cab lift system-error codes.................................................................0 H Heading 3 - 26.3.5 Control system, code group 5.............................................................0 H Heading 4 - Control system-warning codes................................................................0 H Heading 4 - Steering system-error codes.................................................................0 H Heading 3 - 26.3.6 Initial lift and turret head fork unit systems, code group 6 (T code 712)................0 H Heading 4 - Initial lift and turret head fork unit systems - warning codes..............................0 H Heading 3 - 26.3.7 Shuttle fork system - code group 6 (T code 713)..........................................0 H Heading 4 - Initial lift and shuttle fork unit systems - warning codes..................................0 H Heading 3 - 26.3.8 Navigation Solutions, code group 9.......................................................0 H Heading 2 - 26.4 Extra logging functions........................................................................0 H Heading 4 - External logging unit...........................................................................0 H Heading 1 - 27. Hydraulic system – 6000.............................................................................0 H Heading 2 - 27.1 General........................................................................................0 H Heading 2 - 27.2 Hydraulic cleanliness..........................................................................0 H Heading 3 - 27.2.1 Washing..................................................................................0 H Heading 3 - 27.2.2 Packaging................................................................................0 H Heading 3 - 27.2.3 Handling.................................................................................0 H Heading 3 - 27.2.4 Storage..................................................................................0 H Heading 3 - 27.2.5 Work procedures..........................................................................0 H Heading 3 - 27.2.6 Inspection measures......................................................................0 H Heading 4 - Inspection..................................................................................0 H Heading 2 - 27.3 Symbols........................................................................................0 H Heading 2 - 27.4 Cabin lifting..................................................................................0 H Heading 3 - 27.4.1 General..................................................................................0 H Heading 3 - 27.4.2 Cabin lifting - S44 closed...............................................................0 H Heading 3 - 27.4.3 Cabin lowering - S70 closed..............................................................0 H Heading 3 - 27.4.4 AC hydraulic unit, components............................................................0 H Heading 3 - 27.4.5 Hydraulic flow diagram, cabin lifting....................................................0 H Heading 3 - 27.4.6 B cylinder system........................................................................0 H Heading 2 - 27.5 Fork units and steering........................................................................0 H Heading 3 - 27.5.1 General..................................................................................0 H Heading 3 - 27.5.2 Hydraulic flow diagram, DC system (T code 712)...........................................0 H Heading 3 - 27.5.3 Hydraulic diagram (T code 713)...........................................................0 H Heading 4 - Steering valve..............................................................................0 H Heading 4 - Turret head fork unit valve (T code 712)....................................................0 H Heading 4 - Shuttle fork valve blocks (T code 713)......................................................0 H Heading 3 - 27.5.4 Fork rotation (T code 712)...............................................................0 H Heading 3 - 27.5.5 Side-shift movement......................................................................0 H Heading 3 - 27.5.6 Fork lifting.............................................................................0 H Heading 3 - 27.5.7 Fork lowering............................................................................0 H Heading 3 - 27.5.8 Steering.................................................................................0 H Heading 2 - 27.6 Extra hydraulic function (T code 712)..........................................................0 H Heading 3 - 27.6.1 Valves used for the extra hydraulic functions............................................0 H Heading 3 - 27.6.2 Hydraulic diagram, extra hydraulic function (T code 712).................................0 H Heading 2 - 27.7 Operations/repair..............................................................................0 H Heading 3 - 27.7.1 General..................................................................................0 H Heading 4 - Work on hydraulic components................................................................0 H Heading 3 - 27.7.2 Filter...................................................................................0 H Heading 4 - Overview....................................................................................0 H Heading 4 - Filter replacement (air and oil)............................................................0 H Heading 3 - 27.7.3 Hydraulic hoses:.........................................................................0 H Heading 4 - Routing.....................................................................................0 H Heading 3 - 27.7.4 Hydraulic connections....................................................................0 H Heading 4 - Conical hose couplings with O–ring..........................................................0 H Heading 4 - Quick change connector......................................................................0 H Heading 4 - Assembling the quick change connector.......................................................0 H Heading 4 - Dismantling the quick change connector......................................................0 H Heading 4 - Hydraulic couplings, for valve unit.........................................................0 H Heading 4 - Pipe couplings..............................................................................0 H Heading 4 - Valves......................................................................................0 H Heading 3 - 27.7.5 General repair instructions, valves......................................................0 H Heading 4 - Replacing the pressure sensor...............................................................0 H Heading 4 - Replacing the valve assembly................................................................0 H Heading 4 - Replacing a valve section...................................................................0 H Heading 4 - Composition of valve unit...................................................................0 H Heading 4 - Replacing valve insert, routing valves......................................................0 H Heading 4 - Installing the valve in the truck...........................................................0 H Heading 4 - Tightening torque...........................................................................0 H Heading 4 - Replacing the non-return valve in the control valve.........................................0 H Heading 1 - 28. Hydraulic tank - 6110...............................................................................0 H Heading 2 - 28.1 Hydraulic tank generally.......................................................................0 H Heading 2 - 28.2 Replace the hydraulic oil......................................................................0 H Heading 3 - 28.2.1 Emptying the tank........................................................................0 H Heading 4 - Preparations................................................................................0 H Heading 4 - Empty the accumulators......................................................................0 H Heading 4 - Empty the hydraulic tank, alternative 1.....................................................0 H Heading 4 - Empty the hydraulic tank, alternative 2.....................................................0 H Heading 3 - 28.2.2 Filling the hydraulic oil tank...........................................................0 H Heading 2 - 28.3 Replacing the tank.............................................................................0 H Heading 2 - 28.4 Fitting the new tank...........................................................................0 H Heading 1 - 29. Hydraulic pump – 6140...............................................................................0 H Heading 2 - 29.1 General........................................................................................0 H Heading 2 - 29.2 Bleeding the hydraulic pump....................................................................0 H Heading 3 - 29.2.1 Bleeding the hydraulic pump for steering and fork hydraulics (B).........................0 H Heading 3 - 29.2.2 Bleeding the hydraulic pump for main lift (A1, A2).......................................0 H Heading 2 - 29.3 Replacing the hydraulic pump for main lift (A1, A2)............................................0 H Heading 3 - 29.3.1 Disassembly..............................................................................0 H Heading 3 - 29.3.2 Installation.............................................................................0 H Heading 2 - 29.4 Replacing the hydraulic pump for steering and fork hydraulics (B)..............................0 H Heading 3 - 29.4.1 Disassembly..............................................................................0 H Heading 3 - 29.4.2 Installation.............................................................................0 H Heading 2 - 29.5 Troubleshooting internal leakage in the hydraulic pump for steering and fork hydraulics (B)....0 H Heading 1 - 30. Accumulators – 6280.................................................................................0 H Heading 2 - 30.1 Charging of the lifting and steering accumulators..............................................0 H Heading 3 - 30.1.1 Preparations.............................................................................0 H Heading 3 - 30.1.2 Measuring the pressure in the lifting accumulator........................................0 H Heading 3 - 30.1.3 Charging the lifting accumulator.........................................................0 H Heading 3 - 30.1.4 Order numbers for country-specific adapter kits..........................................0 H Heading 2 - 30.2 Measuring the pressure in the steering accumulator.............................................0 H Heading 3 - 30.2.1 Charging the steering accumulator........................................................0 H Heading 1 - 31. Main lift cylinder – 6610...........................................................................0 H Heading 2 - 31.1 Replacing the seal in the B cylinder...........................................................0 H Heading 1 - 32. Main mast and mast – 7100...........................................................................0 H Heading 2 - 32.1 Setting the cab and mast stoppers..............................................................0 H Heading 3 - 32.1.1 Cab stoppers.............................................................................0 H Heading 3 - 32.1.2 Setting the cab stoppers.................................................................0 H Heading 3 - 32.1.3 Mast stoppers............................................................................0 H Heading 1 - 33. Main lift chain system – 7120.......................................................................0 H Heading 2 - 33.1 General........................................................................................0 H Heading 2 - 33.2 Checking the chain setting.....................................................................0 H Heading 2 - 33.3 Checking the chain.............................................................................0 H Heading 3 - 33.3.1 Noise....................................................................................0 H Heading 3 - 33.3.2 Surface rust.............................................................................0 H Heading 3 - 33.3.3 Rusty links..............................................................................0 H Heading 3 - 33.3.4 Stiff links..............................................................................0 H Heading 3 - 33.3.5 Bolt rotation............................................................................0 H Heading 3 - 33.3.6 Loose bolts..............................................................................0 H Heading 3 - 33.3.7 Outline wear.............................................................................0 H Heading 3 - 33.3.8 Stretching...............................................................................0 H Heading 3 - 33.3.9 Damage...................................................................................0 H Heading 3 - 33.3.10 Damaged discs...........................................................................0 H Heading 3 - 33.3.11 Damaged bolts...........................................................................0 H Heading 3 - 33.3.12 Dirty chain.............................................................................0 H Heading 2 - 33.4 Cleaning.......................................................................................0 H Heading 2 - 33.5 Lubrication....................................................................................0 H Heading 2 - 33.6 Adjusting chains...............................................................................0 H Heading 3 - 33.6.1 Tool list................................................................................0 H Heading 3 - 33.6.2 Main lift chain adjustment...............................................................0 H Heading 3 - 33.6.3 Cabin chain adjustment...................................................................0 H Heading 3 - 33.6.4 Initial mast chain adjustment............................................................0 H Heading 1 - 34. Initial mast/turret head fork unit – 7200...........................................................0 H Heading 2 - 34.1 General description............................................................................0 H Heading 2 - 34.2 Adjustment.....................................................................................0 H Heading 2 - 34.3 Checking the chain.............................................................................0 H Heading 3 - 34.3.1 Noise....................................................................................0 H Heading 3 - 34.3.2 Surface rust.............................................................................0 H Heading 3 - 34.3.3 Bolt rotation............................................................................0 H Heading 3 - 34.3.4 Loose bolts..............................................................................0 H Heading 3 - 34.3.5 Damage...................................................................................0 H Heading 3 - 34.3.6 Damaged plates...........................................................................0 H Heading 3 - 34.3.7 Damaged bolts............................................................................0 H Heading 3 - 34.3.8 Dirty chain..............................................................................0 H Heading 3 - 34.3.9 Initial mast installation/removal........................................................0 H Heading 3 - 34.3.10 Mast installation.......................................................................0 H Heading 3 - 34.3.11 Installation of belts on a new truck....................................................0 H Heading 3 - 34.3.12 Installing hydraulic hoses and electric cables..........................................0 H Heading 3 - 34.3.13 Mast removal............................................................................0 H Heading 2 - 34.4 Inspection and replacement of belts used for fork traversing...................................0 H Heading 3 - 34.4.1 Check....................................................................................0 H Heading 3 - 34.4.2 Replacing the belt.......................................................................0 H Heading 3 - 34.4.3 Checking belt tensioning.................................................................0 H Heading 2 - 34.5 Friction plate adjustment......................................................................0 H Heading 2 - 34.6 Parallel adjustment of forks...................................................................0 H Heading 3 - 34.6.1 Measuring fork parallelism...............................................................0 H Heading 1 - 35. Shuttle fork unit – 7800............................................................................0 H Heading 2 - 35.1 Installing the shuttle forks...................................................................0 H Heading 2 - 35.2 Maintenance....................................................................................0 H Heading 3 - 35.2.1 Maintenance schedule.....................................................................0 H Heading 3 - 35.2.2 Lubrication..............................................................................0 H Heading 4 - Oil and lubricant specification.............................................................0 H Heading 3 - 35.2.3 Chain adjustment.........................................................................0 H Heading 2 - 35.3 Replacing the shuttle forks....................................................................0 H Heading 2 - 35.4 Measures.......................................................................................0 H Heading 3 - 35.4.1 Shuttle forks coming loose from the fork carriage holders................................0 H Heading 1 - 36. Magnet installation in narrow aisle - 8100..........................................................0 H Heading 2 - 36.1 General........................................................................................0 H Heading 2 - 36.2 Magnetic Sensor Switch Positions...............................................................0 H Heading 2 - 36.3 Standard Magnet Positions – Rail and Wire Guided...............................................0 H Heading 3 - 36.3.1 Number of magnet positions required per aisle............................................0 H Heading 2 - 36.4 Aisle indication - method of operation.........................................................0 H Heading 2 - 36.5 Aisle End Brake................................................................................0 H Heading 3 - 36.5.1 How the AEB works........................................................................0 H Heading 3 - 36.5.2 AEB Magnet Positions.....................................................................0 H Heading 1 - 37. Wire guidance equipment – 8200......................................................................0 H Heading 2 - 37.1 General........................................................................................0 H Heading 2 - 37.2 Generator......................................................................................0 H Heading 3 - 37.2.1 Technical data...........................................................................0 H Heading 1 - 38. Height preselection – 9390..........................................................................0 H Heading 2 - 38.1 General........................................................................................0 H Heading 2 - 38.2 Parameters.....................................................................................0 H Heading 3 - 38.2.1 MCU parameters...........................................................................0 H Heading 2 - 38.3 Programming....................................................................................0 H Heading 3 - 38.3.1 Programming a level......................................................................0 H Heading 3 - 38.3.2 Operation/Automatic operations...........................................................0 H Heading 1 - 39. Appendix A: Technical update........................................................................0 H Heading 2 - 39.1 AC pump motor, C code 1710, main lift..........................................................0 H Heading 3 - 39.1.1 Description..............................................................................0 H Heading 3 - 39.1.2 Replacing the temperature sensor.........................................................0 H Heading 3 - 39.1.3 Replacing the speed sensor...............................................................0 H Heading 3 - 39.1.4 Replacing bearings.......................................................................0 H Heading 2 - 39.2 AC drive motor, C code 1760....................................................................0 H Heading 3 - 39.2.1 Description..............................................................................0 H Heading 3 - 39.2.2 Replacing the temperature sensor.........................................................0 H Heading 3 - 39.2.3 Replacing the speed sensor...............................................................0 H Heading 3 - 39.2.4 Disassembly..............................................................................0 H Heading 3 - 39.2.5 Replacing bearings.......................................................................0 H Heading 3 - 39.2.6 Assembly.................................................................................0 H Heading 2 - 39.3 Motor controls, C code 5460, ACTL (A1), ACTR (A31) and ACH (A2) generation 5...................0 H Heading 3 - 39.3.1 General..................................................................................0 H Heading 3 - 39.3.2 ACT regulators, A1/A31...................................................................0 H Heading 4 - Technical data, ACT regulators..............................................................0 H Heading 3 - 39.3.3 ACH regulator, A2........................................................................0 H Heading 4 - Technical data, ACH regulator...............................................................0 H Heading 3 - 39.3.4 Troubleshooting..........................................................................0 H Heading 4 - Troubleshooting diagram, motor control......................................................0 H Heading 3 - 39.3.5 Power cable connections..................................................................0 H Heading 3 - 39.3.6 Installing a new frequency converter in the truck........................................0 H Heading 3 - 39.3.7 Programming..............................................................................0 H Heading 3 - 39.3.8 Maintenance..............................................................................0 H Heading 3 - 39.3.9 Safety...................................................................................0 H Heading 3 - 39.3.10 Cleaning................................................................................0 H Heading 2 - 39.4 New pivot point/steering potentiometer for C15, VCE150A and VCE125ASF..........................0 H Heading 3 - 39.4.1 General information......................................................................0 H Heading 3 - 39.4.2 Replacing the potentiometer..............................................................0 H Heading 4 - The potentiometer's voltage can be read via TruckCom........................................0 H Heading 4 - The potentiometer's voltage cannot be read via TruckCom.....................................0 H Heading 2 - 39.5 Wiring diagram VCE150 (T code 712) from serial number 6213314 onwards..........................0 H Heading 2 - 39.6 Wiring diagram VCE125ASF (T code 713) from serial number 6213314 onwards.......................0 H Heading 1 - 40. Index...............................................................................................0
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